P08427 LED Lighting Technologies for a Sustainable Lighting Solution in Developing Nations System Level Design Review 16 January 2009.

P08427LED Lighting Technologies for a Sustainable

Lighting Solution in Developing Nations

System Level Design Review16 January 2009

Team Members

Design Review Objectives

• Receive feedback on our current system design

• Get answers to specific questions formulated for the individual subsystems

• Please feel free to ask questions at any time• Topics running over their scheduled time may

be tabled for discussion at the end of the session.

Project Mission• Employ LED lighting technologies• Provide clean, reliable, high quality lighting at ‐

an affordable price• Final design to be built in the target nations• Work on a truncated timetable due to EPA

Design Expo in April

Customer NeedsCustomer

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

Need/Specification Relationships

Concept Generation

Concept Generation

Final Concept

Power Module Lighting Module

+

System Definition

Power Module

Lighting Module

Power Module (Mechanical)

Power Module (Mechanical)

Model #Single Unit Price (USD)

Rated Torque (oz-in)

Rated Speed (RPM)

Power (Watt)

Cost per watt

Time of charge (hours)

BLWS233D-36V-4000 $68.60 31.154 4000 92 $0.75 1.96

BLWS233S-36V-4000 $68.60 31.154 4000 95 $0.72 1.89

BLWS234D-36V-4000 $82.30 45.315 4000 134 $0.61 1.34

BLWS234S-36V-4000 $82.30 45.315 4000 135 $0.61 1.33

BLWS235D-160V-3000 $96.30 70.8 3000 157.2 $0.61 1.15

BLWS235S-36V-4000 $96.30 56.644 4000 180 $0.54 1.00

BLY172S-24V-4000 $61.20 17.701 4000 52 $1.18 3.46

BLY173S-24V-4000 $73.40 26.198 4000 77 $0.95 2.34

BLY174S-24V-4000 $85.70 35.402 4000 104 $0.82 1.73

BLWR173S-24V-4000 $83.50 21.241 4000 62 $1.35 2.90

BLWS232S-36V-4000 $59.90 31.154 4000 50 $1.20 3.60

BLWS232D-36V-4000 $59.90 31.154 4000 92 $0.65 1.96

Power Module (Electrical)

Sample Schematic for use with AC source and SLA battery

Power Storage

Power Generation

Connector/Receptacle Batter Pack Stored Power

Light Module Power Condiditoning

Stored Power Amplifier Dimmer Diffusible LightLED (Single or Array)

Light Generation

Light Color

Light Diffusion

Going Forward• Incorporate customer/faculty feedback• Decide on major project components• Detail subsystem design• Begin to purchase components• Begin to test subsystems

Do all of this in next three weeks!