1. P08427 LED Lighting Technologies for a Sustainable Lighting Solution in Developing Nations Detail Design Review 6 February 2009

2. Design Review Objectives To receive feedback on the aspects of our current design Come away with direction for the final stages of the project – Suggested changes to the design – Additional prototype verification that should be conducted Be ready to provide the best possible product to our end users. Please Feel Free to Ask Questions at any Time

3. Action Items From SLDR TaskResponsibleCompletion DateStatus Feasibility of One Unit SystemSee Below19-Jan-09Completed – Turned Down Power Generation, Distribution, & StorageJesse“ Power StorageMike“ Materials for Prototyping, System UsageLuke“ Bike Mechanical Components, CostsNick“ Treadle Mechanical Concepts, CostsMatt“ Finalized Concept SelectedAll19-Jan-09Completed Research Power Storage Concerns from SLDRJesse & Mike21-Jan-09 Completed – Final PS selected Determine battery charging cost and time to pay off capital equipment Luke21-Jan-09 Open – Initial Estimates Made Determine Feasibility of DimmerMike21-Jan-09 Completed – Added to design Finalized Selection of ComponentsAll21-Jan-09Completed Start Ordering Major Components for testingAll21-Jan-09Completed Look into materials (PLA and PET)Luke23-Jan-09Completed Benchmark Current Product MaterialsLuke23-Jan-09Complete

4. Needs/Specifications 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

5. #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 cycles @ 3m) 12 Meets UL and CSA Standards Pass/Fail****YES 13 Exposed Components Resist Scratching Mohs Hardness***5+6+ 14Battery 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

6. 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 1234567891011121314151617181920212223 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

7. Concept Selection

9. Costs of Treadle vs. Bike

10. Treadle vs. Bike

11. System Block Diagrams

12. Final Can Concept

13. Power Module

14. Complete Power Generation Module

15. Battery Charging Device

17. Gear Ratio/RPM Analysis RPM at Pedal RPM at Motor 201040 301560 Gear ratios 402080 Fastest GR on bike3.71 502600 Wheel Dia. To motor Dia.20.00 603120 Efficiency 703640 0.70 804160 = 904680 Total Gear ratio52.00 1005200 1105720 1206240

18. Power Module Electrical Schematic

19. Lighting Module

20. Power Conditioning Circuit

21. Lighting Module Design

22. Thermal Analysis

23. Reduced Power

24. Light Dispersion

26. Conical LensPrismatic Diffuser

28. Bill of Materials Risks

29. BOM Item #Vendor P/NVendorItem DescriptionQuanityUnit PriceExtended PriceStatusOwner POWER MODULE Electrical Components 1546-186F48MouserHammond 2.4:1 Transformer, 96VA1$25.52 greenJesse 2512-FAN1587AMC15XMouserFairchild FAN1587 Adjustable Voltage Regulator TO-2634$1.18$4.72greenJesse 3863-MC33340DGMouserOn Semi MC33340 NiMH Charger SOIC84$1.56$6.24greenJesse 4645-598-8260-107FMouserGreen LED - 12064$0.10$0.40greenJesse 5625-SS3P3-E3MouserDiode - Vishay 3A Schottky D)-220AA20$0.17$3.40greenJesse 6262-1.5-RCMouserResistor - 1.5Ohm, 2W, Through-hole8$0.19$1.52greenJesse 7263-6.8k-RCMouserResistor - 6.8k, 12064$0.05$0.20greenJesse 8263-91-RCMouserResistor - 91 ohms, 12064$0.05$0.20greenJesse 9290-1.0K-RCMouserResistor - 1k, 12064$0.05$0.20greenJesse 10290-4.0K-RCMouserResistor - 4k, 12064$0.05$0.20greenJesse 11290-250-RCMouserResistor - 250 ohms, 12064$0.05$0.20greenJesse 12140-XRL10V3300-RCMouserCapacitor - 3300uF4$0.42$1.68greenJesse 13647-UHM1C102MPD3TDMouserCapacitor - 1000uF4$0.11$0.44greenJesse 14647-UVR1E330MDD1TDMouserCapacitor - 33uF4$0.03$0.12greenJesse 15NAExpressPCBCharger PCB1$60.00 yellowJesse 16NALocalNetworking Cable6 feet$0.00 greenJesse Mechanical Components 17NACampus SafteyBike1$0.00 yellowJesse 181 330 SETGL7 pricepoint.comSette Power Glyde Trainer1$68.89 greenMatt 19Motor-E100 Motorpartsforscooters.com100 Watt DC Motor1$18.99 yellowMatt 20NA Motor Support Bracket1redMatt 58637K56McMaster1.25" OD, 0.5" ID, 6" Long Neoprene Tube1$3.99 yellowMatt 227798K41McMasterScrew Connector2$1.03$2.06greenMatt 2369935K61McMaster14-2 Romex Wire10$0.38$3.80greenMatt 2405M4060Newark4"x5"x6" Aluminum Minibox Enclosure1$12.74 greenMatt 2515275A53McMasterNickel Plated L Bracket3$0.57$1.71greenMatt 2691770A148McMaster1/2" 6-32 Truss Machine Screws100$6.12greenMatt 2791240A007McMaster6-32 7/64" heigth SS Hex Nut25$10.92greenMatt 28TC258BAction Electronics2.5 mm Male Straight DC Jack4$1.75$7.00greenJesse

