P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture Team Members Sponsor: RIT Facilities Management Services Shawn RussellProject Manager David EellsMechanical Engineer Taylor ShivellMechanical Engineer Arthur DeaneElectrical Engineer Phil PietrantoniElectrical Engineer Christine LagreeIndustrial Engineer

Agenda Project Description & High Level Customer Needs (Shawn) Project Description & High Level Customer Needs (Shawn) Design Concept (Taylor) Design Concept (Taylor) System Design, Analysis and Testing System Design, Analysis and Testing – Light Output (David) – Fixture Lifetime – Color of Light (Arthur) Manufacturing Plan (Christine) Manufacturing Plan (Christine) Economic Analysis & Sustainability (Christine) Economic Analysis & Sustainability (Christine) Remaining Improvements and Tasks (Shawn) Remaining Improvements and Tasks (Shawn) Questions Questions

Project Description Create a new walkway lighting system with the use of LEDs to: Create a new walkway lighting system with the use of LEDs to: Reduce power consumption Reduce power consumption Increase replacement interval Increase replacement interval Primary market is RIT Facilities Management Services Primary market is RIT Facilities Management Services Current annual cost to maintain and power 125 residential lights: $10,020 Current annual cost to maintain and power 125 residential lights: $10,020 Customer NeedsEngineering Specifications Provide as much light as current system Minimum of ½ ft-cd on walkway (spread of 80’x12’) Long lifetime of fixtureDesign for 30 years Color temperature & CRI comparable to metal halide Color temperature between 3500K- 5400K, CRI > 70

Design Concept Replace internal components of existing fixture with LED retrofit assembly Replace internal components of existing fixture with LED retrofit assembly Use 5 individual circuit boards to angle the light where it is needed Use 5 individual circuit boards to angle the light where it is needed Use simple design to direct light while minimizing component and assembly cost Use simple design to direct light while minimizing component and assembly cost

Light Output Analysis Ray-tracing software (TracePro) used to optimize design Ray-tracing software (TracePro) used to optimize design – Geometry of internal fixture components – Reflector design – Placement of LEDs – Lens configuration Plot shows a minimum of 0.5 foot-candle over entire area. Plot shows a minimum of 0.5 foot-candle over entire area. Plot assumes three fixtures spaced 80’ apart. Plot assumes three fixtures spaced 80’ apart.

Light Output Testing Small scale tests with 1 – 5 LEDs to determine: Small scale tests with 1 – 5 LEDs to determine: – Number of LEDs – Wattage of LEDs – Optics – Verify software models Photometry Testing Photometry Testing – Individual LEDs and Lens combinations tested to determine validity of datasheets Full scale light output on assembled prototype Full scale light output on assembled prototype – Prove software models – Verify that specifications were met

Fixture Lifetime Reduce maintenance costs Reduce maintenance costs Two Components: Two Components: – Fixture Lifetime Corrosion resistant components used to prevent premature failure Corrosion resistant components used to prevent premature failure Existing fixture housing re-used Existing fixture housing re-used – LED Lifetime & Ease of Replacement LEDs have a lifetime of 50,000 hrs LEDs have a lifetime of 50,000 hrs Each PCB can be easily removed when needed Each PCB can be easily removed when needed Thermal, environmental, and vibration testing were completed Thermal, environmental, and vibration testing were completed

Light Color/CRI Low color rendering index (CRI) indicates poor distinction between colors viewed under that light Low color rendering index (CRI) indicates poor distinction between colors viewed under that light Color temperature should be close to existing metal halide fixtures Color temperature should be close to existing metal halide fixtures – Not too blue, not too yellow Color temperature and CRI are properties of the LEDs, so LEDs were chosen with this in mind Color temperature and CRI are properties of the LEDs, so LEDs were chosen with this in mind A questionnaire was used to judge the CRI of the light from the LEDs and aesthetic appeal of the light color A questionnaire was used to judge the CRI of the light from the LEDs and aesthetic appeal of the light color

Power Analysis & Testing Current Metal Halide fixtures use 160 Watts Current Metal Halide fixtures use 160 Watts LED fixture uses 60 Watts LED fixture uses 60 Watts

Thermal Analysis & Testing Each circuit board was analyzed to determine the size and spacing requirements Each circuit board was analyzed to determine the size and spacing requirements Aluminum was laminated to the back of the boards to improve heat transfer Aluminum was laminated to the back of the boards to improve heat transfer More surface area was added to the back plate to dissipate added heat More surface area was added to the back plate to dissipate added heat Transformers were placed on their own mounting plate, away from the LEDs to distribute heat Transformers were placed on their own mounting plate, away from the LEDs to distribute heat Thermal tests were performed to further optimize the design and prove the FEA models Thermal tests were performed to further optimize the design and prove the FEA models – Temperature measured at several points – Large changes in temperature were examined and corrected

Summary of Testing TestPass/FailComments Light OutputPass EnvironmentalPass ThermalPass Light Color/CRIPass Power ConsumptionPass

Manufacturing Plan

Economic Analysis Budget for prototypes Budget for prototypes – Total of 3 prototypes: $ shipping Initial prototype cost – one fixture Initial prototype cost – one fixture – Initial investment per kit: $ Retrofit scenario – 125 fixtures Retrofit scenario – 125 fixtures – Approximate sale price per fixture: $430 – Total initial investment: $58,732 – Annual savings: $8,049 Energy savings: $3,777 Energy savings: $3,777 Labor and material savings: $4,600 Labor and material savings: $4,600 – Payback period: 7.3 years – Rate of return: 13.7%

CO 2 Emissions LEDMH kWh/year/fixture kWh for 125 fixtures32, , Annual lbs/kWh/fixture Annual lbs/kWh/125 fixtures38, , lbs/kWh for NY0.86 lbs/kWh for Hess/RIT Fuel Sources: Hess Biomass<1% Coal31% Gas23% Hydro11% Nuclear23% Oil12% Solar0% Solid Waste<1% Wind<1% Sustainability

Remaining improvements & tasks

Questions