DEVELOPMENT OF NEW THIRD LIGHT BRAKE SIGNAL ON

MOTORCYCLE HELMET

AHMAD REZDUAN ZAINAL

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 2009

ii

DECLARATION

“I hereby declare that the thesis is based on my original work except for quotations

and citations which have been duly acknowledged”

Signature :………………………………..

Author’s Name: AHMAD REZDUAN ZAINAL

Date : 18 MAY 2009

iii

DEDICATION

My special dedication towards my beloved parents, family, Mr. Mohd Zakaria Mohd

Nasir; my supervisor and all friends. May god bless them for all the help to complete

this thesis.

iv

ACKNOWLEDGEMENT

In the name of ALLAH s.w.t; 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.

To the most respectful supervisor, Mr. Mohd Zakaria Mohd Nasir, I would

like to express my higher gratitude and thank you for the guidance, advices, ideas,

moral support and also endless encouragement during the time of completing this

thesis.

My sincere thank also to Mr. Mohd Nazim Abdul Rahman, all technicians

and staffs in Automotive section in Faculty of Mechanical, UTEM; thank you so

much for the co-operations, helps, patience and also friendship.

Not to forget, special thank to my family and friends who are always willing

to help and also for their understanding, encouragement and support in all

circumstances throughout the time of completing this project

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ABSTRACT

A new third light brake system explore in this thesis is a new applications of

the wireless technology. The light brake was attached at the back of the motorcycle

helmet in order as warning signal to other road user about the appearance of

motorcyclist. This device related to a transmitter unit placed at the motorcycle and

the receiver unit at the back of the motorcycle helmet. When the motorcyclist press

the front or rear brake, the red light illumination signal appear at the back of the

motorcycle helmet. The illumination will represent the brake light as brake light at

motorcycle.

vi

ABSTRAK

Lampu brek ketiga yang direkacipta dalam Projek Sarjana Muda ini adalah

salah satu aplikasi dari sistem tanpa wayar dalam industri automotif. Lampu brek

ketiga ini diletakkan dibelakang topi keledar motosikal sebagai tanda amaran kepada

pemandu lain tentang kehadiran penunggang dan pembonceng motosikal. Alat ini

berdasarkan kepada sebuah unit pemancar yang ditempatkan pada motosikal dan unit

penerima pada bahagian belakang topi keledar motosikal. Apabila pedal brek depan

atau belakang ditekan, sinaran lampu berwarna merah akan terpancar. Sinaran lampu

berwarna merah yang terhasil ini memainkan peranan yang sama seperti yang

terdapat pada lampu brek motosikal.

vii

TABLE OF CONTENT

TOPIC PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF TABLE x

LIST OF FIGURE xi

LIST OF SYMBOLS xiii

LIST OF APPENDICES xiv

CHAPTER 1 INTRODUCTION

1.1 Problem Statement

1.2 Objective

1.3 Scope

1

4

5

5

CHAPTER 2 LITERATURE REVIEW

2.1 Motorcycle Helmet Design

2.1.1 Outer Shell

2.1.2 Impact-Absorbing Liner

2.1.3 Comfort Padding

2.1.4 Retention System

2.1.5 Choose the Motorcycle Helmet

2.2 Overview of Wireless System

6

6

7

7

7

8

10

viii

2.2.1 Radio Frequency(RF) System

2.2.2 Bluetooth System

2.2.3 Infrared System

2.3 Simple Transmitter

2.4 Frequency Modulator(FM)

2.4.1 basic Block of RF

2.5 Overview Electrical Wiring of Motorcycle

2.6 Electronic Component in Circuit Fabrication

2.6.1 Light Emitting Diode(LED)

2.6.1.1 LED Characteristic

2.6.1.2 LED Function

2.6.2 Resistor

2.6.2.1 Resistor Characteristic

2.6.2.2 Resistor Function

2.6.2.3 Basic of Resistive Unit

2.6.3 Capacitor

2.6.3.1 Capacitor Characteristic

2.6.3.2 Capacitor Function

2.6.3.3 Basic Unit Of Capacitance

2.6.4 Transistor

2.6.4.1 Transistor Characteristic

2.6.4.2 Transistor Function

2.6.5 Integrated Circuit(IC)

2.6.5.1 IC characteristic

2.6.5.1 IC function

2.6.6 Relay

2.6.6.1 Relay Characteristic

2.6.6.2 Relay Function

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CHAPTER 3 METHODOLOGY

3.1 PSM Flow Chart

3.2 Wireless System Selection

3.3 System Attachment Prediction

33

35

36

ix

3.4 Block Diagram Of System

3.4.1 Block Diagram of Transmitter Unit

3.4.2 Block Diagram of Receiver Unit

3.5 System Design of Transmitter and Receiver

3.5.1 Circuit Design by MultiSim Software

38

39

39

39

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CHAPTER 4 RESULT AND DISCUSSION

