P08427LED Lighting Technologies for a Sustainable

Lighting Solution in Developing Nations

Detail Design Review6 February 2009

Design Review Objectives

• To receive feedback on the aspects of our current design

• Come away with direction for the final stages of the project– Suggested changes to the design– Additional prototype verification that should be conducted

• Be ready to provide the best possible product to our end users.

• Please Feel Free to Ask Questions at any Time

Action Items From SLDRTask Responsible Completion Date Status

Feasibility of One Unit System See Below 19-Jan-09 Completed – Turned Down

Power Generation, Distribution, & Storage Jesse “ “

Power Storage Mike “ “Materials for Prototyping, System Usage Luke “ “

Bike Mechanical Components, Costs Nick “ “

Treadle Mechanical Concepts, Costs Matt “ “

Finalized Concept Selected All 19-Jan-09 CompletedResearch Power Storage Concerns from SLDR Jesse & Mike 21-Jan-09 Completed – Final PS

selectedDetermine battery charging cost and time to pay off capital equipment

Luke 21-Jan-09 Open – Initial Estimates Made

Determine Feasibility of Dimmer Mike 21-Jan-09 Completed – Added to design

Finalized Selection of Components All 21-Jan-09 CompletedStart Ordering Major Components for testing All 21-Jan-09 Completed

Look into materials (PLA and PET) Luke 23-Jan-09 CompletedBenchmark Current Product Materials Luke 23-Jan-09 Complete

Needs/SpecificationsCustomer

Need # Importance Description Comments/Status

1 1 Provides a Better Lighting Solution If this not met, product is useless2 2 Off-Grid Energy Source Primary purpose

3 2 Low Purchase Cost End user cost will have to by partially subsidized due to the high cost of the technology

4 3 Low Operating Cost This cost should be zero there are no consumables

5 4 Able to be Manufactured in Developing World At least in part - this plays into the micro-economy part of the project

6 5 Safe Should not be a fire or health hazard

7 6 Universal Application (Transferability) The product and the production of the production may be adapted to the many potential deployment markets

8 7 Easy to Use Low Maintenance, Straightforward, etc.

9 8 Long Operation timePower storage unit can last for a decent amount of time before

being charged - Additionally, the life of the unit is long enough to justify initial costs

10 9 Able to Withstand Harsh Climate Conditions Water Resistance/Particulate Proof11 9 Durable/Robust Withstands the rigors of operation

12 10 Provides Comfortable lighting Quality of lighting greatly determines usability of system - however, nearly anything is better than what already exists

13 11 Can be made out of Recycled Materials Lots of waste materials that could be used in manufacturing process

14 12 Clean energy source EPA would like a planet-friendly solution15 13 Can be easily recycled at end of life EPA would like a planet-friendly solution

# Metric Units Importance Marginal Ideal Note/Comment

1 Production Cost U.S. $ ***** 40 10Unfortunately the technology requested is quite expensive…will probably need to have purchase cost subsidized

2 Usable Temperature Range °F or °C *** (4.5-38)°C (0-50)°C Tested with environmental chamber

3 Water Resistant IPX Standard *** 3 3Perhaps only applies to some of the components…or different values for different components

4 Particulate Resistant Binary *** YES YES Tested with environmental chamber

5 Storage Capacity Hrs **** 6 30Ideally the product would not have to be charged everyday (if using a central power station)

6 Battery Lifetime Years ***** 3 10 Based on 1000 charge cycles at 30 hours per charge and 8 hours of usage/day

7 Base Unit Lifetime Years ***** 10 30 Based on 100,000 hour lifetime of LED lights and 8 hours of usage/day

8 Color of Light CRI *** 89 100 LED Specifications

9 Temperature of Light K ***4000K-7000K

5000K-6000K LED Specifications

10 Light Distribution Lux ***** >50 >150The metric is best tested by lighting a table (2mx2m) at a distance of about 1m - This is similar to the conditions that the end product will be used in

11 Passes Drop Test Pass/Fail *** YES YES Functional Drop Height and Drop Cycles (+50 cycles @ 3m)

12Meets UL and CSA Standards

Pass/Fail **** YES YES

13Exposed Components Resist Scratching

Mohs Hardness *** 5+ 6+

14 Battery Installation Time sec *** <45 <20 Before and After Charging (if battery unit is removable)

15 Unit Start Time sec *** <5 <2All you really have to do is push a button to turn it on, should be pretty easy to use

16 Charge time (manual) min *** ≤30 ≤5

17 Charge Time (solar) hrs *** ≤6 ≤4

18 Recyclable Parts % by weight ** >25 >50

19 Environmentally Friendly Meets ROHS *** YES YES Need better metric - takes materials, efficiency, and recyclability into account

