Inertial Progressive BrakeLamp

Model Engineering College
Inertial Progressive Brake Lamp
CHAPTER 1
INTRODUCTION
Motorcyclists are hard to see in traffic, and most accelerate and decelerate faster than cars. These combined factors increase the chances for accidents involving motorcycles. The existing automobiles brake lights simply turn on and off and it is up to the driver behind the braking vehicle to judge the deceleration and, in turn, be prepared to slow down or to stop suddenly. Many rear-end collisions occur simply because of the lack of communication between drivers.
Inertial Progressive Brake Lamp is designed to minimize rear end collisions by providing a visual level indication of the vehicles deceleration to the drivers behind. With this system, drivers will be able to anticipate exactly the intention of the motorcyclist/driver in front of them, so they will not have to spend valuable reaction time determining how fast the vehicle in front is decelerating and how hard they should apply their own brakes to prevent a collision.
The system comprises of the MMA7260QT tri-axis, low- g accelerometer for measuring deceleration of the vehicle, the Atmega8 AVR microcontroller for A/D conversion and processing of accelerometer outputs and an LED driver which drives a brake light array comprising a plurality of individual lights arranged as discrete Braking levels, the array being mounted so as to be visible to a driver of a trailing vehicle.
Department of Electronics Engineering
CHAPTER 2
SYSTEM OVERVIEW
2.1 SYSTEM FEATURES

The Inertial Progressive Brake Lamp is a sequential or progressive brake lamp with light output proportional to vehicles deceleration. The brake lamp does additional functions beyond brake light: High brightness LED output with sixteen, 5mm traffic LEDs.
Four warning levels based on deceleration magnitude. (LOW,MEDIUM, HIGH , EMERGENCY)
Variable blink rate for each braking level.
Photo - sensor that compensates for brightness output in day light or night
light.
Can be easily ported to any vehicle since it is independent of the braking system used.
Inertial Progressive Brake Lamp nertial
2.2 BLOCK DIAGRAM OF THE SYSTEM
Fig. 2.1 Block Diagram The Fig. 2.1 shows the block diagram of the system. It consists of three sections: system. 1. SENSOR SECTION 2. PROCESSING AND CONTROL 3. OUTPUT SECTION
CHAPTER 3
BLOCK DIAGRAM DESCRIPTION

3.1 SENSOR SECTION 3.1.1 MMA7260QT Accelerometer
The heart of the system is the MMA7260QT 3 m 3-axis accelerometer. The MMA7260QT accelerometer is a surface-micro machined integrated-circuit accelerometer. The device surface circuit consists of two surface micro machined capacitive sensing cells (g-cell) and a signal (gconditioning ASIC contained in a single integrated circuit package.
Fig. 3.1 Internal Block Diagram of MMA7260QT accelerometer The Figure 3.1 shows the block diagram of the MMA7260QT accelerometer which is a surface-micro machined integrated-circuit accelerometer. The device consists of two integrated surface micro machined capacitive sensing cells (g-cell) and a signal conditioning ASIC cell) contained in a single integrated circuit package. In the capacitive transduction method, the sensor can be considered a mechanical capacitor in which one of the plates moves with respect to the applied physical stimulus.
Department of Electronics Engineering 4
This changes the gap between the two electrodes with a corresponding change in the capacitance. This change in capacitance is the electrical equivalent of the input mechanical stimulus.
Accelerometer Module
Fig. 3.2 Accelerometer Module Circuit Diagram
The Fig. 2.2.1 shows the circuit diagram of the accelerometer module. ows module MMA7260Q Board F Features
Two Jumpers for selecting sensitivity (1.5g/2g/4g/6g) (1.5g/2g/4 Power supply ranges from 5V to 10V On board 3.3V regulator Three On Board RC filter for minimizing clock noise of each angle
3.1.2 Photo sensor

Light-dependent resistor ( (LDR) is used as the photo sensor.It measures ambient lighting easures conditions and provides a corresponding variable resistance This sensor measures co
ambient light levels so that the brightness of the LEDs can be increased during daytime for better visibility and reduced during nighttime to prevent blinding of trailing drivers.
3.2 PROCESSING AND CONTROL Atmega8L Microcontroller

The microcontroller used is the ATMEGA 8L AVR. The ATmega8 is a low-power CMOS 8-bit microcontroller based on the AVR RISC architecture. By executing powerful instructions in a single clock cycle, the ATmega8 achieves throughputs approaching 1 MIPS per MHz. The microcontroller accepts the 3 analog signals corresponding to each axis (x, y and z) and the input from the LDR, converts these to digital data, interprets it, decides what the required LED output should be and communicates this to the LED Driver.
3.2.1 ADC
The ATmega8 (DIP) features a 10-bit successive approximation 6-channel ADC having a conversion time in the range of 65us 260us and has a sampling rate of up to 15k Samples/sec at maximum resolution. The ADC supports both single conversion and free running modes.
3.2.2 USART
The USART of the AVR is used to transmit the real time sensor data to a PC for logging. This sensor data can be used for analysis of the performance of the accelerometer and the ADC, and be utilized to optimize the system.
3.3 OUTPUT SECTION

