DESIGN OPTIMIZATION OF THIRD BRAKE LIGHT AND SIGNAL SYSTEM

ON MOTORCYCLE HELMET

LOGESWARAN A/L KANASIN

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

“It is hereby certified that I have read this thesis by Logeswaran A/L Kanasin and in our opinion it is satisfactory in terms of scope, quality and presentation as a fulfillment of the requirements

for the course Bachelors Degree in Mechanical Engineering (Automotive)”

Signature :

Supervisor 1 : Mr. Mohd Zakaria Mohammad Nasir

Date :

Signature :

Supervisor 1 : Mr. Razali bin Mohd Tihth

Date :

DESIGN OPTIMIZATION OF THIRD BRAKE LIGHT AND SIGNAL SYSTEM ON

MOTORCYCLE HELMET

LOGESWARAN A/L KANASIN

This report was submitted in accordance with the partial requirements for honor of

Bachelor of Mechanical Engineering (Automotive)

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

MAY 2010

ii

DECRALATION

I hereby, declare this thesis entitled

“DESIGN OPTIMIZATION OF THIRD BRAKE LIGHT AND SIGNAL SYSTEMON

MOTORCYCLE HELMET”

is the result of my own research except as cited in the reference.

Signature : Author’s Name : LOGESWARAN A/L KANASIN Date :

iii

DEDICATION

To my beloved family.

iv

ACKNOWLEDGEMENTS

In name of GOD I would like to express my first and foremost thankfulness

for giving me the optimum health, courage and strength along the period of

completing this project.

It gives me the greatest pleasure to express my sincere gratitude to my

supervisor, Mr. Mohd. Zakaria Mohammad Nasir of which we had an excellent

working relationship, and who offered tremendous help and encouragement

throughout the course of my graduate studies and completion of this project.

My sincere thank also to my friends, all technicians and staffs in Faculty of

Mechanical, UTeM; thank you for the co-operations, helps, and patience.

Thanks also to Universiti Teknikal Malaysia Melaka for giving me the

opportunity to complete my degree program successfully.

I would also like to take this opportunity to thank my family members who

inspired and supported me throughout the completion of my project.

v

ABSTRACT

A new helmet design where it is integrated with wireless based third brake light and

turn signal lights is being developed in this thesis. This invention will function to be more

flexible, and increase the safety of motorcyclists. The presence of third brake light and turn

signal light at the back of helmet will increase the visibility of the rider and his motorcycle

especially at night and raining. The design is based on existing third brake light system using

wireless system. Extra feature that is added to this invention is the addition of turn signal

lights at the back of helmet. The new design will be integrated into an air spoiler unit to make

it as an accessory. The systems will be functioning by signal transmission between

transmitter and receiver using radio frequency (RF). The transmitter unit will be attached to

motorcycle and receiver will be placed at the helmet.

vi

ABSTRAK

Satu reka bentuk topi keledar yang terkini disepadukan dengan sistem tanpa wayar yang

menghubungkan lampu brek ketiga dan satu suis membelok adalah dibangunkan dalam tesis ini.

Ciptaan ini akan berfungsi supaya lebih fleksibel, dan meningkatkan keselamatan penunggang

motosikal. Kehadiran lampu brek ketiga dan lampu isyarat membelok di belakang topi keledar

akan meningkatkan jarak penglihatan penunggang dan pengguna jalanraya yang lain di belakang

motosikal terutama pada waktu malam dan semasa hujan. Reka bentuk adalah berdasarkan

terdapat brek ketiga sistem lampu menggunakan sistem tanpa wayar. Ciri-ciri tambahan yang

ditambah untuk ciptaan ini adalah lampu isyarat membelok kiri dan kanan di belakang topi

keledar. Reka bentuk ini adalah berdasarkan kepada lampu brek ketiga menggunakan sistem

tanpa wayar yang sedia ada. Reka bentuk baru ini akan diintegerasikan ke dalam bekas

aerodinamik udara bagi menjadikan ia seperti satu aksesori topi keledar. Sistem-sistem itu akan

berfungsi oleh transmisi isyarat antara pemancar dan penerima menggunakan frekuensi radio.