4.1 Fabrication of Transmitter and Receiver

Circuit

4.2 Component of the System

4.2.1 Transmitter Unit

4.2.2 Receiver Unit

4.3 Specification for Circuit System Operating

4.4 Alignment of Tone Frequency

4.5 Alignment of RF Signal Frequency

4.6 The Distance Range Setup and Testing

4.7 System Unit Attachment

4.7.1 Transmitter Unit Attachment

4.7.2 Receiver Unit Attachment

4.8 Estimate Cost for Overall System Unit

4.9 Radio Frequency Radiation Effect on Human

4.9.1 Non-Ionization Radiation

4.9.2 Measurement of RF Radiation

4.9.3 Biological Effect Caused by RF Energy

4.9.4 Emission for radio and Television

Broadcast Antennas

47

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CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion

5.2 Recommendation

68

69

REFERENCE 69

APPENDICES 70

x

LIST OF TABLE

NO TITLE PAGE

1.1 Registered vehicle according type of vehicle(1993-

2007)

1

1.2 Statistic of Road Fatalities from June to July 2008 2

2.1 Requirements components for FM circuit 17

2.2 LED characteristics 23

2.3 Resistor characteristic 25

2.4 Value of the resistive according to the colour 26

2.5 Type of the capacitor 27

2.6 Functions of Transistor leg 28

2.7 Type and symbol of transistor 29

2.8 Types of the existing relay 32

3.1 Project specifications 35

4.1 Requirements components for Transmitter circuit 49

4.2 Requirements components for Receiver circuit 51

4.3 Result of distance range between transmitter and

receiver

57

4.4 List of total cost 63

xi

LIST OF FIGURE

NO

TITLE PAGE

2.1 Basic components of helmet design 8

2.2 SIRIM standard sticker for motorcycle helmet 9

2.3 The peripheral vision of helmet 10

2.4 Electromagnetic spectrum 13

2.5 No deflection of compass 14

2.6 Deflection of compass 14

2.7 The appearence of voltage and current effect from

electromagnetis field

14

2.8 The square wave produced 15

2.9 A sine wave fluctuated produces 15

2.10 The wave identification 16

2.11 Single Bulb with two filaments 21

2.12 The location of the contact switch at motorcycle 22

2.13 Red LED 23

2.14 Ordinary resistor 24

2.15 capacitor 26

2.16 Type of the transistor 28

2.17 IC in variable sizes 29

2.18 The cross section of IC 30

2.19 Single pole 2 way relay 30

2.20 The main part of relay 31

3.1 Helmet design selection 36

3.2 Major design modification of helmet 37

3.3 Sample location of transmitter circuit 37

xii

3.4 12V Relay 40

3.5 Example listed of the variable component in

MultiSim software

41

3.6 Example changing the value of the component 42

3.7 Other component setting 43

3.8 Grouping setup for new component 44

3.9 Example of Transmitter circuit drawing in MultiSim 45

3.10 Example of Receiver circuit drawing in MultiSim

Software

46

4.1 Printed circuit board for receiver and transmitter 47

4.2 Transmitter Circuit 50

4.3 Transmitter switch location at the front brake 50

4.4 Receiver circuit 52

4.5 Transmitter switch location at the rear brake 52

4.6 Adjusting trimmer potentiometer 54

4.7 The LED at the receiver board light up 54

4.8 Adjusting trimmer capacitor in variable distances 55

4.9 Distance between the transmitter and receiver units 56

4.10 Example for range test process 57

4.11 Full scale of motorcycle model 58

4.12 Combination of brake switch at the front and rear

brake

59

4.13 Compressed of board circuit 59

4.14 The red LED in parallel arrangement 60

4.15 6V battery for receiver unit 60

4.16 Location of receiver circuit’s switch 61

4.17 Receiver unit attachments on air spoiler of the helmet 62

4.18 Condition of light brake before(a) and after(b)

operating

62

4.19 Instantaneous light up of brake of each system 63

xiii

LIST OF SYMBOLS

Z = Impedance

R = Resistance

X = Reactance

xiv

LIST OF APPENDICES

NO TITLE PAGE

1 PSM1 Chart 73

2 PSM2 Chart 74

3 Figure of new design of motorcycle helmet 75

4 Reference patent 83

1

CHAPTER 1

INTRODUCTION

Motorcycle is the most popular transport and become the main mode used by

commuters in Malaysia. In 2007, about 7943,364 vehicles were registered with

Jabatan Pengangkutan Jalan (JPJ) which was motorcycle. Not surprisingly,

motorcycle consumed the highest road accidents compared to other vehicle involved

in accident. From the statistic recorded, almost every year begin from 1993 until

