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 Design50 minutes, x slides I. Family Tree, System Overview II. System Components III. CAD Models/Drawings IV. Component Assembly Plans V. Schematics, Pseudo-Code VI. Bill of Materials III. Feasibility Analysis, Prototyping, and Experimentation30 mins, x slides I. Testing for critical components IV. Test Plans5 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/Running Lights System Power Switch Motorcycle Power Connector User Control Panel On Chest Strap Ambient Light Sensor

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 Shell 16 Shell Drawing Shell Back Shell Front

Backpack Assembly 17 Shell Cut and assemble main compartment zipper to length. Apply Liquid Nails to inside edges of top shell Attach and clamp fully zipped zipper to shell following the instructions of the Liquid Nails Wait for glue to fully cure Safety pin unglued zipper side to soft backpack back Unzip zipper Sew second half of zipper to soft back Cut and assemble bottom compartment zipper to length Apply Liquid Nails to one connection corner of both shell halves Attach only the starting section the zipper following 3-4 Attach the rest of the zipper using non-permanent method. Using a paintmarker or sharpie make marks on shell/zipper in 1in increments (these will be used to make sure zipper and shell are lined up properly when adhering). Unzip sections Remove zipper from both sections and clean off non-permanent adhesive Attach zippers halves to each shell section separately following 2-4. Unzip Apply Liquid Nails to back edge of bottom shell section. Attach and clamp bottom fabric backpack flap to back edge of shell following Attach quick access panel following LEDs Drill Wire holes in all light strip slots. Place LED light strips in their appropriate slots with proper adhesive. For each light signal slot line lens ridge with silicone sealer. Press each lens into their appropriate slot. Wipe off any excess sealer and allow to dry Electronics Pouch, Easy Access Pouch and Other Place adhesive on edges of neoprene pouch. Press pouch into the top surface of the bottom backpack compartment. Allow to dry. For easy access pouch follow 25-27; except the easy access pouch will be attach on the inside perimeter of the easy access panel. Drill hole on the bottom right side of shell in appropriate location for power switch. Apply sealer to edge of hole. Pop power switch into hole and hold. Wipe off any excess sealer and allow to dry. Drill hole in the bottom of the shell for the power cord. Drill hole in specified location on top access panel for light sensor. Place light sensor in through the shell. Apply sealant to back of the sensor to hold in place. Allow to dry. Disconnect chest strap clip from strap. Slide user control panel onto strap. Reconnect chest strap clip. Wire all components. Battery Health Panel: Press fit PCB into top panel Apply silicone sealer to back Fit back panel against the top Clamp and allow to dry for appropriate time

Lights Selection 18 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 19 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 20 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 21 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 22

Electronics Housing Assembly 23 Components Main Housing Base (Aluminum) Long side (on battery side, straight, 2 holes tapped on top) Long side (dividing board and battery, has slot for wires) Long side (battery side, has 5 holes (2x DB9, I USB 2x 2-in-1) and 2 holes tapped on top) 2x Short side (identical, each has slot in the top) Top piece 4 screws Glue Assembly 1.Use mill to dimension pieces to specified dimensions 2.Create required holes (tapped and for plug) 3.Glue long sides and short sides to base as detailed in assembly drawing 4.Add board, with bushings underneath 5.Install board with screws 6.Install top with screws

24 Transmitter Box 24 Original plans were to fabricate a custom-sized waterproof box for the transmitter Availability and competitive prices of prefabricated boxes outweigh the benefits of a custom box Selected box: HAMMOND Plastic Instrument Enclosures Black Project Box Pictured: Bottom (facing up and down) Complete box Price: $4.49 (free shipping)

Chest Strap User Control Panel 25 Control Panel (Cover Off) Control Panel (w/ Cover) View of Attachment Loop Hazard Button Light Pattern Select Brake/Turn Signal Function Toggle Status LEDs Status LED On/Off

Chest Strap User Control Panel 26 Control Panel Top Control Panel Bottom

Cord Retraction 27 In order to prevent the charging cable from being caught in the rear wheel if disconnected, a retraction system is necessary. Original plans resembled a retractable dog leash, but because of the size and stiffness of the wire this idea was abandoned. Rather than have the wire wind up, it will be an extendable coiled wire with the male and female ends being the connectors.