Unit pemancar akan menjadi diletakkan pada motosikal dan penerima akan dipasang pada topi

keledar.

vii

TABLE OF CONTENT

CHAPTER SUBJECT PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF DIAGRAMS xiiii

LIST OF ABBREVIATIONS xv

CHAPTER 1 INTRODUCTION 1

1.1 Problem Statement 3

1.2 Objective 6

1.3 Scope 6

viii

CHAPTER 2 LITERATURE REVIEW 7

2.1 Wireless system 7

2.1.1 Bluetooth 7

2.1.2 Infrared system 9

2.1.3 Radio Frequency 11

2.2 RF Transmitter 13

2.2.1 Transmitter circuit 15

2.3 RF Receiver 16

2.4 Motorcycle Helmet Design 17

2.4.1 Choices of Motorcycle Helmet 18

2.4.2 Retention System 21

2.4.3 Comfort Padding 21

2.4.4 Outer Shell 21

2.4.5 Impact Absorbing Liner 22

2.5 Motorcycle Electrical Wiring System 23

2.5.1 Turn Signal Light 24

2.5.2 Brake Light 24

2.6 Electrical Components 25

2.6.1 Resistor 25

2.6.1.1 Fixed resistors vs. Variable resistors 26

2.6.1.2 Resistive Unit 27

2.6.2 Capacitor 28

2.6.2.1 Types of Capacitors 28

2.6.2.2 Capacitance 29

2.6.3 LED (Light Emitting Diode) 29

2.6.4 Transistor 30

2.6.4.1 Type of Transistors 31

2.6.5 Integrated Circuit (IC) 32

2.6.6 Relay 33

2.6.6.1 Operation of Relay 33

viiii

2.6.6.2 Single Pole Single Way relay (SPSW) & 34

Single Pole Two Way relay (SPTW)

2.7 Ergonomics of helmet design 35

2.7.1 Design Considerations 36

2.7.2 Design Criteria 37

2.7.3 Standard for Helmet Strength 38

2.7.4 Helmet Weight and Aerodynamics 39

2.7.5 Design Issues 39

CHAPTER 3 METHODOLOGY 41

3.1 Flow Chart of Thesis 41

3.2 Wireless System Selection 43

3.3 Helmet Design Compatibility (Accessory) with 44

RF System

3.4 Block Diagram of RF System 47

3.5 Circuit Design 48

3.6 Helmet modelling in MSC CATIA V5 49

viiiii

CHAPTER 4 RESULTS AND DISCUSSION 50

4.1 Transmitter Unit 50

4.2 Receiver Unit 53

4.3 System Unit Attachment on Motorcycle Model 55

4.3.1 System attachment on helmet 57

4.3.2 Testing on motorcycle 60

4.4 Range setup and testing 61

4.5 Radio Frequency (RF) Radiation Effect on Human 62

4.5.1 Non-Ionizing Radiation 62

4.5.2 Measurement of Radio Frequency Radiation 63

4.5.3 Biological Effect Caused By Radio Frequency 63

Energy

4.5.4 Emissions from Radio and Television Broadcast 64

Antennas

CHAPTER 5 CONCLUSION AND RECOMMENDATION 66

5.1 Conclusion 66

5.2 Recommendation 67

REFFERENCES 68

BIBLIOGRAPHY 69

APPENDIX 70

xi

LIST OF TABLES

NO. TITLE PAGE 1.1 Breakdown of registered vehicles from 1999 to 2007 2

1.2 Road Accident Fatalities according to type of road users 2

2.1 Comparison of Performance Characteristics of wireless 11

systems

2.2 Breakdown of RF system 12

2.3 Type of resistors comparison 26

2.4 Helmet test criteria for CSPC, ASTM F1447 and Snell B-95 38

3.1 Wireless system comparison 43

xii

LIST OF FIGURES

NO. TITLE PAGE 1.1 Downward visual clearance 4

1.2 Downward visual clearance (side view) 4

1.3 Upward visual clearance 5

1.4 Upward visual clearance (side view) 5

2.1 Bluetooth radio frequency bandwidth 8

2.2 Electromagnetic spectrum 10

2.3 No deflection 13

2.4 Deflection 13

2.5 Compass deflection and effect on voltmeter 14

2.6 Sine wave and square wave forms 14

2.7 Wave characteristics 15

2.8 Receiver circuit flow 17

2.9 Cross section of a full-face motorcycle helmet 18

2.10 Full face helmet 19

2.11 Open face helmet 19

2.12 Half-helmet 20

2.13 Contact switch 25

2.14 Fixed resistor 26

2.15 Resistor color code system 27

2.16 Capacitor 28

2.17 LED configuration 29

2.18 Transistors 30

2.19 NPN and PNP transistor configurations 31

2.20 IC (Integrated Circuit) 32

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2.21 Simple electromechanical relay 33

