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  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  Incandescent bulb  100  Metal Halide  ~85  HPS  22 Color Temperature  Degree warmth or coolness of a light source  LED  (cool white)  Metal Halide  3000 K (very yellow) to K (very blue)  HPS  2700 K Lifetime  LED  100,000 hours  Incandescent  1000 hours  Fluorescent  10,000 hours

Efficiency Comparisons

Outdoor  HPS: Shawn  Metal Halide: Courtney Indoor  T8 Tube: Naresh  CPL Replacement: Win Power Module  Matt Developing Nations  Ian Start Term: for MSD1 End Term: for MSD2 Start Term: for MSD1 End Term: for MSD2 Project Breakdown Comparison

Preliminary Work Breakdown Structure Three Week Project Plan Person Week (03 Dec 07) Week (10 Dec 07) Week (17 Dec 07) All Establish team values and normsUnderstand customer needsPresent individual "research" to group Review and understand the projectMeet with customers to establish any additional needsParticipate in brainstorming session Meet with faculty guide and consultants(or Brainstorm any additional needs)Determine product target specifications Team building exercises/ice breakersParticipate in benchmarking session- Identify and gather any additional benchmarking materials -- ME 1 Introduce project to teamArrange meeting with customers Look into possible interface options and prepare report Help team get up to speed(Or lead needs brainstorming session)Lead brainstorming Arrange the necessary meetingsLead benchmarking sessionHelp 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 1 Review EE analysis programsFocus on power supply portion of benchmarking sessionLook into power supply options and prepare report Review chosen control language-- EE 2 Review EE analysis programs Focus on power storage and light emitting portions of benchmarking session Look into storage and lighting options - prepare report Review MATLAB-- ISE 1 Review CAD tutorials Focus on manufacturing, sustainability, and environmental concern portions of benchmarking session Look 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 Thorough Each 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 Accurate Each team member will accurately complete and document their work Professional and Ethical Each 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. Committed Each 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 Scheme Grade LevelSenior Design ISenior Design II D Have 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 BHave a working concept nearly developedHave 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  for Senior Design I End Term  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: Planning Staffing Requirements Mechanical Engineers 3  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep in contact with team leads from other projects  Prepare deliverables  Contribute to mechanical design  Mechanical Engineer 2  Primary mechanical engineer  Develop casing for LED light  Integrate parts together  Develop CAD package  Mechanical Engineer 3  Develop light fixture  Integrate parts together  Develop CAD package Electrical Engineers 1  Electrical Engineer 1  Primary electrical engineer  Determine power source  Develop interface to power source  LED integration  Any computer programming Industrial and Systems Engineers 2  Industrial Engineer 1  Primary industrial engineer  Develop fixture for LED light  Communicate with other LED teams  Industrial Engineer 2  Create a sustainable system  Help to optimize the system  Make system manfactureable Business Majors Consultant  Business Major 1  Aid with the manufacturing process  Create a potential business plan to manufacture product

Customer Needs

Target Specifications MetricImportance (Stars)UnitsTarget Value Production Cost4US $~$400 Usable Temperature Range5Degrees (F or C) F, ( C) Water-Proof4BinaryYes Heat/Cold Resistant4BinaryYes Vandal Resistant4BinaryYes Lifetime5Hours100,000 CRI Level1No units85 Energy Efficient5lumen/watt85 Standardized4BinaryYes Weight of Light (Mass)3Lbs (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 lamp A Basic design of a high pressure sodium lamp P08421

Phase 0: Planning Staffing Requirements Mechanical Engineers 3  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep in contact with team leads from other projects  Prepare deliverables  Contribute to mechanical design  Mechanical Engineer 2  Develop light dispersing lens  Conduct Heat Transfer analysis  Develop FEA package  Mechanical Engineer 3  Develop light fixture  Integrate parts together  Develop CAD package Electrical Engineers 1  Electrical Engineer 1  Primary electrical engineer  Determine power source  Develop interface to power source  LED integration Industrial and Systems Engineers 1  Industrial Systems Engineer 1  Integration of the Design and Manufacturing process  Implement Lean Manufacturing processes  Observe ergonomic issues 1 Business Majors  Business Major 1  Marketing Campaign  Budget  Web page

Customer Needs

Target Specifications MetricImportance (Stars)UnitsTarget Value Material Properties2BinaryYes Lifetime2years30 Inexpensive materials1US$700 Simple design2Subj.Yes Minimum output2Ft-Candles1 Ballast efficiency2%95 Color Temperature1K2700 CRI1None22 UL codes and IEEE standards 1BinaryYes Light fixture mounting1Subj.Good Manufacturability2Minutes30 Low maintenance1Subj.Yes Electrical connections1Minutes2 Efficiency2Lumens/Watt LED’s are powerful2Ft-Candles1 Accepts AC and DC inputs3BinaryYes Bending Strength1kNNA Availability of parts2Subj.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 Information Project Name LED Lighting Technologies Project Number P08426 Project Family Sustainable Entrepreneurial Venture Track Sustainable Products, Systems, and Technologies Track Start Term for MSD1 End Term 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

Compact Fluorescent Lamp Replacement Commonly used in classroom, dorm, lab replacement by LED lamp Uses 110 V or 277V Research fixture Save energy cost Interview with customer for more detailed needs

Phase 0: Planning Staffing Requirements Mechanical Engineers 3  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep in contact with team leads from other projects  Prepare deliverables  Contribute to mechanical design  Mechanical Engineer 2  Develop light dispersing lens  Conduct Heat Transfer analysis  Develop FEA package  Mechanical Engineer 3  Develop light fixture  Integrate parts together  Develop CAD package Electrical Engineers 1  Electrical Engineer 1  Primary electrical engineer  Determine power source  Develop interface to power source  LED integration Industrial and Systems Engineers 1  Industrial Systems Engineer 1  Integration of the Design and Manufacturing process  Implement Lean Manufacturing processes  Observe ergonomic issues 1 Business Majors  Business Major 1  Marketing Campaign  Budget  Web page