20 Assembly % of VA ** 25 ≥80 Value added in Local Economy

21 Simple Manufacture Process Pass/Fail **** YES YESParts to be manufacture in developing nations must be designed to be built on simple machinery that will be available in the countries of interest - Phase II concentration

22 Lifecycle Plan in Place Pass/Fail **** YES YES

Cradle-to-grave or cradle-to-cradle manufacture process in place for full production runs. As such some sort of end-of-life recollection/exchange/recycling program will need to be in place or at least conceived of

23 Weight lb * <10 <3 Weight of mobile portion of unit

Concept Selection

Concept Selection

Selection Criteria Weight Rating Weighted Score Rating Weighted Score Rating Weighted Score Rating Weighted ScoreEasy to Use 10% 2.5 0.25 3 0.3 4 0.4 4 0.4Durable/Robust 8% 2.5 0.2 3.5 0.28 3 0.24 3 0.24Safe to Operate 9% 3.5 0.315 3.5 0.315 4 0.36 4 0.36Low Cost 13% 2.5 0.325 3.5 0.455 3 0.39 2 0.26Sustainable (cradle to grave) 4% 2.5 0.1 3.5 0.14 2.5 0.1 3 0.12Provides Sufficient Lighting 14% 3 0.42 3 0.42 2.5 0.35 2.5 0.35Provides Comfortable Lighting 4% 2.5 0.1 2.5 0.1 2.5 0.1 2.5 0.1Sufficient Power Storage 12% 3 0.36 3.5 0.42 2.5 0.3 3.5 0.42Transferibility of Application 11% 2 0.22 4 0.44 3 0.33 3.5 0.385Feasible to Implement 8% 2.5 0.2 3.5 0.28 2.5 0.2 3.5 0.28Ceates Micro-Business 7% 3 0.21 4 0.28 2.5 0.175 4 0.28

100%Total Score

Treadle Peddle

2.9 3.23.4

POWER MODULE CONCEPTS

Induction Ankleband

2.7

Performance Rating not met 0 poorly met 1

adequately met 2 well met 3

execptionally met 4

Key Components

*Foot (treadle) powered *Internal battery *Wire connecting power unit to lamp

*Walking motion creates magnetic induction *Removable battery pack

*Community solar charging station (free) *Removable pattery packs

*Dynamo turned by biking *Community charging station (pay-per-charge) *Removable battery packs

Community Bike Community PV

Costs of Treadle vs. Bike

Gears - Acetate QTY. Prototype price Final price I tem QTY. Prototype price Final price20 tooth 2 3.84 0.94 Motor 1 65.00 65.00120 tooth 2 7.52 3.56 V-belt 1 11.00 11.00Crank arms motor mount.375" AL bar stock ~24" ~$4.57 4.57 L-stock ~6" ~4.00 4.00Motor Battery3 watt dc 1 6.00 6.00 AA NiMh 4 8.00 8.00

BatteryBattery/ electronics enclosure

AA NiMh 1 2.00 2.00 Battey enclosure 1 4.00 4.00Motor mount and gear housing Sheet metal container 1 ~8.00 8.00AL L - stock ~6" ~$4.00 4.01 Bike stand 1 50.00 30.00Foot pedals motor pulley 1 5.00 5.00DESIGN from stock 2 ~ 1.50 3.00 155.00 135.00HousingPrototype - stock sheet metal ~$5.00 ?Production - plastic ? 4.00

34.43 28.08

Treadle

Total

Bike

Total

Treadle vs. Bike

Selection Criteria Weight Rating Weighted Score Rating Weighted ScoreEasy to Use 10% 3 0.3 3.5 0.35Durable/Robust 8% 2 0.16 3 0.24Safe to Operate 9% 3 0.27 3 0.27Low Cost 13% 2 0.26 2.5 0.325Sustainable (cradle to grave) 4% 3 0.12 2 0.08Provides Sufficient Lighting 14% 3 0.42 3 0.42Provides Comfortable Lighting 4% 3 0.12 3 0.12Sufficient Power Storage 12% 4 0.48 3 0.36Transferibility of Application 11% 4 0.44 3.5 0.385Feasible to Implement 8% 2.5 0.2 4 0.32Ceates Micro-Business 7% 2 0.14 3 0.21

