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The Equalizer: Advanced Electromagnetic Bicycle Trainer

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The Equalizer is an innovative electromagnetic bicycle trainer that allows users to customize their workout resistance from 1 to 10 levels at the push of a button. It features a heart rate monitoring system integrated with an LCD display for real-time tracking. This trainer simulates various terrains for both indoor riding and competitive training, making it ideal for cyclists of all skill levels. A lightweight rechargeable battery powers the system, ensuring mobility and ease of use while addressing challenges faced by modern cyclists.

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The Equalizer: Advanced Electromagnetic Bicycle Trainer

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  1. The Equalizer Jeremiah Harmon Greg Buzulencia

  2. Topics of Interest • Overall Design Description • Component by Component Description • Interface Description • Design Issues • Cost Estimates

  3. Inspiration • Challenges facing cyclists today

  4. Resistance Level: 4 Heart Rate: 95 bpm The Equalizer – Summary • Electromagnetic Bicycle Trainer system. • The resistance from 1-10 can be selected using push buttons connected to the HCS12.

  5. The Equalizer - Uses • Riding with others of varying skill. • A rider in a flat area can simulate hills. • Act as an indoor trainer. • Interfaced heart rate monitoring system.

  6. System Block Diagram 12V Battery 5V Supply Voltage to Current converter (DC) Magnetic Hysteresis Brake Micro-controller Heart rate sensor Push buttons LCD screen

  7. Full System Diagram

  8. The Equalizer - MCU to Brake • The brake is controlled by the HCS12 with a voltage-current converter. • The converter can apply a DC current to an electromagnetic brake. • An electromagnetic hysteresis rotary brake can provide resistance against the rear wheel of the bike.

  9. The Equalizer - Power • Since the bike is mobile, a lightweight 12V nickel metal-hydride rechargeable battery is used. • Power is supplied to brake (primarily), MCU and device controller. • Considerations are being taken for issues dealing with bursts of current drawn by brake.

  10. Electromagnetic Brake • Applies a constant resistance against rotation of rear wheel of the bike. • Can increase the amount of power a user needs to exert on the bike by 5-40%. • The user can pick from 11 levels of resistance. • Each level provides preset resistance.

  11. Electromagnetic Brake – Overview • A Magnetic Hysteresis Brake best met our project design constraints. • The hysteresis effect. • Two components –a reticulated pole structure and a steel rotor/shaft assembly. • Ball bearing can spin freely without touching – no friction • Magnetizing force creates a flux field.

  12. Electromagnetic Brake – Overview • The rotor is magnetically restrained • Smooth, infinitely controllable torque loads • Torque independent of speed • Quiet operation • No wear components exist • Long, maintenance free life

  13. Electromagnetic Brake – Operational Specifications • High maximum operating speed. • The maximum rotational speed was calculated using a top road speed of 40 MPH. (40mi/h) * (5280 ft/mi) * (12 in/ft) * (1/60 hr/min) * (1/(26*) in-1) = 517 RPM • Given a 4” brake, the maximum RPM of the brake will be 3361 RPM.

  14. Resistance level Force (lbs) Torque on Wheel (in-lb) 0 0 0 1 .5 6.5 2 1 13 3 1.5 19.5 4 2 26 5 2.5 32.5 6 3 39 7 3.5 45.5 8 4 52 9 4.5 58.5 10 5 65 Electromagnetic Brake – Operational Specifications Resistance conversion table: brake torque vs total force.

  15. Electromagnetic Brake - Schematic

  16. Electromagnetic Brake – Operating Limitations

  17. Rear view of brake system

  18. Battery • The largest power consumer is the Magtrol HB-8-3 brake which uses 15 Watts to power itself. • Maximum current draw from the brake, assuming a top speed of 40 mph, is 750 mA. • At maximum speed (3400 RPM) for 3 hours: 3hrs x 750 mA = 2250 mAh • Other components draw an additional 50mA. • Total: 3hrs x 800mA = 2400 mAh

  19. Power Consumption Problem • When the brake has a sudden current draw, power could be drawn away from other components. • Solution: Add capacitors to maintain voltage.

  20. Nominal Voltage Minimum charging time Minimum Life Cycles Standard charging time Capacity 12 V 1.2 hours 500 14 – 16 hours 1800mAh Battery - Operational Specifications

  21. Heart Rate Monitor • Heart rate monitor must be accurate but un-cumbersome for the user. • The ideal solution: not connected to user accurate can remain with the bike when not in use. • Requirements met by the Salutron Model 4000. Two electrical contacts determine the user’s EKG.

  22. Heart Rate Monitor • Stainless steel contacts are durable and weather-proof • Simplified wiring • The sensor is recreational, not medical, with a tolerance of 0.65%.

  23. HR Monitor - Specifications • Salutron Model 4000 • Power: 3 volts (+/- 10%) @ 2.2 mA maximum • PCB Dimensions: 1.6 x 0.75 x 0.4 inches (41 x 19 x 10 mm) • Input signals: Right and Left sensors, Vcc and Ground. • Output signals(TTL compatible): • 1.      One pulse signal per each detected heartbeat • 2.      UART serial port: heart rate reported at each heart beat • 3.      SPI serial port: heart rate or ECG waveform reported

  24. HR and LCD Mount Diagram

  25. LCD Display • The LCD displays the current heart rate and resistance • The center button turns the resistance on and off • The user can scroll through modes by pressing the ‘Enter’ button and the ‘up’ or ‘down’ button • The users are defined by going to the user mode and selecting <New User> from the list of users

  26. LCD – Operational Specifications • Okaya RC2004LRSASOK • Vdd = 2.7v – 5.5v max • Max Temperature = 70ºC • Min Temperature = -20ºC • Display Dimensions: 76 mm x 25.2 mm • Display Characteristics: 20 characters x 4 lines • LCD Controller: Samsung KS0066U LSI

  27. Resistance Level: 4 Heart Rate: 95 bpm LCD Diagram

  28. Device Controller • Device controller takes PWM signal from HCS12 and outputs a linearly equivalent current to the electro-magnetic brake

  29. Device Controller - Specifications • LORD Rheonetic Wonderbox Device Controller Kit (RD-3002-03) • Power: 12 Vdc (2 A max output) • Size: 3.5 x 2.5 x 1.1 inches • Input: 2.1 mm Female banana plug • PWM: 30 KHz unfiltered ( input )

  30. Interface to HCS12 • The HCS12 must have sufficient I/O interfaces for the sensors and controllers. Heart Rate Sensor: serial connection LCD: 13 parallel bits Brake Controller: PWM output Push Buttons: 3 timer ports • These ports are all available on the HCS12

  31. Interface Diagram HCS12 Brake Controller PWM A SER1 B P2 P1 P0 PWM SPI R L CR DB CMD Heart Rate Monitor Buttons LCD

  32. Component Product Quantity Item Cost Total cost to us Brake Magtrol HB-8-3 1 $174.95 $174.95 Push Buttons GC Electronics 3 $3.78 $11.34 LCD Display Okaya RC2004LRSASOK 1 $25.80 $0 (Donated) Battery w/ solder tabs Dantona DANAA1800MMHWT 10 $3.50 $35.00 50 pin connectors Philmore 70-4250 2 $1.78 $3.56 Device controller LORD RD-3002-03 1 $170.00 $170.00 Microcontroller with Evaluation Board Technological Arts Adapt9S12E256 with Motorola MC9S12DP256D 1 $133.00 $0 Heart Rate Monitor Salutron 1 $25.95 $25.95 Total $579.60 $420.80 Cost Estimates

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