30. BOM Continued Lighting Module 29N/ARecyclingTin can1$0.00 green Nick 3091309A552McMaster2.5", (1/4"-20), Hex Cap Screw25$0.19$4.66green Nick 319049A029McMaster5/32", (1/4"-20), Hex Jam Nut100$0.01$1.08green Nick 3291090A105McMaster.266" ID,.5" OD, Washer, (.05" Thick)100$0.04$4.46green Nick 33163-4024MouserDC Power Jacks PANEL MOUNT 2.5MM1$2.09 green Nick 36Wiregreen Nick 377667A12McMaster0.125" Dia. Solder, 50%tin / 50%lead1$16.02green Nick 387369A34McMasterLoctite #US1152 Urethane Thermal Paste1$13.12green Nick 397445A12McMasterPermatex Gel-Twist Threadlocker #240101$12.94green Nick 40301805Lowes1 1/4" Galvanized 2-Hole Pipe Strap 4 Pack4$1.43greenNick 41 wire connectorsyellowNick 42thin thin sheet steelyellowNick 43Onlinemetals.com1/16" Acrilic Sheet1$2.38 yellowNick 44shrink wrapyellowNick 45 10304All-battery.comFast Charging AA 2300mAh NiMH Rechargeable batteries4$1.79$7.16greenMike 46 72-P16NP-50KMouserKnob Potentiometer1$9.62 greenMike 47 72-P16NP-50KMouserN-Channel MOSFET1$0.40 greenMike 48 NAExpressPCBLighting Module PCB1yellowMike 49 LED1greenMike 50 163-4024Mouser2.5 mm Female Panel Mount DC Jack1$2.09 greenMike Item #Vendor P/NVendorItem DescriptionQuanityUnit PriceExtended PriceStatusOwner

32. Life Cycle Assessment

33. Characterization

34. Weighted Characterization

35. Single Score

36. Networks

38. Action Plan Task Expected Date Responsible Team Member Comments Discuss Design Feedback06 Feb 2009All Test motor drive13 Feb 2009All Measure power output Test different configurations Test LED heat sink13 Feb 2009All Attach thermocouples Measure temp at different power All Ordering Complete23 Feb 2009AllOrder most parts BEFORE this date All Parts in House09 Mar 2009AllShipped over break Initial Prototype Assembled13 Mar 2009All Will be iterated over the next month Final Prototype Completed10 Apr 2009All P3 EXPO18 Apr 2009AllGET PHASE 2 GRANT!!

39. Drawing Package