Gear indicator. Free Technical Library article

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Motorcycle gear indicator

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Encyclopedia of radio electronics and electrical engineering / Automobile. Electronic devices

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This device is used to display the current gear of the motorcycle. The main difference of this device is that it displays the current transmission depending on the signals from the sensors on the switch handle. Unlike other devices, where the current gear of the motorcycle was determined based on data from the speedometer and tachometer (used in some models of expensive motorcycles). The device contains a main board with a 7-segment indicator, two Hall sensors placed on the motorcycle frame and a small magnet placed on the gear lever.

Motorcycle gear indicator. The location of the sensors on the gear handle

The electrical circuit is based on the AVR ATTINY25/45/85 microcontroller, which processes the signals from two sensors and outputs transmission data to the indicator, through the 4026 counter / decoder.

Motorcycle gear indicator. Schematic diagram of the device

(click to enlarge)

The source code of the program is written in AVR-GCC (WinAVR). Fuses during programming - all by default (MK ATTINY25 and programmer USBTiny). The only thing is that the constant TOP_GEAR 5 should be changed to 6 for a six-speed motorcycle.

The printed circuit board is made double-sided, in a miniature design. Microcontroller and microcircuit 4026 in SMD version. The 7-segment indicator is made by a separate modular board and is connected to the end of the main board (letter G). There are 2 options for the indicator printed circuit board - for red and blue 7-segment indicators.

Motorcycle gear indicator. Printed circuit boards

List of elements used:

R1	10 to 220 ohm, 0.5 W	Depends on the required brightness of the indicator
R2, R3	10 kΩ, 0.25 W
C1	220uF / 35V
C2	100 nF
МК	ATTINY25/45/85
Counter	4026	Mouser Store Number 595-CD4026BPWE4
IC1, IC2	Hall Sensor	Melexis shop number US5881LUA
IC3	7805	5V stabilizer in TO-220 package
BLUE	Kingbright 0.3"	Mouser Store Number 604-SC03-11PBWA/A
NET	Kingbright 0.3"	Mouser Store Number 604-SC03-12EWA
Jpx	Pin connectors

If the LED-type indicator used, then the resistor R3 can be replaced with a 1N4148 diode:

Photos of the assembled device:

Connections:

When power is connected to the circuit (supplying 12V to the contacts TO_POWER_1 and TO_POWER_2), the device self-tests by enumerating all the digits of the indicator. After the test is completed, the device is ready for use.

The sensor must be positioned as follows - the north pole of the magnet should look at the sensor (if it is the other way around, it will not work). Therefore, if it does not work, then deploy the magnet or sensors.

Also, if a neutral gear is detected (from the neutral switch connected to TO_POWER_4), the display will show zero.

When the power is turned off, the current transmission is written to the EEPROM memory of the microcontroller and when the device is turned on again, it is read from the memory and displayed on the display.

The cable to the sensors is 4-wire. Soldering points and exposed wire leads are placed in a heat shrink tube. The conclusions near the sensor itself can be filled with varnish or epoxy. You can try to put the entire sensor with the leads into the heat shrink.

A few photos of installing the device in a Suzuki Intruder VS400 motorcycle:

Download schematic files for EAGLE, source code and firmware, PCB files

Author: Koltykov A.V.; Publication: cxem.net

See other articles Section Automobile. Electronic devices

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