Project Plan Presentation P0842X – LED Lighting Technologies

COURTNEY WALSH (ME)IAN FRANK (ME)

MATT BENEDICT (ME)SHAWN RUSSELL (ME)

WIN MAUNG (ME)NARESH POTOPSINGH (ME)

Project Plan Presentation P0842X – LED Lighting

Technologies

Why LEDs?

RIT spends approximately $6 million on electricity every year Half goes towards lighting (~$3 million)

LED Reduce energy consumption Longer lifetime

Lower maintenance costs Less waste

Environmentally friendly

LED Information

Efficacy Light output divided by power

input LED 30 lumen/watt Future LEDs 150-200

lumen/watt Fluorescent Light 85 lumen/watt Incandescent bulb 16

lumen/watt HPS ~ 125 lumen/watt

Color Rendering Indices (CRI) CRI measures fidelity of the colors

of objects reflecting the emitted light

LED Vary from 62-91 Incandescent bulb 100 Metal Halide ~85 HPS 22

Color Temperature Degree warmth or coolness of a

light source LED 5000-7500 (cool white) Metal Halide 3000 K (very

yellow) to 20000 K (very blue) HPS 2700 K

Lifetime LED 100,000 hours Incandescent 1000 hours Fluorescent 10,000 hours

http://lighting.sandia.gov/XlightingoverviewFAQ.htm

Efficiency Comparisons

http://www.iolighting.com/efficacy.htm

Outdoor HPS: Shawn Metal Halide: Courtney

Indoor T8 Tube: Naresh CPL Replacement: Win

Power Module

Matt

Developing Nations

Ian

Start Term: 2007-2 for

MSD1

End Term: 2007-3 for

MSD2

Start Term: 2008-2 for

MSD1

End Term: 2008-3 for

MSD2

Project Breakdown Comparison

Preliminary Work Breakdown Structure

Three Week Project Plan

Person Week 0 - 1(03 Dec 07)

Week 1 - 2(10 Dec 07)

Week 2 - 3(17 Dec 07)

All

Establish team values and norms Understand customer needs Present individual "research" to group

Review and understand the project Meet with customers to establish any additional needs Participate in brainstorming session

Meet with faculty guide and consultants (or Brainstorm any additional needs) Determine product target specificationsTeam building exercises/ice breakers Participate in benchmarking session -Identify and gather any additional benchmarking materials - -

ME 1

Introduce project to team Arrange meeting with customers Look into possible interface options and prepare report

Help team get up to speed (Or lead needs brainstorming session) Lead brainstormingArrange the necessary meetings Lead benchmarking session Help others when/where needed

Schedule a meeting with all team leads to coordinate projects

Focus on human interface portion of benchmarking session -

- Record and publish results from benchmarking and needs evaluation -

ME 2

Review CAD package tutorials Focus on materials and mechanical analysis portion of benchmarking session Look into possible materials and prepare report

Review Fatigue analysis package for deformation, stress, and thermal (heat transfer) analysis - -

EE 1Review EE analysis programs Focus on power supply portion of benchmarking session Look into power supply options and prepare report

Review chosen control language - -

EE 2Review EE analysis programs Focus on power storage and light emitting portions of

benchmarking sessionLook into storage and lighting options - prepare report

Review MATLAB - -

ISE 1Review CAD tutorials Focus on manufacturing, sustainability, and environmental

concern portions of benchmarking sessionLook into sustainability and DFM options - prepare report

Review sustainability guidelines - -

Preliminary Work Breakdown Structure

Diagram Representation

Team Values and Norms

Punctual Each team member will arrive on time and will notify fellow team members of any expected absences. It is important that the team member ensures that at least one member of the team confirms the notification

ThoroughEach team member is expected to do their assigned work in a manner such that it does not have to be redone by another, and if they feel that they have been assigned too much work to do that they seek out help from other team members or faculty consultants

AccurateEach team member will accurately complete and document their work

Professional and EthicalEach team member will credit work and information to the proper sources and will be trustworthy in all of their dealings.

Demonstrates the core RIT values of SPIRIT.Each team member will remember that they are representing RIT and as such the reputation of RIT and the SD program are reflected in their work.