The output section consists of the LED Driver and an array of suitable number of Traffic LEDs.
LED Driver
The I/O ports of the microcontroller can source or sink an absolute maximum DC current of 40mA only. Thus for driving the LEDs, a ULN2803A Eight channel Darlington array (with common emitter) IC is used, as low side switches. The ULN2803A has a 2.7kOhm 2803A series input resistor for operation directly with 5 V TTL or CMOS. The Darlington arrays are furnished in 18-pin DIP packages and are pinned with outputs opposite inputs to pin facilitate ease of circuit board layout layout.
Output LEDs
The LEDs used in the deceleration level indicator are the 5mm Red Transparent LEDs LED (suitable for use in Traffic lights). lights).The board layout allows for spacing of the LEDs for visual separation of the different deceleration levels when mounted to a vehicle. The arrangement of the LEDs may be linear, concentric circles or other suitable fashion. linear, The Fig. 3.3 shows a linear arrangement:
Fig. 3.3 Brake Lamp LED Array
3.4 POWER SUPPLY SECTION

The input dc supply used is the motorcycles battery which provides a voltage of 12V. The ripples in the battery output are removed using an LC filter before applying to the regulators. Two separate power supplies are used one for providing a constant voltage of 5V supply to the microcontroller and the accelerometer and the other is used to provide a voltage of 6.2V to the LED driver and LED array. The LM7805 Voltage Regulator IC is used for the 5V constant voltage source and the LM317 is used as a constant current source. A Zener diode is used to derive a 3.3V reference voltage for the ADC of Atmega8L.
CHAPTER 4
CIRCUIT DIAGRAM
Fig. 4.1 Circuit Diagram of Main Board
Fig. 4.2 Circuit Diagram of Power Supply Section
10
CHAPTER 5
CIRCUIT DIAGRAM DESCRIPTION

Sensor Section
The accelerometer module integrates the 3.3V supply required by MMA7260QT IC. There are also onboard RC Low Pass Filters (1.159 kHz cut-off) for each output axis and a 0.1uF power supply decoupling capacitor. Logic high is applied to the SLEEP` pin through a 15k resistor to always enable the device. The LDR is used as one of the resistors of a voltage divider of which the other is a pot. The output voltage from this sensor is made to come within the range of 0V to 3.3V by adjusting the pot.
Microcontroller
The microcontroller is given a 5V supply. An external crystal 0f 7.3728 MHz is used as clock source. The ADC is given 5V supply through an LC filter to minimize supply noise and a decoupling capacitor is used at the Vref input pin. The accelerometer outputs and the LDR outputs are applied to the PORTC pins PC0 (ADC0)-PC3 (ADC3). The PWM output is generated by the 16-bit Timer and available at the pin PB1 (OC1A). The deceleration level indication of the LEDs is controlled by the Pins PB2 - PB5. The PWM output is given to the input of all the gates of a Quad 2-input AND gate IC, 74HC08 since we need the same brightness adjustment for all LEDs depending on the ambient lighting level. The other inputs to the AND gates are the output pins PB2 - PB5.
Output Section
The output of each AND gate is applied to 2 channels each of the ULN2803A Darlington array, one channel for the LEDs on the Left half and the other for the LEDs on the Right
half. For each deceleration level, there are two LEDs connected in series on the right and left halves. In such a way, all the channels are connected.
Power Supply Section

The 7805 uses bypass capacitors at the input and output to filter the noise from the input supply and to filter the transient changes of the load. The LM317 supplies an output voltage of 6.2V to the LED driver and the LED array.
12
CHAPTER 6
SOFTWARE
6.1 Flow Chart for Real Time Data Collection
13
Fig. 6.1 Flow Chart for Real Time Data Collection
ADC Interrupt Service Routine
14
6.2 Flow Chart of the System
15
Fig. 6.2 Flow Chart of the System
16
CHAPTER 7
PCB FABRICATION AND SOLDERING

The materials required for PCB fabrication are copper clad sheet, little paint drilling machine and ferric chloride solution. The PCB fabrication involves the following steps.
1. Preparation of the PCB layout

First the circuit is drawn using Express schematic and PCB layout is prepared using PAD 2 PAD as explained in the layout making procedure. The mirrored image of layout of bottom layer PAD 2 PAD software is printed on an A4 size translucent tracing sheet or butter paper. Using this, the thin film can be made and is exposed to the UV.
2. Film preparations
In this process, the negative of the plate is made into photographic film. For this the printed image of the layout in the butter paper is placed over the film and is exposed to UV rays from the top so that the film will be exposed to the UV rays from the top so that the film will be exposed to the UV rays in the region other than the layout. The developer solution then the reaction will take place, then the region not exposed by UV rays will become transparent and the other regions are dark in colour. Thus the negative is produced. Then the film is washed in fixing solutions. After that the solution is kept for drying.
3. Transferring the layout to copper clad sheet

