P08427 LED Lighting Technologies for a Sustainable Lighting Solution in Developing Nations System Level Design Review 16 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 Needs Customer Need # ImportanceDescriptionComments/Status 11Provides a Better Lighting SolutionIf this not met, product is useless 22Off-Grid Energy SourcePrimary purpose 32Low Purchase Cost End user cost will have to by partially subsidized due to the high cost of the technology 43Low Operating Cost This cost should be zero there are no consumables 54Able to be Manufactured in Developing World At least in part - this plays into the micro-economy part of the project 65SafeShould not be a fire or health hazard 76Universal Application (Transferability) The product and the production of the production may be adapted to the many potential deployment markets 87Easy to UseLow Maintenance, Straightforward, etc. 98Long Operation time Power 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 109Able to Withstand Harsh Climate ConditionsWater Resistance/Particulate Proof 119Durable/RobustWithstands the rigors of operation 1210Provides Comfortable lighting Quality of lighting greatly determines usability of system - however, nearly anything is better than what already exists 1311Can be made out of Recycled MaterialsLots of waste materials that could be used in manufacturing process 1412Clean energy sourceEPA would like a planet-friendly solution 1513Can be easily recycled at end of life EPA would like a planet-friendly solution

#MetricUnitsImportanceMarginalIdealNote/Comment 1Production CostU.S. $*****4010 Unfortunately the technology requested is quite expensive…will probably need to have purchase cost subsidized 2Usable Temperature Range °F or °C *** (4.5-38)°C(0-50)°C Tested with environmental chamber 3Water ResistantIPX Standard***33 Perhaps only applies to some of the components…or different values for different components 4Particulate ResistantBinary***YES Tested with environmental chamber 5Storage CapacityHrs****630 Ideally the product would not have to be charged everyday (if using a central power station) 6Battery LifetimeYears*****310Based on 1000 charge cycles at 30 hours per charge and 8 hours of usage/day 7Base Unit LifetimeYears*****1030Based on 100,000 hour lifetime of LED lights and 8 hours of usage/day 8Color of LightCRI***89100LED Specifications 9Temperature of LightK*** 4000K- 7000K 5000K-6000KLED Specifications 10Light DistributionLux*****>50>150 The 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 11Passes Drop TestPass/Fail***YES Functional Drop Height and Drop Cycles (+50 3m) 12 Meets UL and CSA Standards Pass/Fail****YES 13 Exposed Components Resist Scratching Mohs Hardness*** Battery Installation Timesec***<45<20Before and After Charging (if battery unit is removable) 15Unit Start Timesec***<5<2 All you really have to do is push a button to turn it on, should be pretty easy to use 16Charge time (manual)min***≤30≤5 17Charge Time (solar)hrs***≤6≤4 18Recyclable Parts% by weight**>25>50 19Environmentally FriendlyMeets ROHS***YES Need better metric - takes materials, efficiency, and recyclability into account 20Assembly% of VA**25≥80Value added in Local Economy 21Simple Manufacture ProcessPass/Fail****YES Parts 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 22Lifecycle Plan in PlacePass/Fail****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 23Weightlb*<10<3Weight of mobile portion of unit

Need/Specification Relationships Metrics Production Cost Usable Temperature Range Water Resistant Particulate Resistant Storage Capacity Battery Lifetime Base Unit Lifetime Color of Light Temperature of Light Light Distribution Passes Drop Test Meets UL and CSA Standards Exposed Components Resist Scratching Battery Installation Time Unit Start Time Charge time (manual) Charge Time (solar) Recyclable Parts Environmentally Friendly Assembly Simple Manufacture Process Lifecycle Plan in Place Weight (Mass) Needs Provides a Better Lighting Solution 1 XXX X Off-Grid Energy Source 2 X Low Purchase Cost 3X Low Operating Cost 4 X Able to be Manufactured in Developing World 5 X XX Safe 6 X Universal Application (Transferability) 7 X XXX Easy to Use 8 XXXX X Long Operation time 9 XXX Able to Withstand Harsh Climate Conditions 10 XXX X Durable/Robust 11 XXX X X Provides Comfortable lighting 12 XXX Can be made out of Recycled Materials 13 XX Clean energy source 14 X X Can be easily recycled at end of life 15 XX X

Concept Generation

Final Concept Power ModuleLighting Module +

System Definition

Power Module Lighting Module

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$ $ BLWS233S-36V-4000$ $ BLWS234D-36V-4000$ $ BLWS234S-36V-4000$ $ BLWS235D-160V-3000$ $ BLWS235S-36V-4000$ $ BLY172S-24V-4000$ $ BLY173S-24V-4000$ $ BLY174S-24V-4000$ $ BLWR173S-24V-4000$ $ BLWS232S-36V-4000$ $ BLWS232D-36V-4000$ $

Power Module (Electrical) Sample Schematic for use with AC source and SLA battery

Power Storage

Light Module Power Condiditoning

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!