100%Total Score

Performance Rating not met 0 poorly met 1

adequately met 2 well met 3

execptionally met 4

Key Components

*Foot (treadle) powered *Internal battery *Wire connecting power unit to lamp

*Dynamo turned by biking *Community charging station (pay-per-charge) *Removable battery packs

Community BikeTreadle Peddle

3.082.91

System Block Diagrams

Final Can Concept

Power Module

Complete Power Generation Module

Battery Charging Device

Gear Ratio/RPM AnalysisRPM at Pedal

RPM at Motor

20 1040

30 1560

Gear ratios 40 2080

Fastest GR on bike 3.71 50 2600

Wheel Dia. To motor Dia. 20.0060 3120

Efficiency 70 3640

0.70 80 4160

= 90 4680

Total Gear ratio 52.00 100 5200

110 5720

120 6240

Power Module Electrical Schematic

Lighting Module

R 1

R 2V a r

V 14 . 8 V d c

0 00

M 1

M b re a k N

D b re a kD 1

Power Conditioning Circuit

Lighting Module Design

Thermal Analysis

cc

ccf mrImrKmrKmrI

mrKmrImrImrKC

211012110

211121112

2

122

1

2

2

rrm

r

Cc

kt

hm

2

hAR

f1

qRT h 4 W/(m^2*K) m 6.4535019 I0(m*r1) 1.000042

t 0.125 in 0.003175 m k 60.5 W/(m*K) c2 0.394513 I1(m*r1) 0.006454r1 0.002 m q 3 W m*r1 0.012907 I1(m*r2c) 0.129115r2 1.5 in 0.0381 m Tamb 28 °C m*r2c 0.2561234 K0(m*r1) 4.466144r2c 1.5625 in 0.039688 m K1(m*r1) 77.44527At 0.006129 K1(m*r2c) 3.648185

eta 0.9315005w 0.060325 R 43.789084l 0.0508 dT 131.37

To 159.37

Dimensions Environmental Variables Calculated Values Bessel FunctionsImperial Metric

Reduced Powerh 4 W/(m^2*K) m 6.4535019 I0(m*r1) 1.000042

t 0.125 in 0.003175 m k 60.5 W/(m*K) c2 0.6842953 I1(m*r1) 0.006454r1 0.002 m q 2.5 W m*r1 0.012907 I1(m*r2c) 0.097789r2 1.5 in 0.0381 m Tamb 28 °C m*r2c 0.1946538 K0(m*r1) 4.466144r2c 1.1875 in 0.030163 m K1(m*r1) 77.44527At 0.006129 K1(m*r2c) 4.916715

eta 0.9639454w 0.060325 R 42.315212l 0.0508 dT 105.79

To 133.79

Dimensions Environmental Variables Calculated Values Bessel FunctionsImperial Metric

Light Dispersion

Conical Lens Prismatic Diffuser

Bill of MaterialsRisks

BOMItem # Vendor P/N Vendor Item Description Quanity Unit Price Extended Price Status Owner

POWER MODULEElectrical Components

1 546-186F48 Mouser Hammond 2.4:1 Transformer, 96VA 1 $25.52 $25.52 green Jesse

2 512-FAN1587AMC15X Mouser Fairchild FAN1587 Adjustable Voltage Regulator TO-263 4 $1.18 $4.72 green Jesse

3 863-MC33340DG Mouser On Semi MC33340 NiMH Charger SOIC8 4 $1.56 $6.24 green Jesse

4 645-598-8260-107F Mouser Green LED - 1206 4 $0.10 $0.40 green Jesse

5 625-SS3P3-E3 Mouser Diode - Vishay 3A Schottky D)-220AA 20 $0.17 $3.40 green Jesse

6 262-1.5-RC Mouser Resistor - 1.5Ohm, 2W, Through-hole 8 $0.19 $1.52 green Jesse