Establish the Importance of the Customer Needs Need The Product Needs to Importance 1. LED reduces RIT power demand/consumption 5 2. 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 LED is recyclable LED does not generate excess heat LED is adaptable on natural energy resources 5

Target Specifications MetricImportance (Stars)UnitsTarget Value Production Cost4US $~$400 Usable Temperature Range5Degrees (F or C) F, ( C) Water-Proof4BinaryYes Heat/Cold Resistant4BinaryYes Vandal Resistant4BinaryYes Lifetime5Hours100,000 CRI Level1No units85 Energy Efficient5lumen/watt85 Standardized4BinaryYes Weight of Light (Mass)3Lbs (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: Estimated Budget: $2, 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  End Term  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

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~120V Very low wattage ~ 40W Already Very efficient

Phase 0: Planning Staffing Requirements Mechanical Engineers 3  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep in contact with team leads from other projects  Prepare deliverables  Contribute to mechanical design  Mechanical Engineer 2  Develop light dispersing lenses  Conduct Heat Transfer analysis  Develop FEA package  Mechanical Engineer 3  Develop light fixture  Integrate parts together  Develop CAD package Electrical Engineers 3  Electrical Engineer 1  Primary electrical engineer  Determine power source  Develop interface to power source  LED integration  Electrical Engineer 2  Secondary electrical engineer  Simulation software eg PSpice  Modeling  LED integration  Electrical Engineer 3  Circuit builder  Simulation  Data collector  Theoretical calculations Computer Engineer 1  Computer Engineer 2  Interface circuit with computer  Use programming to simulate the circuit  Web 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 MetricImportance (Stars)UnitsTarget Value Production Cost3US $~$400 Usable Temperature Range3Degrees (F or C) F, ( C) Water-Proof4BinaryYes Heat/Cold Resistant2BinaryYes Vandal Resistant4BinaryYes Lifetime5Hours100,000 CRI Level2No units85 Energy Efficient9lumen/watt85 Standardized5BinaryYes Weight of Light (Mass)2Lbs (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 lighting Use brighter LED’s Protect fixture for durability

Power Conversion & Conditioning Power Storage Power Controller/Switch 277 VAC 208 VAC 110 VAC 12 VDC 24 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 EdisonRest of StateCon EdisonRest of StateCon EdisonEverywhere $600/kW$300/kW$200/kW$50/kW$150/kW$1,500/meter Incentives for Reductions in Peak Electric Demand

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: Planning Staffing Requirements Mechanical Engineers 3  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep in contact with team leads from other projects  Prepare deliverables  Contribute to mechanical design  Mechanical Engineer 2  Develop light dispersing lens  Conduct Heat Transfer analysis  Develop FEA package  Mechanical Engineer 3  Develop light fixture  Integrate parts together  Develop CAD package Electrical Engineers 1  Electrical Engineer 1  Primary electrical engineer  Determine power source  Develop interface to power source  LED integration Industrial and Systems Engineers 1  Industrial Systems Engineer 1  Integration of the Design and Manufacturing process  Implement Lean Manufacturing processes  Observe ergonomic issues 1 Business Majors  Business Major 1  Marketing Campaign  Budget  Web 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

Continue through list of potential faculty guides Conduct thorough patent search Refine 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 2  Mechanical Engineer 1  Team Lead  Assign tasks to rest of the team  Keep Team on Track for April 2009 Delivery  Prepare deliverables  Contribute to mechanical design (human interfacing)  Mechanical Engineer 2  CAD Work  Mechanical Testing  Mechanical Analysis Electrical Engineers 2  Electrical Engineer 1  Power Supply Design  Power Supply Integration  Controls  Electrical Engineer 2 Power Storage Selection/Design Power Supply Integration Light Emission Sub-System Industrial and Systems Engineers 1  Industrial Systems Engineer 1  Design for Manufacture  Sustainability Aspects  Environmental Concerns  Implement Lean Manufacturing processes  Observe ergonomic issues Industrial Designers 1  Industrial Designer 1  Design of Exterior Shell  Light Distribution  Aesthetics Business Majors Consultant Roll  Entrepreneurial Aspects  Economic Efficiency and Feasibility

Customer Need – Engineering Metrics Matrix

Preliminary Metrics #MetricUnitsImportance (Stars)Potential Value 1Production CostU.S. $*****50 2Has On-Board Power SupplyBinary*****Yes 3Usable Temperature Range°F or °C***(30-120)°F or (0-50)°C 4Water-ProofBinary***Yes 5Heat/Sand-Proof (Air Tight)Binary***Yes 6Storage CapacitymAh****6000 7Recharge-abilityCycles*****500 8Lifetimehrs*****100,000 9Distribution of Light(Δ Lux)/(Δ m)**~0 10Intensity of LightLux** 11Functional Drop Heightm***3 12Drop CyclesCycles*** Lens Hardness (Resists Scratching) Mohs Hardness***6+ 14EfficiencyLumens/Watt***** 15Efficiencyhrs/charge*****60 16Charge Timehrs***≤4 17Recyclable PartsBinary*Yes 18Environmentally FriendlyBinary*Yes 19Aesthetically PleasingSubjective*Yes 20Weight (Mass)lb (kg)**<10lb (<4.5kg)

Future Plans 2007  12 November – 20 December  Write P3 Grant Proposal with Dr. Steven 2008  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?