2.22 Relay condition 34

2.23 Structure and components of a helmet 35

2.24 Helmet’s comfort padding comparison 40

3.1 KHI Helmet 44

3.2 Position of transmitter 46

3.3 Relay (12 V) 46

3.4 Sample transmitter circuit drawn in MultiSim 48

3.5 Surface modelling of helmet 49

4.1 Assembled transmitter unit 51

4.2 Front brake transmitter switch location 52

4.3 Rear pedal brake transmitter switch location 52

4.4 Assembled receiver circuit 54

4.5 Flasher circuit schematic 54

4.6 Motorcycle model 56

4.7 Brake switch at (a) front and (b) rear 56

4.8 Signal light switch box 57

4.9 Power supply location 58

4.10 Connecting wires 58

4.11 Location of LEDs 59

4.12 Fabricated helmet with motocycle model 60

4.13 Instantaneous light up of brake on each system 60

4.14 Distance between the transmitter and receiver units 61

xiiii

LIST OF DIAGRAMS

NO. TITLE PAGE 2.1 FM Transmitter circuit diagram 15

2.2 Basic motorcycle wiring harness 23

3.1 Transmitter unit 47

3.2 Receiver unit 47

4.1 Transmitter circuit schematic diagram 51

4.2 Receiver circuit schematic diagram 53

xv

LIST OF ABBREVIATIONS

JPJ = Jabatan Pengangkutan Jalan

JKJR = Jabatan Keselamatan Jalan Raya

IR = Infrared

RF = Rado Frequency

Hz = Hertz

ISM = Industrial, Scientific and Medical

CPU = Central Processing Unit

FM = Frequency Modulator

AM = Amplitude Modulator

VHF = Very High Frequency

UHF = Ultra High Frequency

PPE = Personal Protective Equipment

ISO = International Standards Organization

EPS = Expanded Polystyrene

IC = Integrated Circuit

LED = Light Emitting Diode

SPSW = Single Pole Single Way

SPTW = Single Pole Two Way

MTBI = Mild Traumatic Brain Injury

CPSC = Consumer Product Safety Commission

SAR = Specific Absorption Rate

ERP = Effective Radiated Power

1

CHAPTER 1

INTRODUCTION

In Malaysia, the major mode of transportation is motorcycle since 1980’s.

Currently, the motorcycles on the road constitutes more than halves of all registered

vehicles population in Malaysia. According to Jabatan Pengangkutan Jalan (JPJ),

about 485,236 new motorcycles have been registered in the year 2007 alone. The

percentage of motorcycles registered annually in Malaysia is about 60% with an

annual growth rate of 7% (Highway Planning Unit, Ministry of Works, 2003).So,

the presence of higher number of motorcycles on the road constitutes to higher

number of cases involving road accidents compared to other vehicles. The use of

motorcycles and motor vehicles imposes risks of death or permanent impairment

due to head injury. So, for motorcycles, the proper use of protective helmets can

minimize the risk of death or permanent impairment.

2

Table 1.1: Breakdown of registered vehicles from 1999 to 2007

(Source: JKJR, January 2009)

Year No. Of Registered Vehicles

Car Motorcycle Lorry/Van Bus Taxi

1999 3,787,047 5,082,473 642,976 47,674 55,929

2000 4,145,982 5,356,604 665,284 48,662 56,152

2001 4,557,992 5,609,351 689,668 49,771 56,579

2002 5,027,173 5,859,195 714,796 51,251 58,385

2003 5,428,774 6,164,953 740,462 52,846 60,723

2004 5,911,752 6,572,366 772,218 54,997 65,008

2005 6,473,261 7,008,051 805,157 57,370 67,451

2006 6,941,996 7,458,128 836,579 59,991 70,409

2007 7,419,643 7,943,364 871,234 62,308 72,374

Table 1.2: Road Accident Fatalities according to type of road users

(Source: JKJR, August 2009)