7 263-6.8k-RC Mouser Resistor - 6.8k, 1206 4 $0.05 $0.20 green Jesse

8 263-91-RC Mouser Resistor - 91 ohms, 1206 4 $0.05 $0.20 green Jesse

9 290-1.0K-RC Mouser Resistor - 1k, 1206 4 $0.05 $0.20 green Jesse

10 290-4.0K-RC Mouser Resistor - 4k, 1206 4 $0.05 $0.20 green Jesse

11 290-250-RC Mouser Resistor - 250 ohms, 1206 4 $0.05 $0.20 green Jesse

12 140-XRL10V3300-RC Mouser Capacitor - 3300uF 4 $0.42 $1.68 green Jesse

13 647-UHM1C102MPD3TD Mouser Capacitor - 1000uF 4 $0.11 $0.44 green Jesse

14 647-UVR1E330MDD1TD Mouser Capacitor - 33uF 4 $0.03 $0.12 green Jesse

15 NA ExpressPCB Charger PCB 1 $60.00 $60.00 yellow Jesse

16 NA Local Networking Cable 6 feet $0.00 $0.00 green Jesse

Mechanical Components

17 NA Campus Saftey Bike 1 $0.00 $0.00 yellow Jesse

18 1 330 SETGL7 pricepoint.com Sette Power Glyde Trainer 1 $68.89 $68.89 green Matt

19 Motor-E100 Motor partsforscooters.com 100 Watt DC Motor 1 $18.99 $18.99 yellow Matt

20 NA NA Motor Support Bracket 1 red Matt

5 8637K56 McMaster 1.25" OD, 0.5" ID, 6" Long Neoprene Tube 1 $3.99 $3.99 yellow Matt

22 7798K41 McMaster Screw Connector 2 $1.03 $2.06 green Matt

23 69935K61 McMaster 14-2 Romex Wire 10 $0.38 $3.80 green Matt

24 05M4060 Newark 4"x5"x6" Aluminum Minibox Enclosure 1 $12.74 $12.74 green Matt

25 15275A53 McMaster Nickel Plated L Bracket 3 $0.57 $1.71 green Matt

26 91770A148 McMaster 1/2" 6-32 Truss Machine Screws 100 $6.12 green Matt

27 91240A007 McMaster 6-32 7/64" heigth SS Hex Nut 25 $10.92 green Matt

28 TC258B Action Electronics 2.5 mm Male Straight DC Jack 4 $1.75 $7.00 green Jesse

BOM ContinuedLighting Module

29 N/A Recycling Tin can 1 $0.00 $0.00 green Nick30 91309A552 McMaster 2.5", (1/4"-20), Hex Cap Screw 25 $0.19 $4.66 green Nick31 9049A029 McMaster 5/32", (1/4"-20), Hex Jam Nut 100 $0.01 $1.08 green Nick32 91090A105 McMaster .266" ID, .5" OD, Washer, (.05" Thick) 100 $0.04 $4.46 green Nick33 163-4024 Mouser DC Power Jacks PANEL MOUNT 2.5MM 1 $2.09 $2.09 green Nick36 Wire green Nick37 7667A12 McMaster 0.125" Dia. Solder, 50%tin / 50%lead 1 $16.02 green Nick38 7369A34 McMaster Loctite #US1152 Urethane Thermal Paste 1 $13.12 green Nick39 7445A12 McMaster Permatex Gel-Twist Threadlocker #24010 1 $12.94 green Nick40 301805 Lowes 1 1/4" Galvanized 2-Hole Pipe Strap 4 Pack 4 $1.43 green Nick

41 wire connectors yellow Nick

42 thin thin sheet steel yellow Nick

43 Onlinemetals.com 1/16" Acrilic Sheet 1 $2.38 $2.38 yellow Nick

44 shrink wrap yellow Nick

45 10304 All-battery.com Fast Charging AA 2300mAh NiMH Rechargeable batteries 4 $1.79 $7.16 green Mike46 72-P16NP-50K Mouser Knob Potentiometer 1 $9.62 $9.62 green Mike47 72-P16NP-50K Mouser N-Channel MOSFET 1 $0.40 $0.40 green Mike48 NA ExpressPCB Lighting Module PCB 1 yellow Mike49 LED 1 green Mike50 163-4024 Mouser 2.5 mm Female Panel Mount DC Jack 1 $2.09 $2.09 green Mike

Item # Vendor P/N Vendor Item Description Quanity Unit Price Extended Price Status Owner

Risk Description Consequence Preventative Controls Corrective ControlsNo. Risk Description

