hd-mcu

bluetooth supported mcu for harley davidson 99-03 with raspberry pi pico

this is not a ecu but a diy -and for fun- project for a monitoring hardware via an mcu since there is no can-bus support for 99-03 models. it replaces the default turn signal module (tsm) to provide monitoring features for battery voltage, rpm, voes, ignition, and external thermo sensors via bluetooth to the mobile application. it does not involve a reverse engineering for the original hd-tsm module.

• programmable idle timeout for turn signal
• pcb provides signal switching via h-bridge module or mosfet + oc
• built-in battery voltage sensor
• built-in rpm reader
• built-in temperature sensor via rpi-pico
• aux inputs for ignition and voes signals (may require custom ignition module ie. ultima/dyna 2000i)
• vehicle information with editable fields for maintenance records
• external 6x thermocpouler raiser for max6670
• supports up to 8x thermocpouler sensors for various purposes

features

• hardware serial
  • raw ft232 usb serial
• bluetooth serial
  • raw bluetooth serial (hc-06 @ 9600 bps)
  • mobile app
• data polling/broadcasting
  • reduced power consumption
  • reduced cpu clock usage
• turn signal flasher module
  • left/right turn signal flasher
  • hazard flasher
  • flash on startup
  • adjustable flash rate
• throttle control module
  • linear hall sensor input
  • servo pwm output
  • adjustable base parameters
  • adjustable idle speed
  • [ ]
  • adjustable throttle curves
• supported sensor inputs
  • multiplexed thermocouples
    • up to 8 thermocouples
  • direct sensor inputs
    • uptime counter (onboard)
    • mcu voltage (onboard)
    • temperature (onboard)
    • vbus input (onboard)
    • battery voltage input
    • rpm input
    • speed input
  • tpms
    • 433mhz receiver implementation
    • tpms decoder / man-i or man-ii (tbd)
  • ignition module
    • dyna 2000i / ultima 2000i timer & pickup
    • programmable ignition advance
      • advance curve
      • temp compensation
      • rpm compensation
      • wideband o2 sensor for afr

software

mobile app

• platform

  • react 18.2.0
  • react-native: 0.73.2

• react-native

  • android
  • ios

mobile app ui

mcu firmware

• platform

  • nodejs: 20
  • kaluma-cli: 1.4.0
  • kalumajs runtime: 1.2.1

• FLASH: 2044/24 kb

• SRAM: 264 total, 184/62 kb

hardware

assembly

• 12v-5v buck converter / switching regulator
  • lm2596 datasheet
• raspberry pi pico
  • pinout
  • datasheet
• hc-06 bluetooth module
  • datasheet
• TSM / turn signal module
  • (option-1) - with mosfet extension board
    • pick this if your rectifier is 3 pin and charge flux is 12v-15v
    • IRF4905 datasheet
  • (option-2) - l298n h-bridge driver module
    • datasheet
• THE / thermocouple module
  • cd4051 multiplexer
    • datasheet
  • max6675 thermocouple digitizer
    • datasheet
    • k-type thermocouple (maximum of 8)
• TCM / throttle control module
  • linear hall sensor / 49e
  • DS3230MG digital servo
• 5v super capacitor
• 5805 voltage regulator
• 33k resistor
• 10k resistor
• 7.5k resistor
• 4.7k resistor
• 1k resistor
• 1n4001 diode

pcb

front

back

blueprint

setup & building & installing

• initialization

  git clone
  npm run install
  

• cook everything

  npm run build
  

• create mcu firmware

  npm build:mcu
  

• flash firmware to pico

  npm run flash:mcu -- /dev/tty.usbmodem2XXX
  

• create mobile app

  • create local build

    npm run build:app
    

  • create distributable bundle .apk

    nom run bundle:app
    

usb serial interface

• usb: 115200 bps
• bt: 9600 bps

service interaction

• query only: [SVC]+[CMD]\n
• set svc data: [SVC]+[CMD]=[DATA]\n

service list:

service	description
SYS	mcu information system
THE	thermocouple sensor module
TSM	turn signal module
TCM	throttle control module
VHC	vehicle healthcheck module
VHI	vehicle information system

command list

command	description
INFO	get information from service
DATA	get data from service
SET	send data to service
START	start monitoring
STOP	stop monitoring

TSM extended command set

command	description
LEFT	left turn signal
RIGHT	right turn signal
ALL	hazard signal
NONE	turn signal off

module interaction

• query only: [MOD]+[CMD]\n

module list:

name	description
M0	main mcu module

command list

command	description
DIAG	execute diagnostic
START	start ON_DEMAND services in module and publish data
STOP	stop ON_DEMAND services in module and stop publishing data
LIST_ALL	list all registered services in module
LIST_RUN	list running/active services in module