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 $ ~$400
Usable Temperature Range
5 Degrees (F or C)-10-100 F, (-25-40 C)
Water-Proof 4 Binary Yes
Heat/Cold Resistant 4 Binary Yes
Vandal Resistant 4 Binary Yes
Lifetime 5 Hours 100,000
CRI Level 1 No units 85
Energy Efficient 5 lumen/watt 85
Standardized 4 Binary Yes
Weight of Light (Mass) 3 Lbs (kg) ~10
Future Plans
Await PRP approval
High Pressure Sodium Lamp Replacement
This is a low pressure sodium lamp
This is a spectrum of a high pressure sodium
lampA Basic design of a high pressure sodium lamp
P08421
Phase 0: PlanningStaffing Requirements
Mechanical Engineers 3Mechanical Engineer 1
Team LeadAssign tasks to rest of the teamKeep in contact with team leads from other projectsPrepare deliverablesContribute to mechanical design
Mechanical Engineer 2Develop light dispersing lensConduct Heat Transfer analysisDevelop FEA package
Mechanical Engineer 3Develop light fixtureIntegrate parts togetherDevelop CAD package
Electrical Engineers 1Electrical Engineer 1
Primary electrical engineerDetermine power sourceDevelop interface to power sourceLED integration
Industrial and Systems Engineers1Industrial Systems Engineer 1
Integration of the Design and Manufacturing processImplement Lean Manufacturing processesObserve ergonomic issues
1Business Majors
Business Major 1Marketing CampaignBudgetWeb page
Customer Needs
Target Specifications
Metric Importance (Stars) Units Target ValueMaterial Properties 2 Binary YesLifetime 2 years 30Inexpensive materials 1 US$ 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
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 2Develop light dispersing lensConduct Heat Transfer analysisDevelop FEA package
Mechanical Engineer 3Develop light fixtureIntegrate parts togetherDevelop CAD package
Electrical Engineers 1Electrical Engineer 1
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
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
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
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
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 2Develop light dispersing lensesConduct Heat Transfer analysisDevelop FEA package
Mechanical Engineer 3Develop light fixtureIntegrate parts togetherDevelop CAD package
Electrical Engineers 3Electrical Engineer 1
Primary electrical engineerDetermine power sourceDevelop interface to power sourceLED integration
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
Target Specifications
Metric Importance (Stars) Units Target Value
Production Cost 3 US $ ~$400
Usable Temperature Range
3 Degrees (F or C)-10-100 F, (-25-40 C)
Water-Proof 4 Binary Yes
Heat/Cold Resistant 2 Binary Yes
Vandal Resistant 4 Binary Yes
Lifetime 5 Hours 100,000
CRI Level 2 No units 85
Energy Efficient 9 lumen/watt 85
Standardized 5 Binary Yes
Weight of Light (Mass) 2 Lbs (kg) ~10
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
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 2Develop light dispersing lensConduct Heat Transfer analysisDevelop FEA package
Mechanical Engineer 3Develop light fixtureIntegrate parts togetherDevelop CAD package
Electrical Engineers 1Electrical Engineer 1
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
• 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
Mechanical Engineers 2Mechanical Engineer 1
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
Electrical Engineers 2Electrical Engineer 1
Power Supply DesignPower Supply IntegrationControls
Electrical Engineer 2Power Storage Selection/DesignPower Supply IntegrationLight Emission Sub-System
Industrial and Systems Engineers1Industrial Systems Engineer 1
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?