2007, motorcycle have recorded highest road accidents compared to cars, van, bus

and other vehicle that involved in accidents.(source: www.panducermat.org.my)

Table 1.1: Registered vehicle according type of vehicle(1993-2007)

(Source: JKJR (September 2008))

REGISTERED VEHICLE

Year Private Car

Private

Motorcycle

Lorry/Van Bus Taxi

1993 2,255,420 3,703,838 466,871 33,358 36,458

1994 2,426,546 3,977,047 495,736 34,771 40,088

1995 2,532,396 3,564,756 430,716 35,224 27,276

1996 2,886,536 3,951,931 512,165 38,965 59,456

1997 3,271,304 4,328,117 572,720 43,444 51,293

1998 3,452,852 4,692,183 599,149 45,643 54,590

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

2

Year Private Car

Private

Motorcycle

Lorry/Van Bus Taxi

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

According to the road statistic which reported by PDRM, motorcyclist and

pillions have involved at the highest road fatalities which consumed about 304 in Jun

2008 and 300 for the next month. (Source: www.panducermat.org.my (September

2008))

Table 1.2: Statistic of Road Fatalities from June to July 2008

Source: JKJR (September 2008)

2008 2008

Category of road user JUNE JULY

Car driver and passenger 143 102

Motorcyclist and pillions 304 300

Pedestrians 47 47

Cyclist 13 21

Bus driver and passenger 10 1

Lorry diver 13 14

Van driver 5 12

Four wheel vehicle driver 11 11

Others 9 1

Total 555 509

3

In year 2005, from 6188 road fatalities, about 58% which consumed 3584

death involved motorcyclist and pillion. About 68% of the read fatalities recorded

caused by the head injuries among the motorcyclist and pillion. Even the small

accident can caused body injuries especially head and other important of body parts.

(Source: www.panducermat.org.my (August 2008))

The usage of the motorcycle helmet was the effective way in order to protect

and reduced head injuries. However, the usage of motorcycle helmet needs to fulfill

the standard specifications which stated from Jabatan Keselamatan Jalan

Raya(JKJR). The standards are related to the design of the helmet in reducing the

impact to the head when the accident happens.

The Center of the Road Safety in Universiti Putra Malaysia (UPM) reported

of suggestion of using the right helmet and the application of each type of helmet.

The right application of helmet need to subjected because of the success of helmet

used which can reduced almost 50% head injuries caused by road accidents.

In order to reduce the road accident among motorcyclists and pillions, a lot of

method have been developed and derived. One of the way is by exposed the

motorcyclist to used the recommended and standard which stated from JKJR.

In achieving the objective of reducing the road accidents among the

motorcyclist, a lot of ways to improved the safety elements of the motorcycle

helmet. One of the ways is develop the light brake at the back of the helmet. The

relevant of this project which to mentions the other road user about the appearance of

the motorcyclist and pillions especially during heavy rain and at night. The

difficulties to mentions appearance of the motorcyclist will possibly consumed to

road accidents and fatalities.

4

1.1 Problem Statement

There is a lot of problem facing in order to minimize the risk of motorcyclist

and pillions involved in accidents especially at night and during heavy rain where the

other vehicle hard to detect the appearance of motorcyclist. This is because the bad

weather will interrupt other road user to see clearly towards the motorcyclist and

pillions.

Besides, the appearances of single of brake light at the back of the

motorcycle sometimes fail to function due to certain cases. This also contributes in

road accident because the other road user can not see the motorcyclist clearly

especially at night and bad whether. Also, the appearance of the dirt and luggage will

act as barrier for the clear brake light illuminations in order to mentions other road

user about the appearance of the motorcyclist.

5

1.2 Objective

1. Development light brake at the back of motorcycle helmet via wireless

system.

2. Development of wireless system for flexibility and safety features for

motorcyclist.

1.3 Scope

1. Literature review on wireless system and electrical system of motorcycle.

2. Literature review on the existing helmet design.

3. Fabrication of the motorcycle and helmet model for the light brake system.

4. Analytical study of the components for prototype fabrication.

5. Combination of existing design of helmet with the attachment of the wireless

unit.

6. Study the effect of the wireless system to environment

6

CHAPTER 2

LITERATURE REVIEW

2.1 Motorcycle Helmet Design

Different helmets operated with different application of used such as hard

hats on construction and heavy-industry heads and Kevlar caps on military heads.

The compositions of the type material and design will not interchangeable.

