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Sponsor: U.S. Environmental Protection Agency P3 Design Competition Grant
Aiding Organizations: SOIL & H.O.P.E.
Affordably provide clean, reliable, high-quality lighting
Market: People in developing nations without clean/healthy lighting
Key High Level Customer Needs/Engineering Specs
Low Purchase Cost Light Module Cost < $40Power Module Cost < $160
Long Operation Time Storage Capacity @ 100 Lumens > 4hrsBattery Lifetime > 3 yearsBase Unit Lifetime > 10 Years
Universal Applicability Useable Temperature 4.5°C-38°CSurvives 3 meter dropWater Resistant to IPX Std. 3Value Added in Local Economy >25%
Final cost over production target cost ($40)
Current LM Materials Cost $35 – this leaves only $5 for workL
ED temperature exceeds operational range Conservative thermal analysis shows that this shouldn’t be a
problem Test plan in place to thermally test system as soon as all
necessary parts are inS
ubsystems do not behave as expected Test plans in place to test individual subsystems ASAP
Mechanical testing to verify power Bread-boarding to verify circuits
Once subsystems are verified complete system verification
SLDR
Served to answer open questions about batteries, power conditioning, materials, and overall design (bike vs. treadle)
DDR
Mechanical Electrical Interface was not well defined Problem was solved by looking into the drive system and
creating a mounting bracket Light Stand – How are people going to use the light?
Stand and mounting options defined BOM was incomplete with regards to some pricing and
outdated components Updates made and prices found for prototype and at quantity
Needs and Specs not completely revisited/updated Action taken to look into design and needs/specs to ensure that
everything agrees – final specifications set
Design Meets all Customer Needs
Design Meets all Engineering Specifications
Light Module Production Costs will be close to over as the materials alone are in the $35 range
Current Materials Costs for Products:
Power Module: $266 ($129 for production levels) Light Module: $158 ($35 for production levels)
Schedule: About 1 week behind on circuit verification, PCB design & order
Mitigation:
Continue looking into lower cost options for components All parts on hand by the end of Spring Break to be ready for
immediate circuit verification and final PCB Design
Significantly Under Budget
Supplies/Material Budget: $3,767 Concept/Benchmarking
Exp. $351 Prototype Materials Exp. $378
Total Expenses to Date: $729
Remaining Supplies and Material Budget: $3,038
CategoryPlanned Actual
Itemized Total Itemized TotalRIT Indirect Cost (40.5% Rate) 2,883 2,883 2,883 2,883Travel to DC
Vehicle 600 237 Gas 100 Hotel 1000 1,347 Food 500 Misc 800
Total 3,000 1,584Supply
Benchmarking 500 351.06 Power Module 750 265.48 Lighting Module 750 121.17
Other Prototypes for Field Testing 1767 Total 3,767 737.71
Contractual Poster Printing 200
Prototype Shipping 150 Total 350
Grand Total 10000
23 February – All ordering Complete (Final Design)
09 March – All parts in House
13 March – Alpha Prototype Assembled
23 March – EPA P3 Documentation Due
27 March – Design verification testing complete, initiate design revisions
10 April – Design verification complete
14 April – Poster complete and printed
17 April – EPA P3 Design Expo, Washington D.C.
05 May – Documentation finalized: DHF & Formal Paper
10 May – MSD II Project Review
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