Design and Construction of a Commercial Aftermarket Automotive Head-Up Display
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Design and Construction of a Commercial Aftermarket Automotive Head-Up Display by Donn Eric Pasiliao A thesis submitted in conformity with the requirements for the degree of Master of Applied Science Mechanical and Industrial Engineering University of Toronto c Copyright by Donn Eric Pasiliao 2014 Design and Construction of a Commercial Aftermarket Automotive Head-Up Display Donn Eric Pasiliao Master of Applied Science Mechanical and Industrial Engineering University of Toronto 2014 Abstract The contents of this report provides a comprehensive look at the details involved in the design and development of an automotive head-up display (HUD). By examining the product's complete assembly, including its optics, mechanical assembly, and embedded system, a portable aftermarket automotive HUD was successfully constructed. The resulting product addresses issues and criticisms present in commercially available HUDs, such as display clutter, placement, price, and versatility, giving it a strong competitive advantage within its target market. A brief overview on some performance improvements is also included, followed by recommendations for future actions to advance the developed product closer to commercialization. ii Acknowledgments I would like to thank my supervisor, Professor Ridha Ben Mrad, for providing me with a perfect balance of direction and creative freedom during my M.A.Sc. program. Throughout the course of this project, his guidance allowed me to consistently maintain a strong sense of enthusiasm for the project, even under seemingly insurmountable challenges. Also, I would like to thank the MIE Machine Shop staff (Ryan Mendell, Fred Gebeshuber, Jeff Sansome, Terry Zak, and Keith Hockley) for teaching me practical machining techniques and practices. If it weren't for their patience during fabrication, the mechanical assembly would not have the precision necessary for the product's optics. Furthermore, I would like to thank my colleagues at the Mechatronics and Microsystems Design Laboratory (MMDL): Alaeddin Bani Milhim, Steffen Blume, Faez Ba Tis, Ali Madani, Vainatey Kulkarni, and Khalil Zahar. Their lively discussions, technical support, and consistent words of encouragement has been invaluable in creating an exciting and creative work atmosphere during the course of my M.A.Sc. program. Lastly, I would like to extend my deepest gratitude to my family for their continuing support through life's many challenges, academic or otherwise. iii Contents 1 Introduction . 1 1.1 Motivation . 1 1.2 Competitive Analysis . 3 1.2.1 Google Glass . 3 1.2.2 Garmin HUD . 7 1.2.3 Design Criteria . 10 1.3 Thesis Outline . 11 2 Design and Fabrication . 12 2.1 Micromirror . 14 2.2 Optics . 14 2.2.1 Projection Film . 15 2.2.2 Laser . 15 2.2.3 Magnifying Lenses . 20 2.3 Mechanical . 22 2.3.1 Materials . 22 2.3.2 First Optical Fixture Design . 23 2.3.3 Final Optical Fixture Design . 27 2.3.4 Complete Assembly . 30 2.4 Electronics . 31 2.4.1 Power Management . 32 2.4.2 Microcontroller . 35 2.4.3 Digital to Analog Converter . 42 2.4.4 Laser Modulation and Driver . 47 iv Contents v 2.4.5 High Voltage Amplifier . 48 2.4.6 Wireless Communication . 51 2.5 Software and Microcontroller Firmware . 53 2.5.1 The Look-Up Table . 53 2.5.2 Microcontroller Firmware . 55 3 Display Performance . 59 3.1 Controls . 59 3.2 Versatility . 60 3.3 Final Product . 62 3.3.1 Directions . 63 3.3.2 Notifications . 64 4 Conclusion and Recommendations . 66 4.1 Recommendations . 67 Appendices . 74 A Optics . 75 A.1 Zemax Model 1 . 75 A.2 Zemax Model 2 . 76 A.3 Zemax Model 3 . 77 A.4 Zemax Model 4 . 78 A.5 Zemax Model 5 . 79 B Mechanical Drawings and Assembly . 80 B.1 Optical Test Fixture . 80 B.2 Final Product Parts and Assembly . 92 C Electronics . 100 C.1 Power Management Circuit . 100 C.2 Microcontroller and Peripherals . 102 C.3 High Voltage Amplifier . 105 C.4 Digital to Analog Converter Selection Chart . 107 D Software . 108 List of Figures 1.1 Google Glass . 4 1.2 Google Glass Display . 5 1.3 Space Glass Display . 7 1.4 Garmin HUD . 8 1.5 Garmin HUD VFD . 9 2.1 Micromirror Design . 12 2.2 Actuated Micromirror . 13 2.3 Micromirror Rotation . 13 2.4 Light Spill Around Micromirror. 16 2.5 Exclamation Mark Projected Without Additional Optics . 17 2.6 Optical Assembly With an Added Pinhole Aperture. 18 2.7 Optical Assembly With the Bi-convex Lens . 19 2.8 Exclamation Mark Projected With Pinhole Aperture . 20 2.9 Final Optical Assembly . 21 2.10 Effect of an Additional Magnification Lens to Scanning Angle . 22 2.11 Complete Assembly of the First Optical Fixture Developed . 23 2.12 Initial Design of XY Stage . 24 2.13 Exploded View of XY stage . 24 2.14 Linear Stage Mechanism of the Micromirror Stage . 25 2.15 Adjustable Lens Fixture . 26 2.16 Laser Barrel . 27 2.17 Final Optical Fixture Design . 28 vi List of Figures vii 2.18 Linear XY Stage . 29 2.19 Laser Barrel Assembly . 30 2.20 Final Product . 31 2.21 Power Management Schematic . 32 2.22 Microcontroller Schematic . 36 2.23 Individual SS Pin SPI Configuration . 38 2.24 Daisy Chain SPI Configuration . 38 2.25 Continuous (left) vs. Non-Continuous Vector (right) . 42 2.26 DAC Schematic . 43 2.27 Voltage Output Verification . 45 2.28 AD5684 Configuration . 47 2.29 AD5684 Input Shift Register Contents . 48 2.30 Load Switch Circuit for Laser Modulation . 49 2.31 High Voltage Amplifier Circuit . 50 2.32 RN42 Bluetooth Schematic using a UART interface . 51 2.33 Smartphone Bluetooth SPP Software with the Output Image . 53 2.34 Microcontroller Firmware Code . 55 2.35 SPI Function . 57 2.36 AD5684 Command Bits and Addressing Mode . 57 3.1 Vector Trace Path for Two-Digit Numerical Display . 61 3.2 Resulting Display of the Vector Trace Path for Two-Digit Numerical Display 61 3.3 Physical Prototype . 62 3.4 Final HUD Screen . 63 3.5 Left Arrow . ..