Download SD II - EDGE

Ian Frank
Matt Walter
Jesse Steiner
Luke Spencer
Mike Celentano
Nick Balducci
Team Lead
Chief Engineer
Electrical Engineer
Industrial Engineer
Electrical Engineer
Mechanical Engineer
Sponsor: U.S. Environmental Protection Agency
P3 Design Competition Grant
Aiding Organizations: SOIL & H.O.P.E.
 Affordably provide clean, reliable, high-quality lighting
 Establish a relationship with a sponsoring organization for field
testing and product feedback
 Market: People in developing nations without clean/healthy lighting
Key High Level Customer Needs/Engineering Specs
 Low Purchase Cost
Light Module Cost < $40
Power Module Cost < $160
 Long Operation Time
Storage Capacity @ 100 Lumens > 4hrs
Battery Lifetime > 3 years
Base Unit Lifetime > 10 Years
 Universal Applicability
Useable Temperature 4.5°C-38°C
Survives 3 meter drop
Water Resistant to IPX Std. 3
Value Added in Local Economy >25%
Bike
Charging Leads
Trainer
Generator
Power Module Box
LED/Diffuser Plate
Power Switch
Tin/Aluminum Can
Charging Jack
Handle
 Sponsoring organizations identified and working connections
established to test prototypes and get user feedback
 Alpha prototype construction complete
 Current power module design fails under high power loading
 Circuit failure necessitates altered design to work under all
conditions
 Current light module functional and is capable of 0.8W
operation
 LED driver limits output power and as such the desired light is not
currently possible
 Field testing on hold until a working power module can be
provided
•Life Cycle assessment completed in
SimaPro
•Proposed LED lighting system
consists of 1 light module and 1/20
of a power module
•Proposed system has less than 3%
of negative environmental effects of
the currently used kerosene lamps
•This is largely due to the refining,
shipping, and burning of kerosene
 Given the state of the project, it has not been possible to prove
the product’s compliance with all engineering specifications
 Two main areas were identified for testing
 Discharge duration – to determine the battery life per charge
 Light intensity and distribution
 Additional testing was done to:
 Characterize the power generator at various speeds
 Determine the operational temperature of the LED at maximum
power
 Determine exterior temperature of light module
 Determine if the light module needs additional shock protection
When used as a reading lamp (on the stand) the light provided by the alpha
prototype light module follows the distribution below
•Light close to the center of the lamp is more than sufficient for reading
•Further out, the light is still better than current kerosene lamps but is
not as useful as it could be
•Light module was monitored
throughout a complete discharge
cycle.
•Special interest was paid to the
voltage supplied by the batteries and
the power supplied to the LED
•LED Driver requires 3.4 V for operation
•System shuts down when batteries
drop to 3.4 V
•Power supplied remained fairly constant
throughout the discharge cycle
 Specs met by component specs
 Useable temperature range (0-50)°C
 Battery lifetime (≥3 years)
 Base unit lifetime (≥10 years)
 Color of light (CRI=75)
 Light Temperature (5,000-10,000K)
 No combustion
 Scratch Resistant
 Recyclability by weight (>75%)
 Components meet ROHS
 Specs met through design
 Particulate Resistant (sealed unit)
 Hook-up time (DC Jack)
 Start time (instant elec. current)
 Local value added & simple manufacture
process
 Most parts can easily be assembled in developing
nations
 Light module weight (<3kg)
 Specs met through testing
 Storage capacity (13 hrs)
 Light distribution (10 lux) – NOT MET!
 Electrical shock (none)
 Surface Temperature (within 5°C of ambient)
 Specs met through material and projected
production costs
 Light module cost
 Power module cost
 Proposed micro-business model provides
waste-stream & life cycle management
 Specs not tested for but with plan in place
 Water Resistance
 Drop Test
 Charge Time
 Supplies/Material Budget: $3,767
 Concept/Benchmarking Exp. $350
 Prototype Materials Exp. $1,770
 Total Expenses to Date: $2,120
 Remaining Supplies and Material
Budget: $1,647
 Surplus from Travel: $172
 Surplus from Contractual: $320
 Total Surplus: $2,139
 Necessary for further
development and field testing
 Did not receive stage II funding
from EPA P3 Award Competition
Planned
Actual
Itemized Total Itemized Total
2,883
2,883
2,883
2,883
Category
RIT Indirect Cost (40.5% Rate)
Travel to DC
Vehicle
Gas
Hotel
Food
Misc
600
100
1000
500
800
Total
169
137.07
1554.25
776.13
191.8
3,000
2828.25
Supply
Benchmarking
Power Module
Lighting Module
Other Prototypes for Field Testing
Total
Contractual
Poster Printing
Prototype Shipping
Total
Grand Total
500
750
750
1767
349.98
975.98
794.11
3,767
200
150
2,120.06
30.10
350
10000
30.10
7,861.41





SUCCESSES
Established a working relationship
with two non-profit organizations
with focus in Haiti
Established the base technology
for the light and power modules
Base light module technology is a
significant improvement over
current kerosene lighting
Design meets most specs
Functioned effectively as a team
throughout the course of the
project




FAILURES
Power module is not fully
functional
Light module does not perform
as highly as anticipated
Unable to send the alpha
prototypes to Haiti for field
testing
Unable to complete testing
with system to determine
compliance with specifications

Suggestions for future work in the product line
 Solve issues with power module – protect module from overcurrent due to higher input
 Increasing lighting levels – LED driver limits light levels but it
would be beneficial if the module could produce more light
 Send fully functional system (lights and power module) to Haiti
for field testing
 Revise design of both modules based on the results of field
testing and feedback provided by the end users