CommittedEach team member will contribute an equal share to the success of the project and commit to the challenge set before them with the understanding that the SD process should a fun and informative

Grading and Assessment

Preliminary Grading SchemeGrade Level Senior Design I Senior Design II

DHave multiple concepts in the works with a semi-clear plan for executing at least one of them

Have completed concept development for at least two of the original concepts and have a project production plan for one of the concepts

C Have a concept singled out and in the process of being completed

Have finished concept development and begun working on the final project

B Have a working concept nearly developed Have finished the bulk of product

A Have finished concept development and are ready to proceed with fabrication Have a completed working product

Issues and Risks

Economic Funding

Secure from FMS and EE Department Environmental Protection Agency P3 Grant

Cost return Lifetime cost comparison to current systems

Technical Light distribution

Design lens/reflector system Longevity

Design for extreme conditions Use proven materials

Social Group dynamics

Team building activities

Safety Health hazards

Consult Underwriters Laboratory and IEEE standards

Outdoor Projects

Mission Statement Walkway Metal Halide Replacement

This specific project will focus on developing a replacement for the Metal Halide walkway fixtures that are located around campus. These metal halide fixtures aim provide a good return on the investment as well as an efficient light source. The LED fixture needs to be energy efficient, cost effective, and easy to maintain.

Parking lot High Pressure Sodium Replacement This product is a LED replacement kit to convert

conventional lighting fixtures to accept LED lights. This kit will be design specifically for RIT and will prove to have a positive economical impact.

Final Project Plan

Project Name LED Lighting Technologies for a Sustainable Entrepreneurial Venture

Project Number P08428

Project Family Sustainable Products, Systems, and Technologies Track

Track Sustainable Technologies for the RIT Campus

Start Term 2007-2 for Senior Design I

End Term 2007-3 for Senior Design II

Potential Faculty Guide Dr. Robert Stevens (ME) Confirmed

Faculty Consultant Dr. Vincent Amuso (EE) Choice

Primary Customer RIT Facilities Management

Metal Halide Replacement

Replacement Primary use on campus is for

walkway lighting Can be seen on quarter mile

Metal Halide High-intensity discharge lamp

High light output for their size Operate under high pressure and

temperature Color Rendering Index

85 Color Temperature

3,000 K (very yellow) to 20,000 K (very blue)

Life Expectancy 10,000 to 12,000 hours

Phase 0: PlanningStaffing Requirements

Mechanical Engineers 3Mechanical Engineer 1

Team LeadAssign tasks to rest of the teamKeep in contact with team leads from other projectsPrepare deliverablesContribute to mechanical design

Mechanical Engineer 2Primary mechanical engineerDevelop casing for LED lightIntegrate parts togetherDevelop CAD package

Mechanical Engineer 3Develop light fixtureIntegrate parts togetherDevelop CAD package

Electrical Engineers 1Electrical Engineer 1

Primary electrical engineerDetermine power sourceDevelop interface to power sourceLED integrationAny computer programming

Industrial and Systems Engineers2Industrial Engineer 1

Primary industrial engineerDevelop fixture for LED lightCommunicate with other LED teams

Industrial Engineer 2Create a sustainable systemHelp to optimize the systemMake system manfactureable

Business MajorsConsultantBusiness Major 1

Aid with the manufacturing processCreate a potential business plan to manufacture product

Customer Needs

Target Specifications

Metric Importance (Stars) Units Target Value

Production Cost 4 US $ ~$400

Usable Temperature Range

5 Degrees (F or C)-10-100 F, (-25-40 C)

Water-Proof 4 Binary Yes

Heat/Cold Resistant 4 Binary Yes

Vandal Resistant 4 Binary Yes

Lifetime 5 Hours 100,000

CRI Level 1 No units 85

Energy Efficient 5 lumen/watt 85

Standardized 4 Binary Yes

Weight of Light (Mass) 3 Lbs (kg) ~10

Future Plans

Await PRP approval

High Pressure Sodium Lamp Replacement

This is a low pressure sodium lamp

This is a spectrum of a high pressure sodium

lampA Basic design of a high pressure sodium lamp

P08421




Mechanical Engineer 2Develop light dispersing lensConduct Heat Transfer analysisDevelop FEA package



Primary electrical engineerDetermine power sourceDevelop interface to power sourceLED integration

Industrial and Systems Engineers1Industrial Systems Engineer 1

Integration of the Design and Manufacturing processImplement Lean Manufacturing processesObserve ergonomic issues

1Business Majors

Business Major 1Marketing CampaignBudgetWeb page

Customer Needs


Metric Importance (Stars) Units Target ValueMaterial Properties 2 Binary YesLifetime 2 years 30Inexpensive materials 1 US$ 700Simple design 2 Subj. YesMinimum output 2 Ft-Candles 1Ballast efficiency 2 % 95Color Temperature 1 K 2700CRI 1 None 22UL codes and IEEE standards

1 Binary Yes

Light fixture mounting 1 Subj. GoodManufacturability 2 Minutes 30Low maintenance 1 Subj. YesElectrical connections 1 Minutes 2Efficiency 2 Lumens/Watt 150-200LED’s are powerful 2 Ft-Candles 1Accepts AC and DC inputs

3 Binary Yes

Bending Strength 1 kN NAAvailability of parts 2 Subj. Readily available

Future Plans

Await PRP approval

Indoor Projects

Mission Statement Compact Fluorescent Lamp Replacement

This project will focus on developing a replacement for Compact Fluorescent Lamp fixtures that are located on RIT campus. These CFL fixtures aim provide a good return on the investment of LED lamp as well as an efficient light resources. The LED fixture needs to be low cost, high energy efficiency, last long life, and easy to maintain.

