Really nice project.<p>If you are thinking commercial you may want to look into IP issues to see if there are active patents (probably expired by now?)<p>As far as design choices, based on my journeys in similar types of projects: (just my$.02, not a critique)<p>USB will be a significant point of failure. The connector has voltage present and electrochemical activity will destroy the connector over time unless you can keep it in a clean, low humidity environment. Consider a different connector or a wireless SOC to eliminate this point of failure and make a completely potted unit possible. If you use usb, make sure there is no voltage normally present, even from the data connections, and you have a good watertight plug for the access port. Everything gets wet on bikes. Everything. nRF52840 or ESP32C3 would be my go to choices here, but there are a lot of excellent candidates. BLE is probably the protocol you will want to use. This will facilitate making a simple app to do firmware updates and feature adjustments.<p>Consider eliminating the need for RPM input. This will be a significant point of failure and your greatest installation headache across different motorcycles.<p>As a failsafe, control the lamp output pass-through with a pulled-up mosfet of at least 50a capacity (you won’t ever see this high current, but it protects from bulb changing short circuits and other unknowns)<p>An Infineon BTS5016-2EKA or its low side equivalent is probably a great choice, and gives you both of the switches you need in one package, for less than $3, with full protection features. ( I assume you will need one to interrupt existing signaling and one to light where’s there is no activation from the brake switches)<p>The main thing is the lamp must light with regular inputs even if the circuit loses power or the chip gets a hole drilled in it. If it comes on when it shouldn’t, that is also bad, but not as bad.<p>Idk what sensor you are using, but consider the icm20948, it’s not too expensive ($3-4) and it has onboard sensor fusion. Only downside is it’s 1.8v, but if you use the nRf52840 that’s not an issue. Even so, level conversion isn’t too big a deal. Sensor fusion will greatly simplify understanding what’s going on.<p>Since power consumption is not critical I would consider using an ML algorithm on the sensor data to detect hazard conditions, lie downs, etc and filter out steep uphill/downhill false activation/failure to activate.<p>You could collect the data easily and train a simple model with off the shelf tools designed specifically for doing that kind of thing with MCUs. I forget the name but it’s commonly used for voice action or gesture training. You might want to train on a few bikes though, especially ones with different vibration frequencies.<p>Now you can add a subscription model for premium flashing features and “enhanced AI” with in-app GPT4 access to an interactive tour guide and a “best rides” feature customized to your riding style and search history! Business could pay-to play, and insurance companies, motorcycle manufacturers, and tire sellers would love that personally identifiable riding data! (Please, don’t)