FEBRUARY 15 TH, 2013 RIT MSDI Detailed Design Review P13265 Motorcycle Safety Light Backpack System

MSD Team Primary Customers:  Sport bike/standard riders who ride with backpacks Surrogate Customers:  Aaron League  Andrew Nauss Faculty Guides:  Leo Farnand  Vince Burolla Industrial Design Consultant:  Killian Castner Team Members:  Mike Baer, Project Manager  Tyler Davis, Lead Engineer  Ben Shelkey, ME Project Engineer  TJ Binotto, EE Project Engineer  Eric Dixon, EE Project Engineer 2

Today’s Agenda 3 I. Overview5 minutes, 1 slide I. Project Description Recap II. Borrowed Motorcycle Specs II. System Model Design45 minutes, x slides I. Family Tree, System Overview II. System Components III. ME- CAD Models/Drawings IV. EE- Schematics, Pseudo-Code V. Bill of Materials III. Feasibility Analysis, Prototyping, and Experimentation30 mins, x slides I. Testing for critical components IV. System Assembly & Test Plans10 mins, x slides V. Next Steps15 mins, x slides I. Updated Risk Assessment II. MSDII Plan VI. Conclusion, Comments15 mins, x slides

4 I. OVERVIEW

Project Description Review 5 This project is intended to be prototype stage for marketable product for motorcyclists: Two major needs identified by motorcyclists: 1. Safety  Hurt Report Motorcyclist safety study performed by Henry Hurt, published in 1981 Of the accidents analyzed, ~75% of motorcycle accidents involved collision with another vehicle “Failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of motorcycle accidents”  Motorcycle Conspicuity Study  Riders wearing any reflective or fluorescent clothing had a 37% lower risk than other riders  Conclusion: “Increasing the use of reflective or fluorescent clothing, white or light coloured helmets, and daytime headlights…could considerably reduce motorcycle crash related injury and death.” 2. Electronics charging  Most motorcyclists have no means of charging electronics

Project Description Review 6 Conducted market survey regarding safety equipment and small electronics charging  Currently at 77 participants (for results visit EDGE website) Summary of target market (motorcyclists who):  Often or always wear backpacks Carry bulky items, such as books or laptops  Ride in 4 seasons, and wet conditions (rain, fog, snow)  Currently do not have method for charging electronics (such as cell phone) Micro USB charging connection required  Believe visibility is important Utilize reflective surfaces, bright colors, and lighting systems  Would consider upgrading their existing lights to LED lights  Place importance of aesthetics and durability of products

Updated Engineering Specs 7

8

Borrowed Motorcycle Type: 2006 Kawasaki Vulcan EN500 Owner: Andrew Nauss, 5 th year ME Gave permission to test on bike and make small modifications, if necessary Not ideal type of bike for target market, but it shares same engine and electronics with the Ninja 500, a popular entry-level sport bike Vulcan EN500 9

10 II. SYSTEM MODEL DESIGN

Physical System Overview Backpack 11 Electronics Box Inside Bottom Backpack Compartment Turn Signals Brake Lights System Power Switch AC Charging Plugin User Control Panel On Chest Strap

Physical System Overview Motorcycle 12 Transmitter Box (Inside Box) Transmitter Board w/ Xbee Transmitter Bike Power In Bike Light Signals In Power Out Wireless Light-Signals Out

Family Tree (1/3) 13 Continued

Family Tree (2/3) 14 From Backpack Assembly Continued

Family Tree (3/3) 15 From Backpack Assembly

Backpack 16 CAD Models and Drawings for the backpack are still in process and will be added once complete.

Lights Selection 17 Lights:  Compared thru-hole vs. flexible strips  Strips proved to be better for application  Colored LEDs documented to be more efficient than using white LED with colored lens cover  Strips available in.5m length w/ 30 LEDs/strip  Can be cut into increments of 3 LEDs Each 3 LED segment has necessary resistors to 12V  3 sets of High Intensity 30 LED SMD Strips  2 amber and 1 red  $15/ strip, $45 total  *Note: 11 sections of red strips are needed, but only 10/ strip  Will instead use one amber section, but will purchase 2 nd red strip in MSDII if budget allows Flexible LED Strip

Lights Flash Functionality 18 Lower Small Arrows Dual Brightness Running/Brake Lights Upper Small Arrows Upper Large Arrows 2 nd stage brake lights 1 st stage brake lights

Lights Requirements 19 Purchase: 1 RED strip 2 AMBER strips *Note: Decision made to eliminate front shoulder strap lights due to installation complexity and marginal benefit to rider (headlight is much brighter)

