EEL 4924 Electrical Engineering Design (Senior Design) Final Report. 19 April Name: Brandon Kalarovich

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1 EEL 4924 Electrical Engineering Design (Senior Design) Final Report 19 April 2011 Project Name: Digital Dashboard Team Name: Uncensored Sensors Team Members: Name: Matthew Greenberg Name: Brandon Kalarovich Project Abstract: Our project is to design a digital dashboard for a motorcycle. We will replace all the gauges including the tachometer with a graphical LCD. The dashboard will include the standard features found on the original gauge cluster, like a speedometer, tripometer, odometer, and engine coolant temperature. Additional features we'd like to implement would be vehicle telemetry data, and other sensors not found on this model of motorcycle, like oil pressure and oil temperature. Calculation based features (those not needing any additional sensors than what is listed above) will include a gear position indicator (using vehicle speed and engine RPM). The tire size and front/rear sprocket ratio will be user customizable. This will allow the speedometer and odometer to remain accurate if the user decides to stray away from original manufacturer's settings.

2 Table of Contents Project Features...3 Analysis of Competitive Products...3 Project Objectives...5 Concept/Technology Selection...6 Project Architecture...8 Bill of Materials Distribution of Labor Projected Timeline Appendix List of Tables/Figures MCV-7000 vs. Project features... 4 LCD module... 5 Gear RPM-speed chart... 6 Project block diagram... 7 Distribution of labor... 9 Gantt chart Digital Dashboard Uncensored Sensors

3 Project Features The objective of the project is to design a digital dashboard that will have the original features, plus many more features than an analog dashboard used in older motorcycles. Features include: Speedometer. Tripometer. Tachometer. Odometer. Gear position indicator. Engine Coolant temperature. Oil temperature and pressure. Customizable tire size and sprocket ratio settings Telemetry data (Lean angle, lateral/longitudinal acceleration rate). Analysis of Competitive Products There are many digital dashboards for motorcycles that have most or all the features our project has but they are far more expensive, ranging from $300 to $1000. Some sample products are shown here. MCL-5400 From Dakota Digital, priced at $ Figure 1 1/mode=prod/prd600.htm 3 Digital Dashboard Uncensored Sensors

4 Features included in the product and in the project: MPH/ kmh user adjustable speedometer Odometer and Trip Odometer Indicators for Left and Right Turn Signals, Highbeam, Neutral, Low Oil Pressure and Check Engine Features not included but implemented in the project: Tachometer Gear position indicator. Engine Coolant temperature. Oil temperature and pressure. Customizable tire size and sprocket ratio settings. Telemetry data. Oval Speedometer/ Tachometer Information Center (MCV-7000 series) From Dakota Digital, priced at $ Figure 2 1/mode=prod/prd508.htm Digital Dashboard MCV-7000 series Speedometer X X Tachometer/RPM gauge X X Longitudinal/lateral acceleration X rates Oil pressure and temperature X X 4 Digital Dashboard Uncensored Sensors

5 Odometer X X Real time clock X Voltmeter X Gear position readout X X Motorcycle signals (neutral, high beam, fuel, oil, turn signals) X X Performance Displays such as 0-60 MPH/KM/H Timer, 1/4 Mile Time and Speed, High Speed and RPM Recall X Lean angle X Cost $XXX.XX $ Figure 3: MCV-7000 vs. Project features. Project Objectives We have a few performance criteria will need to meet, and other's we plan to meet. The most crucial criteria to meet are maintaining accuracy for the speedometer and odometer. The United States mandates an allowed error of 5%. The United Nations Economic Commission for Europe (UNECE) mandates that a speedometer should never read slower than the vehicle is moving, and allows up to 110% + 4 kmh error from true speed for common speeds. The factory speedometer from Yamaha reads about 110% from true speed. This was proven by experiment using multiple unique speed stations found on the interstate (the speedometer would read 80 mph, and the speed station would display 72 mph). Accuracy in additional sensors will also be desired; however because they are only for display purposes only, we feel they can have a tolerance of a few percent. 5 Digital Dashboard Uncensored Sensors

6 Additional performance specifications we would like to meet would be to have the display updated at 0.5 second intervals. This would allow up to date vehicle data, without a refresh rate that may be too high and cause ghosting of numbers, which may become evident in colder temperatures. Because a motorcycle is a small vehicle with space constraints, our device will need to be kept as small as possible, however removal of the existing dashboard will supply additional space. The parts that are required to be in the gauge cluster area are of small volume. Concept/Technology Selection The various features will be implemented as follows: 1. The speed and mileage calculations will be done using pulses from a Hall Effect sensor over a set time in US and metric units. This allows for high accuracy needed for our project objectives rather than integrating the accelerometer longitudinal output. The Hall Effect sensor will be counted using a timer on the microcontroller set to clock using an external source. 2. Temperature sensor data will be obtained through A/D conversion and then used to calculate engine coolant temperature. Oil pressure and temperature data will be obtained through external sensors similarly through A/D conversion. 3. The gyroscope and accelerometer will be used to calculate the telemetry features such as lean angle and lateral/longitudinal acceleration rate. The gyroscope output will be integrated and the accelerometer will also calculate the lean angle based upon the force vector measured. The outputs will be averaged together to smooth out errors and the result will be the lean angle. 4. The tachometer will use a signal wire from one of the ignition coils. This will provide a pulse every engine revolution and they will be counted through timers set to clock from an external source. 6 Digital Dashboard Uncensored Sensors

