Final Report Project Name: Digital Dashboard module ... 4. The tachometer will use a signal wire from one of the ignition coils. This will provide a pulse ... PCB Fabrication

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

Email: [email protected] Email: [email protected]

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.

University of Florida EEL 4924—Spring 2011 19-Apr-11

Electrical & Computer Engineering

2 Digital Dashboard Uncensored Sensors

Table of Contents

Project Features ...............................................................................................................3

Analysis of Competitive Products .....................................................................................3

Project Objectives ............................................................................................................5

Concept/Technology Selection.........................................................................................6

Project Architecture…………………………………………………… …………………….....8

Bill of Materials .............................................................................................................. 10

Distribution of Labor ...................................................................................................... 11

Projected Timeline ......................................................................................................... 12

Appendix ....................................................................................................................... 13

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 .......................................................................................................................... 12




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 $374.95

Figure 1 http://www.dakotadigital.com/index.cfm/page/ptype=product/product_id=600/category_id=560/home_id=-

1/mode=prod/prd600.htm




Features included in the product and in the project:

• 0- 255 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 $524.95

Figure 2 http://www.dakotadigital.com/index.cfm/page/ptype=product/product_id=508/category_id=560/home_id=-

1/mode=prod/prd508.htm

Digital Dashboard MCV-7000 series

Speedometer X X

Tachometer/RPM gauge X X

Longitudinal/lateral acceleration rates

X

Oil pressure and temperature X X




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 $524.95

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.




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.

University of Florida Electrical & Computer Engineering

7

5. The gear position can be calculate

gear equation and compare to the measured RPM. The equation that fits the RPM

the best is the gear the motorcycle is in.

Figure 5 Motorcycle RPM to Speed chart used for calculati

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

plan to use the Atmel Atmega640 for the amount of t

it has.

For development, we will use the Atmel ATmega324P because of

its large number of I/O ports, 1 KB of built

EEL 4924—Spring 2011

Digital Dashboard

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

the best is the gear the motorcycle is in.

Figure 5 Motorcycle RPM to Speed chart used for calculating gear

We will use a large graphical LCD to display all the motorcycle

pushbuttons will be used so the user can

different menu and data screens on the LCD. We

plan to use the Atmel Atmega640 for the amount of timers and I/O

For development, we will use the Atmel ATmega324P because of

its large number of I/O ports, 1 KB of built-in EEPROM, and

Figure 4 The LCD module being used, 4 in. x 5

in. area.

http://www.sparkfun.com/products/8884

19-Apr-11

Uncensored Sensors

by putting in the measured speed into each

gear equation and compare to the measured RPM. The equation that fits the RPM-speed relation

The LCD module being used, 4 in. x 5

ttp://www.sparkfun.com/products/8884

University of Florida Electrical & Computer Engineering

8

included peripherals (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 i

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

a power converter that allows a range on input voltages from +9 V to at least +14.4 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

EEL 4924—Spring 2011

Digital Dashboard

pherals (SPI, UART/USART, etc.); however, after the device has been prototyped, we will


motorcycle, then those sensors will need to be purchased. This will include the Hall Effect sensor,

gyroscopes, accelerometers, and oil temperature/pressure sensors.


DC power converters to supply power to our electronics. We will seek



on the requirements for chips we use.

Figure 6: Device Design Block Diagram

19-Apr-11

Uncensored Sensors

pherals (SPI, UART/USART, etc.); however, after the device has been prototyped, we will


nclude the Hall Effect sensor,


supply power to our electronics. We will seek






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.




Bill of Materials

Atmel ATmega640 ............................................................................................................ $11.80

Hamlin 55505 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-08884 .................................................................................................$69.95

PCB Fabrication ..................................................................................................................................$33.00

PCB Partial Population .....................................................................................................................$250.00

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 ................................................................................................$9.45

100K Potentiometer ........................................................................................................................3 x $1.36

10K Potentiometer ................................................................................................................................$1.36

Op Amp .................................................................................................................................................$1.36

Resistor Arrays................................................................................................................................2 x $0.60

24 pin header, receptacle, and pins .....................................................................................................$16.00

4 pin header, receptacle, and pins .........................................................................................................$4.00

Various Resistors and Capacitors .........................................................................................................$2.50

8" x 10" Lexan Polycarbonate sheet .....................................................................................................$3.98




Distribution of Labor

Matthew Greenberg Brandon Kalarovich

Research 50 50

Board construction/

soldering

50 50

Testing/Debug 50 50

Software

• Speed/Mileage

• Telemetry data (using

accelerometer & gyro)

• GLCD

• Debouncing

• Temperature/Pressure

sensors

50

0

100

50

50

20

50

100

0

50

50

80

Hardware 40 60

Overall task load 50 50

Figure 7: Approximate distribution of tasks




Gantt Chart

Figure 4: Projected timeline of the project.

Figure 8: Work schedule.




Appendix

Figure 9: Board schematic, part 1.




Figure 10: Board schematic, part 2.

Documents

Final Report Project Name: Digital Dashboard module ... 4. The tachometer will use a signal wire from one of the ignition coils. This will provide a pulse ... PCB Fabrication