Motorcycle helmets are very sophisticated and specialized for the activity. They've

been developed carefully and scientifically over the years.

There are four basic components which work together to provide protection

in the motorcycle helmet. The components refer to an outer shell, an impact-

absorbing liner, the comfort padding, and a good retention system.

2.1.1 Outer Shell

The outer shell usually made from fiber-reinforced family composites or

thermoplastics like polycarbonate. This is strong material which designed and

intended to compress when the helmet hits anything hard. This material will

disperses energy from the impact to lessen the force before the force reaches the

motorcyclist head, but outer shell must stand with other components of helmet to full

protective.(source:www.msf-usa.org)

7

2.1.2 Impact-Absorbing Liner

Inside the outer shell there are components that equally important which

referred to impact-absorbing liner. This impact-absorbing liner usually made of

expanded polystyrene or commonly said as Styrofoam. This component will dense

layer cushions and absorbs the shock as the helmet stops and motorcyclist head

wants to keep on moving because of the inertia.

Both the shell and the liner compress if hit hard, spreading the forces of

impact throughout the helmet material. The more impact-energy deflected or

absorbed, the less there is of it to reach the head and do damage. Some helmet shells

delaminate on impact. Others may crack and break if forced to take a severe hit; this

is one way a helmet acts to absorb shock. (Source: www.msf-usa.org)

2.1.3 Comfort Padding

The comfort padding is the soft foam-and-cloth layer that sits next to

motorcyclist head. It helps keep motorcyclist in comfortable and the helmet fitting

snugly. In some helmets, this padding can be taken out for cleaning.

2.1.4 Retention System

The retention system, or chin strap, is very important component of the

motorcycle helmet. It is the one piece that keeps the helmet on motorcyclist head

during crash. A strap is connected to each side of the shell.

8

Figure 2.1: Basic components of helmet design

(source:www.msf-usa.org)

2.1.5 Choosing the Motorcycle Helmet

A full-face helmet gives the most protection since it covers more of

motorcyclist face. Full face helmet usually has a moveable face shield that protects

the eyes when it is closed. Racers prefer full-face helmets for the added protection

and comfort.

A three-quarter, open-face helmet is also a choice of some motorcyclist. This

type of motorcycle helmet is constructed with the same basic components, but this

type does not offer the face and chin protection of full-face helmets. The use an

open-face helmet should have a snap-on face shield in place during ride that can

withstand the impact of stone or other debris.

A half-helmet protects even less of motorcyclists head. It is more likely to

come off from head upon impact. Therefore, half-shell helmets are not

recommended. (Source:www.msf-usa.org)

A lot of good helmets are available today, in a range of prices. The

improvement of helmet made of lightweight, modern materials and additional

9

accessories. Manufacturers are working to make them less expensive, stronger and

more comfortable.

Every single unit of helmet must meet minimum safety standards which

recommended. The way to find reliable helmet is by look at the Standard and

Industrial Research of Malaysia (SIRIM) sticker outside of the helmet. The sticker

means the helmet meets the safety test standards of the JKJR recommendations

.

Figure 2.2: SIRIM standard sticker for motorcycle helmet

The SIRIM sticker was mention that the motorcycle helmets have meet their

specification in terms of safety features and testing. The SIRIM departments have

these responsibilities in testing the helmet before it can meet the user. The principle

and testing of Snell Memorial Foundation which used in West Country are close

with the testing that be done in Malaysia in way of conceptuality and practically.

Each organization has rigid procedures for testing:

• Impact – the shock-absorbing capacity of the helmet.

• Penetration – the helmet's ability to withstand a blow from a sharp object.

• Retention – the chin strap's ability to stay fastened without stretching or

breaking.

• Peripheral vision – the helmet must provide a minimum side vision of 105

degrees to each side.

SIRIM sticker

10

Figure 2.3: The peripheral vision of helmet

(Source: www.smf.org)

2.2 Overview of Wireless System

There is a lot of wireless system which used widely in this modern country

including Malaysia. Most of the wireless system which recently use was Radio

Frequency (RF), Bluetooth and Infrared (IR). In this project, one of the wireless

system will adapted through objective and flexibility of the application of the

system. There is a lot of factor should be in consider to choose either each of the

wireless system are suitable with application of the project. In order to find out the

most flexibility of the system, the system of RF, Bluetooth and IR advantages and

disadvantages will be listed for comparison.

2.2.1 Radio Frequency(RF) System

Radio frequency (RF) is the one of the remote control application which uses

widely such as radio, toys, sensor, mobile phone and many more. This remote

control which use the radio frequency will send the alternating signal which produce

from transmitter unit to the receiver unit. In other words, this system can be turn on