7 University of Florida EEL 4924 Spring Apr The gear position can be calculate calculated from figure 5 by putting in the measured speed into each gear equation and compare to the measured RPM. The equation that fits the RPM-speed RPM relation the best is the gear the motorcycle is in. Figure 5 Motorcycle RPM to Speed chart used for calculati calculating gear We will use a large graphical LCD to display all the motorcycle data. For user input, 4 large pushbuttons will be used so the user can select through different menu and data screens on the LCD LCD. We plan to use the Atmel Atmega640 for the amount of ttimers and I/O it has. For development, we will use the Atmel ATmega324P because of its large number of I/O ports, 1 KB of built built-in EEPROM, and 7 Digital Dashboard Figure 4 The LCD module being used, 4 in. x 5 in. area. ttp:// Uncensored Sensors

8 University of Florida EEL 4924 Spring Apr-11 included peripherals pherals (SPI, UART/USART, etc.); however, after the device has been prototyped, we will implement the design onto the Atmega640. If the desired sensors are not already available on the motorcycle, then those sensors will need to be purchased. This will include the Hall Effect sensor, gyroscopes, accelerometers, and oil temperature/pressure sensors. Typically this device will be used while the vehicle's engine is running, so power will be readily available. We plan to use DC-to-DC power converters to supply power to our electronics. We will seek a power converter that allows a range on input voltages from +9 V to at least V (the typical voltage range supplied by the vehicles charging system) and the output voltage to be +3.3 V to +5 V, depending on the requirements for chips we use. Project Architecture Figure 6: Device Design Block Diagram 8 Digital Dashboard Uncensored Sensors

9 The 3 axis accelerometer in figure 6 is responsible for calculating the longitudinal and lateral acceleration rates of the motorcycle and the converted A/D data is displayed onto the LCD via UART. The gyroscope and accelerometer calculate the lean angle along the motorcycle axis and their values are averaged together and displayed on the LCD as telemetry data. The brake, clutch, neutral, high beam, turn, and fuel signals are +12 V on and off signals that are stepped down, read by the microcontroller, and then displayed on the LCD if they are triggered. The 4 control buttons are used to select between different menu screens of the LCD and are used to choose between different tire and sprocket sizes. The Hall Effect sensor and tachometer calculate the speed and mileage by counting pulses on timers on the ATmega640 set to clock by an external source. Depending on the tire and sprocket size chosen, the speedometer, odometer and tripometer will be adjusted accordingly so the values remain accurate. The oil temperature and pressure sensor and water temperature sensor data will be converted by the A/D from the ATmega640 and displayed onto the LCD. When the motorcycle is shut off, the odometer, trip, and tire/sprocket size settings will be saved in the ATmega640 EEPROM. 9 Digital Dashboard Uncensored Sensors

10 Bill of Materials Atmel ATmega $11.80 Hamlin Flange Mount Hall Effect Geartooth Sensor... $15.70 SWITCH PUSH SPST MOM 100MA 14VDC... 4 x $0.96 ECS Inc. ECS-2200B-160 Oscillator (16 MHz)... $2.63 Gyroscope... $39.95 MMA7341L 3-Axis Accelerometer +-3/11g... $11.95 Sparkfun Serial Graphic LCD $69.95 PCB Fabrication...$33.00 PCB Partial Population...$ Voltage Regulator, +5V...$0.65 Voltage Regulator, +3.3V...$0.97 Oil Pressure Sensor...$31.59 Oil Temperature Sensor...$12.95 Metric Adaptor for Oil Pressure Sensor...$ K Potentiometer...3 x $ K Potentiometer...$1.36 Op Amp...$1.36 Resistor Arrays...2 x $ pin header, receptacle, and pins...$ pin header, receptacle, and pins...$4.00 Various Resistors and Capacitors...$2.50 8" x 10" Lexan Polycarbonate sheet...$ Digital Dashboard Uncensored Sensors

11 Distribution of Labor Matthew Greenberg Brandon Kalarovich Research Board construction/ soldering Testing/Debug Software Speed/Mileage Telemetry data (using accelerometer & gyro) GLCD Debouncing Temperature/Pressure sensors Hardware Overall task load Figure 7: Approximate distribution of tasks 11 Digital Dashboard Uncensored Sensors

12 Gantt Chart Figure 4: Projected timeline of the project. Figure 8: Work schedule. 12 Digital Dashboard Uncensored Sensors

13 Appendix Figure 9: Board schematic, part Digital Dashboard Uncensored Sensors

14 Figure 10: Board schematic, part Digital Dashboard Uncensored Sensors