T-8 Replacement This particular project targets the T8 light bulb. The T8 is

a long cylindrical low wattage, low mercury fluorescent light bulb which is widely used across the RIT campus. It is already quite efficient. This aim of this project is to create a light bulb using multiple LED's to replace the current T8 model.

Administrative InformationProject Name

LED Lighting Technologies Project Number

P08426 Project Family

Sustainable Entrepreneurial Venture Track

Sustainable Products, Systems, and Technologies Track

Start Term 2007-2 for MSD1

End Term 2007-3 for MSD2

Faculty Guide Dr. Vincent Amuso (EE)

Faculty Consultant Dr. Robert Stevens (ME)

Graduate Teaching Assistant Jeff Webb (ME)

Primary Customer Mr. Dave Harris

Customer contact information RIT Institute of Technology facility Manager [email protected]

Compact Fluorescent Lamp Replacement

Commonly used in classroom, dorm, lab

replacement by LED lamp

Uses 110 V or 277VResearch fixtureSave energy costInterview with

customer for more detailed needs

www.botany.uwc.ac.za










1Business Majors


Establish the Importance of the Customer Needs

Need The Product Needs to Importance 1. LED reduces RIT power demand/consumption 52. LED minimizes energy lost to heat 3 3. LED performs aesthetics 3 4. LED is interchangeable with existing technologies 5 5. LED performs as better than current systems 4 6. LED can be safety to use 4 7. LED reliability in tamper-resistant 3 8. LED has cheaper price for consumer 3 9. LED is easy to maintain/ replace 3 10. LED is recyclable 4 11. LED does not generate excess heat 3 12. LED is adaptable on natural energy resources 5





5 Degrees (F or C)-10-100 F, (-25-40 C)









Future Plans

Finish conducting interviews with the sponsor

Further review old Senior Design project

Develop a more complete draft of the needs assessment based on a particular direction (changing CFL to LED lighting)

Reserve desired workspaces and equipment before the completion of DPM course

Refine P08426 project for SD I

Sponsor: www.rit.edu Estimated Budget: $2,500.00 Questions?

P08430 – Naresh Potopsingh

Project Name P0843x: LED Lighting Technologies for a Sustainable Entrepreneurial Venture

Project Number P08430

Project Family Sustainable Products, Systems, and Technologies

Track Sustainable Technologies for the RIT Campus

Start Term 2007-2

End Term 2007-3

Faculty Guide Dr. Robert Stevens (ME)

Faculty Consultant Dr. Vincent Amuso (EE)

Graduate Teaching Assistant TBA

Primary Customer Rochester Institute of Technology

Address of Company Rochester Institute of Technology, 1 Lomb Memorial Drive, Rochester, NY 14623-5603

T8 Replacement

T8 is most common lamp used

80,000 to 100,000 in use now

Approximately 25,000 are replaced all over campus annually

Uses 115V~120VVery low wattage ~

40WAlready Very efficient




Mechanical Engineer 2Develop light dispersing lensesConduct Heat Transfer analysisDevelop FEA package




Electrical Engineer 2Secondary electrical engineerSimulation software eg PSpiceModelingLED integration

Electrical Engineer 3Circuit builderSimulationData collectorTheoretical calculations

Computer Engineer 1

Computer Engineer 2Interface circuit with computerUse programming to simulate the circuitWeb page

Customer Needs

• Easily standardized between lighting fixtures

• Needs to be cheap • Recyclable • Avoid bat cave look • Try to spread the light out • Attain the most foot candles

possible • Obtain a light with a higher

CRI • Better lighting • Specify different colors -

white light, warm light, etc.

• Vandal-resistant • Relatively easy to install • Keep peak demand low • Decrease energy bill • Keep the fixture price low • Solar power possible • Most cost-effective method

for power • Good return on investment • Needs to be value in the

lighting and in the fixture • Long life span • Better efficiency of lamp and

fixture





3 Degrees (F or C)-10-100 F, (-25-40 C)









Future Plans

Build a lamp which uses even lower wattage than the T-8

Use a strip of LED’s for efficiency Use a reflector to scatter the light for a

greater lightingUse brighter LED’sProtect fixture for durability

Power Conversion & Conditioning

Power Storage

Power Controller/Switch

277 VAC

208 VAC

110 VAC

12 VDC

24 VDC

12 VDC

12 VDC 12 VDC

Modular Enclosure

P0842X

Design Concept – Intelligent Power Module

Demand Response

Demand Response - any action taken in response to an emergency signal that temporarily limits electric demand. Demand Response is a great way to guard New Yorkers against grid events, reduce dependence on oil, lower peak electric prices, and increase revenue.