Quick-Connect Selection Criteria 28 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

29 Cost analysis of Quick-Connect options 29 Guitar Amp Connector Part cost$4.36 Tax $0 (included) Shipping$1.37 Total $5.73 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

System Block Diagram 30 System Block Diagram Backpack Electronics Housing/PCB Motorcycle System Motorcycle Battery 12VDC Transmitter Housing/PCB Quick Connect 12V->3.3V Regulation Xbee Transmitter Transmitter Signals 1.Headlight 2.Left Turn Signal 3.Right Turn Signal 4.Brake Light AC/DC 12VDC System NiMH Battery 12VDC USB Charger USB2.0USB2.0 5V 12V Xbee Receiver 3.3V Chest Strap PCB 12 LED Groups Battery Monitor / Fuses Battery Status LEDs µCon (MSP430) Voltage Regulation 12V->5V 5V->3.3V 12V Darlington Light Drivers Calibrate Button User Interface Buttons Chest Strap Signals 1-4. Battery Status LEDs 5.Function Toggle 6.Function Toggle Sel 7.Hazard 8.3.3V mm Connector 2.1mm Connector Power Switch

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 31

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 32

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 33

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 34

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 35

Battery Health Monitor/Charging Circuit Function 36 Monitor Internal Battery Voltage  Send Low Bat signal to µCon at desired level Isolate Internal Battery from system under the following conditions.  Low Battery Level  Connected to: Wall Charger or Bike Power Battery Voltage%Comments v100-75% v75-50% v50-25% v25-0% v0%Isolate battery, and turn on indicator LED

Battery Health Monitor Design Design 37 Compare the voltage on the supply to a reference voltage.  Divide voltage supply level by 3.  Use a 6.2V 1% precision Zener diode to set reference.  Use voltage divider resistor string to set reference voltage levels. 100%75%50%25%0%Comments >13.5V4.5V4.52VLLLLL >12.5V4.17V4.19VHLLLL >11.5V3.83V3.85VHHLLL >10.5V3.5V3.52VHHHLL >10V3.33V3.35VHHHHLSystem=Off Indicator=On =10V3.33V3.35VHHHHHFull-System=Off

Battery Monitor/Charging Schematic 38 Comparators Low-Battery Flag to µCon 1% Precision Zener Diode

Power Supply Selection Criteria / Design Power Supply selection criteria:  Low power dissipation.  Low heat generation.  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. Power Supply Design  Vin >10V, 5V Switching Regulator, designed using Manu. Datasheet.  3.3V Linear Regulator using input from 5V Switching Reg. 39

Power Supply Schematic 40 5V Switching Regulator3.3V Linear Regulator

USB Charger Selection Criteria /Design USB Charger Selection criteria:  Meet requirement of Standard USB Dedicated Charging Port  Maximize charging rate, while minimizing power/time. USB Charger Design  IC Solution for a Dedicated Charging port.  1A Charging Current 41

USB Charger Schematic 42 USB Enable from µCon Dedicated Charging Port Controller

Light Sensor Selection Criteria Light Sensor selection criteria:  QSD124 NPN Silicon Phototransistor  Narrow Reception Angle of 24DEG  Power Dissipation is Max 100 mW 43

Light Sensor Schematic 44

LED Driver Selection Drive a # of 3-LED segments requiring 200mA/segment. Switch on/off using a µController input signal  0V->3.3V 45

LED Driver Schematic 46

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 47

Transmitter (Tx) Board Schematic 48 Voltage Regulation Inputs TransmitterBike Signals

Microcontroller Selection Criteria Microcontroller selection criteria:  Minimize controller power consumption.  Maximize # of I/Os.  Have PWM functionality. 49

Microcontroller and Rx Schematic 50 Xbee Receiver Outputs to Light Drivers µController w/ JTAG Prog.

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 51

Chest Strap Schematic 52

Pseudo-Code (1/2) 53

Pseudo-Code (2/2) 54 Continued from above

Overall Bill of Materials 55

Overall Bill of Materials 56

High Cost Items 57 Battery- $66 w/shipping Lights- $53 w/shipping Microcontroller Dev. Kit - $29 Xbee Units - $38 PCBs- (3x$75) Shell Mold Fabrication- $135 w/shipping

58 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 59 Results: Lights bright enough for requirements

Light System Power Consumption Calculations 60 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 61 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 62

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 63

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 64

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 65 Results: Option 3 is best method

Xbee Code 66 Configures the TX unit +++ -Grabs unit attention ATRE -Resets ATID Sets address ATMY 1 -Sets my address to 1 ATD0 3 ATD1 3 ATD2 3 ATD3 3 -Sets DIO 0 through 3 to digital input ATDH 0 -Sets destination address high ATDL 2 -Sets destination address of receiver ATIR 14 -Sets sample rate to 20ms ATPR 0 -Disables internal pull-ups ATWR -Writes to memory Configures the RX unit +++ -Grabs unit attention ATRE -Resets ATID Sets address ATMY 2 -Sets my address to 2 ATD0 5 ATD1 5 ATD2 5 ATD3 5 -Sets DIO 0 through 3 to digital output ATIA 1 -Sets I/O input address to TX address ATWR -Writes to memory

67 IV. TEST PLAN

68 V. NEXT STEPS

Updated Risk Assessment (1/3) 69

Updated Risk Assessment (2/3) 70

Updated Risk Assessment (3/3) 71

MSD II Plan- Overview 72

MSD II Plan- Overview 73

MSD II Plan- 4 week plan 74 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

75 VI. CONCLUSION, COMMENTS

Questions 76