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Final Product Design Presentation P13265 Motorcycle Safety Lightin g Backpack Team. May 10th, 2013 RIT MSDII. MSD Team. Primary Customers: Sport bike/standard riders who ride with backpacks Surrogate Customer Andrew Nauss Faculty Guides: Leo Farnand Vince Burolla Team Members: - PowerPoint PPT Presentation
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MAY 10TH, 2013RIT MSDII
Final Product Design PresentationP13265 Motorcycle Safety Lighting Backpack Team
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MSD Team Primary Customers:
Sport bike/standard riders who ride with backpacks
Surrogate Customer Andrew Nauss
Faculty Guides: Leo Farnand Vince Burolla
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 Killian Castner, Industrial Designer
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Today’s Agenda
I. Overview 3 mins, 2 slides
I. Project Description RecapII. Customer Needs
II. System Model Design 5 mins, 4 slides
I. Final DesignIII. Testing 3 mins, 2 slides
I. Functionality vs. Test PlanIV. Project Management Review 8 mins, 2
slidesI. Schedule vs. MSDII PlanII. Budget vs. Planned Budget
V. Next Steps 10 mins, 6 slides
I. Lessons LearnedII. Next StepsIII. Moving Forward, Comments
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Concept Summary
Problem: Want to reduce number of motorcycle accidents and deaths caused by other motorists
Solution: Visibility product aimed at increasing safety of motorcycle rider
Design: Backpack with LED turn signals, brake, and running lights that operate wirelessly with vehicle
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Customer Needs
Final DesignBackpack
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Electronics Box Inside Bottom Backpack Compartment
Turn Signals
Brake/Running Lights User Control
Panel On Chest Strap
Zipper attachment to hard-shell
Soft back and straps cut from existing backpack
Lower compartment for electronics housing
“Quick” access pouch
Final DesignChest Strap User Control Panel
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Control Panel (w/ Cover)
Control Panel PCB
Hazard Button
StatusLEDs
Battery Health LEDs On/Off Button
Light Brightness High/ Low Button
Concept to Creation- Changes and Problems:• Rapid prototyped instead of vacuum formed• Battery LED colors changed• LED push buttons are not two position (light up all the
time)• Buttons not waterproof
Concept to Creation-Changes and Problems:• Housing container thicker than design• Low voltage battery shut-off non-functional
Final DesignElectronics Housing*
8NiMH rechargeable battery
40 pin ribbon connector for light signals
USB chargingport
Motorcycle Battery“Quick” ConnectPort
AC NiMH ChargerPort
Receiver XBeeOn/Off Power Button
Flash Pattern Select Push Buttons* Lid Not Pictured
Final DesignMotorcycle
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Transmitter Box
(Inside Box)Transmitter Board
w/ Xbee Transmitter
Bike Power
Bike Light Signals In
Wireless Light Signals Out
Bergquist Thermal Adhesive
Concept to Creation-Changes and Problems:• No standoffs used due to Bergquist donation• Board resized due to box being too small• Box is unnecessarily tall
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Test Results
*N/C= not completed
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Test Results
*N/C= not completed
Schedule vs. Plan12
Major Milestones:
Milestone Planned Actual Gap
Shell Formed Week 3 Week 7 1 month
Backpack Assembly Complete
Week 6 Week 9 3 weeks
Electronics Housing Complete
Week 3 Week 7 1 month
Successful Operation of Boards
Week 2 Week 11? ~ 2.5 months
Installation on Vehicle Week 6 Week 11? 1 month
Project Budget vs. Plan13
• Initial budget set to $500• Increased to $1,000
• Team spent ~$1,200
• Unexpected/ high item costs:• 3 revisions of PCB’s with new components:
• 1st $100 (budgeted for)• 2nd $90 (not budgeted for)• 3rd $150 (budgeted for in budget increase)
• Mistakes• 1 Xbee units shorted ~$20• Light covers knocked off chest strap buttons ~$10• Etc.
• Team meeting to divide costs among responsible members
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Lessons Learned: Mechanical
Shell Assembly: Problem: Thermoforming process did not create ideal
results Reason: Did not test assumptions about process Lesson: Confirm manufacturing method limitations
prior to final designBackpack Oversized:
Problem: Backpack is too large for average person to wear
Reason: CAD models not accurate prior to build Lesson: Print out CAD models to scale, check for
tolerances between assemblies
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Lessons Learned: Electrical
Board layout: Problem: Major mistakes made in 2 board layouts Reason: Lack of attention to detail during review Lesson: A systematic, thorough approach is necessary to
prevent careless, costly, and time-consuming mistakesSoftware:
Problem: Software is not fully developed, which prevented full functionality (e.g. PWM and high/low functionality)
Reason: Poor planning/ uneven work distribution Lesson: Make more refined deadlines/ don’t
underestimate the complexity of software development
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Lessons Learned: Group Dynamics
Planning: Problem: Almost every major milestone missed Reason: Did not follow MSDII plan, lack of motivation Lesson: Plans are there for a reason, use them
Communication: Problem: Disconnect/ lack of communication between
team members Reason: Not always prompt in responses, not asking
questions Lesson: Communicate frequently
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Next Steps
Next Week: Populate new board next week (upon arrival) Complete all electronics testing Install and test system on motorcycle
This summer: Will present at RIT’s technology tent at the Wegman’s
LPGA tournament
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Future Improvements
Mechanical: Redesign for smaller size More precise manufacturing process
Electrical: Complete software functionality Change battery and wireless technologies
Overall Product: Redesign for mass production Reduce build cost
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Thank You for Your Time!
Questions?