Description of the impact in the worst case scenario Likelihood Outcome # Preventative Control Description

Corrective Control Description (How should we mitigate the impact?) Likelihood Outcome #

1 Powerful Hot spots Temporary Blind Spots likely Minor 8More effective Lens, LED set lower, direct vision guards

Include a warning on the product Rare Minor 2

2 Inadequate lighting Ineffective product Possible Major 12Informative benchmarking,

subsystem testingInclude more reflectors, slight power

or design modificationsRare Minor 2

3Low Availability of Recycled

Materials (cans)Will not be able to

produce unitsPossible Moderate 9

Further research into availability of materials

Put a program in place for collection and distribution of materials

Unlikely Insignificant 2

4 Components do not fit into unitWill not be able to fully

produce the productPossible Major 12 Prototype Testing

Design Unit to that all components fit with room to spare

Rare Minor 2

5 Unit is Dropped Potential Damage Likely Major 16Benchmarking and design for

robustnessMake sure the product can withstand

some level of abuseLikely Insignificant 4

6 Unit is exposed to water Electrical Failure Possible Major 12 Water Resistant DesignSeal unit from potential water

damageUnlikely Minor 4

7 Corrosion of Metallic Parts Unit Failure Possible Major 12 Corrosion Resistant

Design should take into account increased corrosive environment in

developing nations and take steps to prevent this failure

Rare Moderate 3

8Internal Temperature exceeds

150°CLED Failure Possible Major 12 Heat Dissipative Design

Design will need to appropriately remove heat from the vicinity of the

LEDRare Major 4

9 Indicator cable gets cutCharge indicators no

longer workPossible Insignificant 3 Use strong indicator cable Unlikely Insignificant 2

10 Battery charger cable damagedwires short, battery does

not chargePossible Insignificant 3 Use strong battery cable Unlikely Insignificant 2

11 Generator cable damagedwires short, heat up

when pedaledPossible Minor 6 Use strong generator cable Unlikely Minor 4

12 Water enters housingunintentional short,

charger stops workingUnlikely Minor 4

Use soldermask on PCB, protection diodes

Rare Minor 2

13 PCBs do not arrive in timeStopped Production in

MSD IIPossible Major 12 Order Early

Finish Design and Order Before 23 February 2009

Unlikely Major 8

14All Parts not Available at Beginning

MSD IISlowed/Stopped

Production in MSD IIPossible Major 12

Finalize Design and Order Parts Early

Finish Design and Order Before 23 February 2009

Unlikely Major 8

15 Biker over pedals

increasing current causing overheating and

generator failure, possibly battery failure

and release of chemicals

Possible Major 12

LED stop light indicating when biker is at desireable RPM and

indicator for when charge is complete

Replace unit Rare Major 4

16Mechanical components deteriorate in weather

Likely Minor 8 Oil, Maintience, Keep Indoors Replace part/ scheduled cleaning and

disassembleUnlikely Minor 4

17 Chain breaks over time Likely Minor 8 Oil and maintience Replace part Rare Minor 2

18 Bike falls over Unlikely Moderate 6Robust and stable bike stand.

Engineer for low center of gravity

Replace any broken parts Rare Moderate 3

19Direct friction drive wears down

tire or rollerLikely Minor 8 Use durable materials Replace part Unlikely Minor 4

20Unit does not create power or

produces insufficient powerPossible Major 12

Test at different RPMs and gear ratios.

Adjust gear ratios, find new generator, used belt drive or limit

number of charging unitsRare Major 4

Inherent Exposure Residual Exposure

Life Cycle Assessment

Characterization

Weighted Characterization

Single Score

Networks

Action Plan

TaskExpected

Date

Responsible Team

MemberComments

Discuss Design Feedback 06 Feb 2009 AllTest motor drive 13 Feb 2009 All Measure power output

Test different configurations

Test LED heat sink 13 Feb 2009 All Attach thermocouples

Measure temp at different power

All Ordering Complete 23 Feb 2009 All Order most parts BEFORE this dateAll Parts in House 09 Mar 2009 All Shipped over breakInitial Prototype Assembled 13 Mar 2009 All Will be iterated over the next

month Final Prototype Completed 10 Apr 2009 AllP3 EXPO 18 Apr 2009 All GET PHASE 2 GRANT!!

Drawing Package