Light Covers Selection 20 Lens Covers:  Provide protection from elements  Clear thermoform acrylic sheets  Can bend to required shape  Clear:  ~92% Light 90 degrees incident to surface  Red and Amber:  ~9-15% 90 degrees  Currently in discussion with manufacturer  Will be sending free samples of both clear and red  Can hold off on purchasing until samples are received  Sheets will be cut to size and molded to sit flush with External Shell Diffusion Material:  Diffusion material is not necessary and will not be used  Could potentially be added after completion of build Clear acrylic

Electronics Housing 21

Backpack System Board Schematic 22 Receiver USB Charger Chest-Board Microcontroller Voltage Regulation Inputs and Battery Health Output to Lights

System Block Diagram 23

Battery Selection Technology Re-evaluated initial selection of Li-Po battery due to safety concerns  For scope of project, not possible to design box that is guaranteed to prevent any damage to battery in event of crash  Li-Po and Li-Ion battery can catch on fire if cells are damaged, even with no current draw Decided upon Ni-MH:  They do not catch fire when damaged  Still meet performance requirements  Downside, heavier and larger volume 24

Battery Selection Criteria Battery selection criteria:  Meets minimum 12V voltage requirement (from lights)  Meets minimum required power draw  Meets maximum current draw (~3.5A worst-case)  Can be connected to off-the-shelf AC smart charger  Built in overcharge protection and thermal monitoring 25

Battery Selection Comparison Three options  Selection limited due to required capacity  Selection further limited due to 12V requirement Total price includes pack, charger  Cost between 3 choices was negligible 26

Battery Selection Comparison After comparing in PUGH diagram, Powerizer Flat pack/charger was chosen due to flat size and larger capacity for the same price  4500 mAh, 12V, 4.2A max  Dimensions: 7.2 x 2.9 x.8 inches  Cost: $66, shipped  5 day lead time before shipping 27

Battery Health Monitor Selection Criteria Battery Health Monitor Criteria:  Monitor voltage levels on NiMH Battery (14.5V-10.5V)  Be able to load shed USB charging system at a specific voltage.  Shut off system as safe shutdown (10.5V)  Send signals to Battery Status LEDs on chest strap 28

Battery Monitor/Charging Schematic 29 Inputs and Battery Health

Power Supply Selection Criteria Power Supply selection criteria:  Low power dissipation.  Low heat dissipation.  Pass max voltage to Safety Lights  Regulate battery voltage to 5V for USB Charging System  Regulate battery voltage to 3.3V for µCon, Wireless, User Interface switches and Battery Status LEDs. 30

Power Supply Schematic 31 Voltage Regulation

USB Charger Selection Criteria USB Charger Selection criteria:  Meet requirement of Standard USB Dedicated Charging Port  Maximize charging rate, while minimizing power/time. 32

USB Charger Schematic 33 USB Charger

Light Sensor Selection Criteria Light Sensor selection criteria:  QSD124 NPN Silicon Phototransistor  Narrow Reception Angle of 24DEG  Power Dissipation is Max 100 mW 34

LED Driver Selection Criteria 8-Bit Parallel In/Out Darlington Source Driver  Large peak output current of 500mA  Input Voltage and Current easily supplied by microcontroller  Will drive enough current to power any combination of 3-LED segments 35

LED Driver Schematic 36

Wireless Transmission Selection Criteria Xbee Low-Power module w/ PCB Antenna  Little configuration required for RF Communication  Low-Power Consumption  Low Input Voltage (3.3V) and Current (50mA) requirements  Small Physical Size  Large amount of open-source documentation 37

Transmitter (Tx) Board Schematic 38 Voltage Regulation Inputs TransmitterBike Signals

Microcontroller Selection Criteria Microcontroller selection criteria:  Minimize controller power consumption.  Maximize # of I/Os.  Have PWM functionality. 39

Microcontroller and Rx Schematic 40 Microcontroller Output to Lights Receiver

Chest Strap System Selection Criteria Chest Strap criteria:  House User Interface Switches  House Battery Status LEDs  Minimize Power Consumption  Can be connected to off-the-shelf AC smart charger  Built in overcharge protection and thermal monitoring 41

Chest Strap Schematic 42

Chest Strap User Control Panel 43 Control Panel (Cover Off) Control Panel (w/ Cover)