First the copper clad sheet of required is cut by using a cutting machine. Then the sheet is cleaned by using metal scrubber. After perfect cleaning, the board is dipped in photo resist solution so that the film of the photo resist is formed on the board. Then the copper clad sheet is placed in an oven for some time, so that the photo resist will be fixed to the surface of the board.
17
The next step is to form an image of the layout on the copper clad sheet. For that, the negative of the layout is placed over the sheet. Then it is placed on the UV exposure unit so that the UV rays will fall on the photo resist over the board in the regions of the layout for 1.15 minutes. After that, the board is washed gently in water for about one minute so that the chemical reactions take place in the regions exposed by the UV rays. Then the board is washed in a dye so that the dye will be fixed on to the layout regions. Thus we get the visible image of the layout on the board. Then check the layout on the board with actual circuit. If there is any correction, the above processes are repeated. If layout is correct, the board is now ready for etching.
4. Etching of the board

When the board is ready for etching, it is placed in the ferric chloride of required concentration. It is checked in regular intervals to prevent over etching and successive damage to the part. After the etching is complete the board is taken out of the etch and washed in water to remove the excess ferric chloride. The D13X NC Thinner is applied to remove any dew or paint material on copper tracks. Then the sheet is cleaned by using steel scrubber and washed again in water. Now the copper lines are exposed and hence the body is checked with the magnifying glass to see whether all the lines in the layout are clearly formed. Now the board is ready for thinning.
5. Tinning
For tinning, the PVB is cleaned well and flux is supplied to the surface. Then it is passed through the tinning machine. In tinning the copper lines are plated with an alloy of TIN and LEAD.
6. Drilling
After tinning, the next process is drilling, in this the holes of required sizes are drilled in the PCB wherever needed, using a PCB drilling machine.
18
7. Finishing
In the process after drilling holes on PCB, the board is taken and a light coat of air dying insulating varnish dry up. The application of the insulating varnish is applied to the bottom side carefully avoiding the pad areas The PCB is then left till the insulating varnish dry up. The application of the insulating varnish prevents any type of oxidation on the track further proving better safeguard to the tracks after tinning
Soldering and Desoldering Soldering

Soldering is the process of jointing two or more dissimilar metals by melting another metal having low melting points.
Soldering Flux
In order to make the surface accept the solder readily the components terminals should be free from oxides and other obstructing films. Soldering flux cleans the oxides from the surface of the metal.
19
CHAPTER 8
PCB LAYOUTS
Fig. 8.1 Component Side Layout of Main Board
Fig. 8.2 Bottom Layer of Main Board PCB

Fig. 8.3 Bottom Layer of LED Board PCB
21
CHAPTER 9
DEVELOPMENT TOOLS
AVR Studio 4
AVR Studio 4 is the Integrated Development Environment (IDE) for developing 8-bit AVR applications in Windows NT/2000/XP/Vista/7 environments. AVR Studio provides a project management tool, source file editor, simulator, assembler and front-end for C/C++, programming, emulation and on-chip debugging. It also provides a complete set of features including debugger supporting run control including source and instructionlevel stepping and breakpoints; registers, memory and I/O views.
EAGLE 5.10 Freemium

The EAGLE Layout Editor is an easy to use, yet powerful tool for designing printed circuit boards (PCBs). The name EAGLE is an acronym, which stands for Easily Applicable Graphical Layout Editor The program consists of three main modules

Layout Editor Schematic Editor Auto router
EAGLE was used to design the PCB layout of the main board.
Express PCB
Express PCB is another freeware PCB designing tool. The PCB layout of the LED board was done using Express PCB.
22
CONCLUSION AND FUTURE SCOPE
The project Inertial Progressive Brake Lamp will provide a solution for the problem of judging the correct deceleration of vehicle in front, and reacting to suitably to the situation, faced by automobile drivers, and makes the journey more comfortable and safe. This method is economical, easily attachable and portable to any vehicle. This device will prevent unnecessary rear-end collisions and deaths, and will hopefully be the future standard for all motor vehicles.
The project has many future enhancements and the major component, the accelerometer can be made full use of in the following ways: Variable Blink Rate for each level as blinking catches our attention faster. Electronic Stability Control while executing curves utilizing the acceleration value along the lateral axis. The output from the same accelerometer can be used for other applications like Headlight leveling depending upon the orientation of the vehicle, Theft alarm etc.
23

Inertial Progressive BrakeLamp

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Inertial Progressive BrakeLamp

Uploaded by

Copyright:

Available Formats

Model Engineering College