Permanent Demand Reduction (PDR)

Demand Response

Load Curtailment & Shifting (LC/S)

Distributed Generation

(DG)

Interval Meters (IM)

Con Edison Rest of State Con Edison Rest of State

Con Edison Everywhere

$600/kW $300/kW $200/kW $50/kW $150/kW $1,500/meter

Incentives for Reductions in Peak Electric Demand

http://www.nyserda.org/programs/peakload/default.asp

http://www.nyiso.com/public/webdocs/company/about_us/annual_report/nyiso_areport2006final.pdf

What’s in it for RIT?

RIT has a peak demand for the year of about 15 Megawatts! The associated demand charge is around $11/kW.

~65% of this is due to lighting

If this peak demand is reduced to 14 MW, RIT saves $11,000 in one month!

Note: •Monthly Demand charge is dictated by highest ½ hour of demand during the week.

Reduce lighting costs by reducing demand

Reduce demand by reducing energy consumption

Reduce consumption using more efficient technologies

Make technologies more efficient by making them more intelligent…

LED Project Philosophy










1Business Majors


• Refine project scope: • Inputs/Outputs dependent (somewhat) on

other projects within the family• Possibility for applications outside LED

realm• Detailed cost savings and government

incentives analysis, with recommendations

Opportunities & Options for SDI

http://www.nyiso.com/public/webdocs/company/about_us/annual_report/nyiso_areport2006final.pdf

Continue through list of potential faculty guides

Conduct thorough patent searchRefine project scope and determine design

options and expectations

Future Plans

Applications for Developing Nations

Faculty Guide Dr. Robert Stevens (ME) Currently two billion people live without clean, healthy, reliable

lighting or power. Many of these people use gas and oil lamps, which produce a

great deal of soot and carbon dioxide in addition to consuming vast amounts of fuel to produce relatively little usable lighting.

The average income is very low in these nations, so it will be necessary for these products to be extremely inexpensive

The climate in these nations will necessitate that the product be, among other things, water-proof and able to withstand extreme weather conditions

This project seeks to provide a clean, reliable, inexpensive, and non-power-dependent source of light for developing nations.

Staffing Requirements


Team LeadAssign tasks to rest of the teamKeep Team on Track for April 2009 DeliveryPrepare deliverablesContribute to mechanical design (human interfacing)

Mechanical Engineer 2CAD WorkMechanical TestingMechanical Analysis


Power Supply DesignPower Supply IntegrationControls

Electrical Engineer 2Power Storage Selection/DesignPower Supply IntegrationLight Emission Sub-System


Design for ManufactureSustainability AspectsEnvironmental ConcernsImplement Lean Manufacturing processesObserve ergonomic issues

Industrial Designers1Industrial Designer 1

Design of Exterior ShellLight DistributionAesthetics

Business MajorsConsultant Roll

Entrepreneurial AspectsEconomic Efficiency and Feasibility

Customer Need – Engineering Metrics Matrix

Preliminary Metrics

# Metric UnitsImportance

(Stars) Potential Value

1Production Cost U.S. $ ***** 50

2Has On-Board Power Supply Binary ***** Yes

3Usable Temperature Range °F or °C ***(30-120)°F or (0-50)°C

4Water-Proof Binary *** Yes

5Heat/Sand-Proof (Air Tight) Binary *** Yes

6Storage Capacity mAh **** 6000

7Recharge-ability Cycles ***** 500

8Lifetime hrs ***** 100,000

9Distribution of Light (Δ Lux)/(Δ m) ** ~0

10Intensity of Light Lux **

11Functional Drop Height m *** 3

12Drop Cycles Cycles *** 50+

13Lens Hardness (Resists Scratching)

Mohs Hardness *** 6+

14Efficiency Lumens/Watt *****

15Efficiency hrs/charge ***** 60

16Charge Time hrs *** ≤4

17Recyclable Parts Binary * Yes

18Environmentally Friendly Binary * Yes

19Aesthetically Pleasing Subjective * Yes

20Weight (Mass) lb (kg) ** <10lb (<4.5kg)

Future Plans

2007 12 November – 20 December

Write P3 Grant Proposal with Dr. Steven2008

1 January – End of Summer Quarter Project Promotion (find interested students) Secure Additional Funding if Necessary

Fall Quarter Gear-Up for Senior Design

December (Winter Quarter) Senior Design I

2009 Spring Quarter

Senior Design II April

National P3 Expo on the National Mall in Washington D.C.

Questions?

Documents

Project Plan Presentation P0842X – LED Lighting Technologies