Chest Strap User Control Panel 44 Control Panel Top Control Panel Bottom

Pseudo-Code 45

Quick-Connect Selection Criteria 46 Must attach and detach both quickly and easily Must not shake loose Must have reasonable detaching pull force in order to prevent damage to other systems (if rider forgets to unplug) Aesthetically pleasing Low production cost 3 = Good 2 = Okay 1 = Poor Wire Connected to Buckle/Bayonet clip Wire in Magnetic Housing Laptop-Style Connection Guitar-Style Connection Quick to Attach (Preferable) 2323 Will Release Automatically (Important) 1333 Not Prone to Shaking Loose (Important) 3322 Complexity2233 Aesthetics1323 Points Continue to cost analysis? noyes

Cost analysis of Quick-Connect options 47 Guitar Amp Connector Part cost$9.88 Tax $0.79 Shipping$4.99 Total $15.66 Magnetic Housing style Component ConnectorPlasticMagnets Part cost$7.98$9.96$3.00 Tax$0.64$0.80$0.24 Shipping$6.99$5.00$12.98 Total (each piece)$15.60$15.75$16.22 Total$47.58 Laptop-style Connector Part cost$7.98 Tax$0.64 Shipping$6.99 Total$15.60 Choice: Guitar Amp Connector Reasons: -Quicker to attach because of no directional preference - “Clicks” in, less likely to come off accidentally

Overall Bill of Materials 48

High Cost Items 49 Battery- $66 w/shipping Lights- $53 w/shipping Microcontroller- Xbee Units PCBs- Shell Mold Fabrication-

50 III. FEASIBILITY ANALYSIS, PROTOTYPING & EXPERIMENATION

Light System Luminosity Test Three tests completed: LED florescent tube strip (benchmark) 4.4W 30 LED high power strip 1.1 W 30 LED water resistant strip Tested high-brightness and weatherproof light strips in daylight Observed brightness ~100 ft away from light All strips bright enough during day Illuminated Light Strip *Note: Strip was much brighter than picture shows 51 Results: Lights bright enough for requirements

Light System Power Consumption Calculations 52 Results: With very conservative estimate, in worst-case scenario, system should operate from battery for >2 hrs

Bike Mock-Up Transmitter Box 1.75” 4” 1” A mock-up for transmitter placement was completed on donor bike Test-fit laptop charger into inner cover Dimensions are 1.75 x 4 x 1 inch (H x L x W) Charger fit within cover with extra room Transmitter box will be much smaller than charger => fits Inner cover is protected from elements from outer cover (not pictured) Inner Cover Charger 53 Results: Good location determined for Tx box

Bike Mock-Up Bike Battery Power Wire Routing Proper routing of the wire from the 12V bike battery is very important for several reasons: Mitigation of any risk that wire can catch on rider If wire detaches, should not create safety risk (i.e. catch in chain/wheel) With wire attached, rider should be able to move freely Rider should be able to easily attach wire Considered several routing options: 1. In front of seat 2. Rear of seat 3. Side of seat # 1 # 3 # 2 54

Bike Mock-Up Bike Battery Power Wire Routing: Option 1 Option 1 quickly eliminated due to routing over rider’s legs Safety and rider discomfort issues 55

Bike Mock-Up Bike Battery Power Wire Routing: Option 2 Option 2 is possible, but not ideal Space under seat for wire to route without any stress concerns However, wire would have to route over seat, which could blow around in wind and create greater risk of detachment 56

Bike Mock-Up Bike Battery Power Wire Routing: Option 3 Option 3 presents best routing method No interference with rider No stresses/ methods for damage to wire Shortest wire length of 3 options Mock-up Wire Routed with Seat on Space between frame and chrome 57 Results: Option 3 is best method

Xbee Code 58

59 IV. SYSTEM ASSEMBLY & TEST PLANS

Systems Assembly & Test Plans 60 A detailed system assembly procedure with diagrams will be added for final DDR.

61 V. NEXT STEPS

Updated Risk Assessment (1/3) 62

Updated Risk Assessment (2/3) 63

Updated Risk Assessment (3/3) 64

MSD II Plan- Overview 65

MSD II Plan- Overview 66

MSD II Plan- 4 week plan 67 End Week 1 Complete Final Assembly and Test Plans- All End Week 2 Completed Assembly of Transmitter Housing- Ben Completed Assembly of Transmitter Board- TJ Completed Debugging of Transmitter Housing- TJ End Week 3 Completed Assembly of In-bag Electronics Assembly- Ben Completed In-bag Assembly Board- Eric/TJ Completed Backpack External Shell- Tyler/Mike Completed DC Quick Connect Assembly- Ben End Week 4 Completed Backpack Shell Integration w/Soft Shell- Tyler Completed Light/Light Cover Integration w/Shell- Mike/Tyler Completed Debugging of In-Bag Assembly- Eric/ TJ

68 VI. CONCLUSION, COMMENTS

Questions 69