Iowa State University and Pella Corporation

Dynamic Window Design

Team Members

Project Manager

Carol Faulhaber, ABE

Assistant Project Managers

Isha Labhasetwar, ChemE

Wil Tushaus, EE

Team Members

Ashley Polkinghorn, CprE

Rachel McDaniel, ABE

Leah Merner, ME

Lisa Nielsen, Mat.E

Steve Mueller, Comp. Sci.

Overview

Project Description

Industrial Collaboration

Team Collaboration

Design Process

Timeline

Budget

Challenges

Successes

Future Work

Project Description

Industrial Partner:

Pella Corporation

Project Scope:

Develop R10 window using

Smart Sash 3 as baseline

design

Team Adviser:

Dr. Lie Tang, ABE

Heat Transfer Review

Radiation:

Solar Heat Transfer

Conduction:

Temperature

Difference

Convection:

Transfer due to wind

Source: http://www.reliant.com

Industrial Collaboration with Pella Corp.

Plant Visits

Lab Tour and Project Briefing

Manufacturing Tour

Semi-monthly Meetings

Progress Updates

Brainstorming Sessions

Windows 101

Basic window engineering concepts

Introduction to modeling software

Design Reviews

Team Collaboration

Weekly Large Group Meetings

Weekly Subgroup Meetings

Weekly Management Meetings

Google Groups Page and email communication

Socials

Design ProcessDefine

Criteria and

Constraints

Initial Design

Selection and Review

Final Design

Selection

ModificationsDevelopment

Testing

Design Process

Initial Subgroups

Testing and Market

Research

Sensor Design

Window Materials

Final Subgroups

Window Materials

Programming

Sensors

Algorithm

Development

Criteria and Constraints

Window Cost

Number of

Components

Production Cost

Energy Efficiency

Environmental Impact

Thermal Performance

Appearance

Aesthetically pleasing

Viewable Area

Large viewable area

Function/Durability

Easy to Operate

Durability

Serviceability

Materials Market ResearchWindow Blinds

Silhouette

Luminette

Alouette

Odysee

Aluminum

Wood

Frame Materials

Bamboo

Fiberglass Clad

Pulverized PVC and wood pulp

Vinyl-wood clad

Insulation

Soy-based spray foam

Hard foam sheets

Jean Insulation

Materials Cont’d

Materials Design Selection

Bamboo/Fiberglass Clad

Frame

Bamboo Blinds with Low-E

Silver Coating

Hard Foam Sheets

Algorithm/Programming Research

Complex Algorithm

Location Coordinates

Window Orientation

Additional User

Inputs

Simple Algorithm

Temperature

Light Intensity

Sources: www.efficientwindows.org

and www.physicalgeometry.net

Algorithm/Programming Design Selection

Sleep

Override

?Scan

Night

now?

Turn

Blinds

Day

NightSleep

overnight

Override

?

Sleep

Close

Blinds

MorningOverride

?Sleep Sun up?

Turn

Blinds

Yes

No

Yes

No

Yes

No

Yes

NoYes

No

Hardware Market Research

Hardware Design Selection

Arduino Duemilanove

Shenano Kenshi Stepper

Motor

Photoresistor

2 Temperature Sensors

Stepper

MotorDriver

Arduino

DuemilanoveOverride

Bin

Timeline

Establish Design Criteria: Objectives met

Research/Brainstorm Ideas: Objectives met

Analyze Alternatives: Objectives met/ Changes in project goals

Develop Prototype: Some objectives met, changes in project goals

Test Design: Objectives not completed

Re-Design: Some Objectives met

Evaluate Final Design: Objectives not completed

BudgetFrame Materials

Jean insulation $94

Spray Foam $5

Soy Seal Spray Foam $5

Bamboo lumber $122

Bamboo planks $44

Hardware

Arduino microprocessors (2) $60

Motor shield (1) $22

Temperature sensors (2) $28

Light sensors (2) $17

Stepper Motors and Wire Cutters $91

Manual Override Switch $23

Microprocessor cables $30

Electric Wiring $7

Additional Cost for Prototype

Glass Cost $10

Production Labor $1,720

Miscellaneous

Starter Window and blinds $600

Plant Visit $239

Team Dinner $40

Total Project Spending $3,157

Initial Estimated Budget $5,160

8%

9%

55%

28%

Cost Breakdown

Frame Materials

Hardware

Additional Cost for Prototype

Miscellanious

Savings: $2,003

Overcoming Challenges

Complexity of project scope

Members leaving the team or not anticipating the workload

Components failing to ship on time and communication with vendors

Limited experience with stepper motors

Centralized documentation

Re-focusing and Developing new subgroups

Follow-up emails and phone calls with vendors

Sought advice from electronics shop at Iowa State University

Emailing updated code copies to relevant team members and adding documents to googlegroups page

Successes

Prototype that incorporates selected materials

Team communication and collaboration with Pella

Understanding of individual hardware components

and ability to operate individual components

Complete algorithm design and partial

implementation

Future Work

Integrate hardware components with implemented

software

Component testing

Identification of critical operating parameters

Thank You

Special Thanks

Pella Corporation

Dr. Lie Tang, Iowa State University (ABE)

Dr. David Grewell, Iowa State University (ABE)

Lee Harker, Iowa State University (ECpE)

SWE!

Questions???