Road User Categories 2007 2008

Car driver/passengers 1228 1335

Motorcyclists/pillion riders 3646 3898

Pedestrians 636 598

Cyclists/pillion 190 203

Bus driver/passenger 75 48

Lorry drivers 204 195

Van drivers 133 96

Four-wheel Vehicle drivers 99 106

Others 71 48

Total 6282 6527

3

The seriousness of injuries sustained in road accidents among the users are

more prevalent in motorcyclists and pillion passengers category. Although many

precaution steps have been implemented in recent years, the fatalities keep on

increasing every year. Normally, in motorcycle accidents, our upper parts of human

body especially head and neck are more prone to serious injuries. According to a

research done by Road Safety Research Centre, Universiti Putra Malaysia (UPM) in

1999, the distribution of injuries in fatally injured motorcyclists shows that their

head is the most frequent part of human getting injured at 44.1%.

This alarming rate of road fatality among motorcyclists is contributed largely

by its safety aspects such as safety helmet and hazard lights. Some of these elements

does not comply the standards set by Jabatan Keselamatan Jalan Raya (JKJR) and

Standard and Industrial Research Institute of Malaysia (SIRIM) and also

international standard like Federal Motor Carrier Safety Administration (FMCSA).

Other than that, innovative ideas like new design on helmet which consists of

brake light and signal lights at the back of helmet will help in improving road

fatalities involving motorcycles. The presence of these lights at the back of helmet

will alert other road users behind them. This will be helpful during heavy rain and at

night.

1.1 Problem Statement

The appearance of motorcycles and its riders during night and under rain is

greatly reduced due to poor visibility. The motorists behind a motorcycle can’t see

them under these weather conditions. Furthermore, although the usage of safety

vests can be helpful, not many motorcyclists are using it.

In the meantime, the position of motorcycle’s rear brake light which is low

for other motorists including motorcyclists. In terms of peripheral vision of a helmet,

the downward visual clearance is 30° where the second plane is tilted 30° down

4

from the basic plane. This criteria is suitable for helmets without integrated brake

and signal light on helmet.

Figure 1.1: Downward visual clearance

Figure 1.2: Downward visual clearance (side view)

But for visual clearance above the basic plane (upward visual clearance), the

second plane is tilted 7° up from the reference plane. This implies that the

motorcyclists can view upward up to 7° from their eye (reference plane). For better

safety precaution, the riders need more and better visible brake and signal light.

Attaching brake and signal light on motorcycle helmet based on upward visual

clearance could be the solution for this.

30°

Basic plane

Second plane

Helmet

5

Figure 1.3: Upward visual clearance

(Source: 2005 Standard for Protective Headgear, Snell Memorial

Foundation)

Figure 1.4: Upward visual clearance (side view)

Helmet 7°

Reference plane

Second plane

6

1.2 Objective

i) Develop new third brake light and turn signal on motorcycle helmet

using wireless system.

1.3 Scope

i) Literature study on wireless systems and its effects to environment

ii) Literature study on motorcycle’s existing helmet design

iii) Perform analytical study on critical components

iv) Design and develop a new electrical circuit for wireless brake and

signal system.

v) Design and modelling new concept and design in MSC CATIA V5 of

new helmet design

vi) Fabricate prototype model and testing

7

CHAPTER 2

LITERATURE REVIEW

2.1 Wireless System

In this thesis, wireless system will be used for the new third brake light and

signal system on the helmet. Basically, examples of wireless systems are Bluetooth,

Infrared (IR), and Radio Frequency (RF). Mobility is one of the key terms in

wireless system where users of wireless system tend to be mobile. To choose the

best wireless system for this project, comparisons will be made in terms of

advantages and disadvantages among the three available wireless systems.

2.1.1 Bluetooth

Bluetooth is one method of connecting devices like computers with hand

phones and to other electronic gadgets. Bluetooth is an open wireless protocol that

enables short-range wireless voice and data communications anywhere in the world.