Steve Bennerswb5096@psu.edu
Kevin Greenektg5008@psu.edu
Ernest Hauseremh5102@psu.edu
Aleksey Ryzhakovadr5083@psu.edu
Abdulla Al Hosaniaaa210@psu.edu
04/29/2008

 First, we completed a customer needs assessment to further clarify our initial problem statement.
 Second, we did an external search, including literature, websites and patent searches, to understand what has been done in the past and begin to generate ideas on how to complete the project.
 Third, we started our concept generation in order to pursue multiple concepts and choose the best concept.

 Fourth, after the initial concepts were generated, we created charts, pugh and morphological, to determine the best concept.
 Fifth, using TRIZ, we were able to refine the selected concept and improve it.
 Sixth, the final design was chosen, and sketches and CAD representation were used to convey our idea.

 Finally, we used the final design to create a bill of materials and a material selection chart, thus calculating the cost of the lighting system.

 Steve BennerTeam Leader
 Kevin GreeneResearch and Bill of Materials
 Ernest HauserConcept Selection
 Aleksey RyzhakovCAD and Final Design
 Abdulla Al HosaniCustomer Needs

Satisfies Standard (0.31)
 Lasts 20 minutes
 Survives Impact
 Produces .5-2.5 LUX
Meets Schedule (0.24)
Durable (0.17)
 Survives Impact
Reliable(0.12)
 Low Maintenance
 Reliable Power Source
Installation (0.08)
 Proper Placement
 Small Size
 Small Power Source
Cost (0.05)
Environmental Impact(0.03)
 Energy Efficient

 The objective of this project is to successfully design an emergency lighting system for the
GE Evolution Series Locomotive. The system must meet certain a brightness and time requirements, in addition to having a manual shut off. After completing a customer needs assessment and weighting categories of redesign in order of importance, we have a more accurate goal for this redesign. The overall goal is for the lighting system to meet the pre-determined brightness requirements in addition to being easy to install so that GE can meet their deadline.

Chemical Energy
Stored in
Chemicals
Chemical
Reaction Begins
Located in Back
Energy
Created
Protects
Lights
Circuit Complete
Residual Shock
LED Illuminates i
LIGHT
Circuit Breaks if
Signal Present

 Incandescent Light Bulb:
A commonly used light bulb using a very thin tungsten wire to create high resistivity. That high resistivity dissipates its energy in the form of light.

 LED bulb:
Lighting Emitting Diodes
Tiny light bulbs that fit into electrical circuits
Lack filament so they cannot burn out
Illuminated solely by electrons moving in a semiconductor

 Glow Stick:
Glow sticks use a chemicals to create a light emitting reaction. The concentrations and temperature in which the reaction occurs dictate the speed of the reaction and the intensity of the light emitted.

Top Concepts: Layout of Lights
 Lights Dotted Around Door Frame
The lighting units will be dotted around the door frame to best illuminate the exits of the cabin.

Top Concepts: Layout of Lights
 Cradle:
The design of the cradle houses nine
LED bulbs and uses a mirror to focus the light on the walkway and stairs area.
The cradle also uses steel bars to protect the unit in a crash environment.

Top Concepts: Layout of Lights
 Standard Wall Mount:
The lights will be placed on the walls of the cabin with a protective steel cover.
The cover will also serve to direct the light down towards the walkway and stairs.

Top Concepts: Layout of Lights
 Floor Mount:
The lights will be installed into the floor of the cabin area and outline the walkway and stairs. A transparent cover will provide protection in a crash environment.

 Solar Panel:
Installed on the outside of the train cabin, the solar panels will use the energy given off by the sun to power the emergency lighting system.

 Battery (Li-ion):
The electrodes of a lithium-ion battery are made of lightweight lithium and carbon. The lithium is a light weight material that is very reactive. This means it can store a lot of energy.

Lead Acid Battery:
The lead acid battery uses a plate of lead and a plate of lead dioxide, and they are separated by strong sulfuric acid. The lead and the sulfuric acid react and an extra electron is produced from the reaction.



Principles: Optical changes have been suggested.
Idea: Incorporate underside mirrors (or reflective surfaces) on the protective bars that transverse the light unit so that the light from the LEDs strikes the bottom of those bars, reflects back into the unit, and then reflects once again into open space.
Also incorporate mirrors (or reflective surfaces) inside the light unit itself. This will capture any stray light and navigate it out into open environment.

 Principles: Preliminary Action was suggested.
 Idea: Add mirrors in front of the LEDs to reflect the light towards the back round mirror and thus the overall angle the light covers is greater.

 The system must emit 2.5 LUX on stairwells, and 0.5 LUX in hallways.
 The lighting system must remain in tact upon impact.
 The system must also be able to run for at least 20 minutes.
 Also the system must be able to shut off after the problem is solved.

Iteration I
Light Source
1 Standard Bulb
2 LED
3 Glow Stick
Iteration II
Light Source
1 Standard Bulb
2 LED
3 Glow Stick cost
0
-1
1 efficiency brightness
0
1
-1
0
1
-1 cost
1
0
1 efficiency
-1
0
-1 brightness
-1
0
-1

Iteration III
Light Source
1 Standard Bulb
2 LED
3 Glow Stick cost
-1
-1
0 efficiency brightness
1 1
1
0
1
0
Iteration I
Layout
1 Dotted Around Door
2 Cradle/Mirror on wall
3 Standard Wall Mount
4 Built into Floor cost
0
-1
1
-1 durability effectiveness easy install
0 0 0
-1 1 0
0
-1
-1
-1
1
1

Iteration II
Layout
1 Dotted Around Door
2 Cradle/Mirror on wall
3 Standard Wall Mount
4 Built into Floor
Iteration III
Layout
1 Dotted Around Door
2 Cradle/Mirror on wall
3 Standard Wall Mount
4 Built into Floor cost durability effectiveness easy install
1 1 -1 0
0
1
1
0
1
-1
0
-1
-1
0
1
1 cost
0
0
-1
-1 durability
0
-1
0
-1 effectiveness
1
1
0
-1 easy install
-1
-1
0
0

Iteration IV
Layout
1 Dotted Around Door cost durability effectiveness easy install
-1 1 1 -1
2 Cradle/Mirror on wall -1
3 Standard Wall Mount 0
4 Built into Floor 0
1
1
0
1
1
0
-1
0
0
Iteration I
Power Source
1 Solar Panel
2 Li-ion Battery
3 Rechargeable Li-ion
4 Lead Acid Battery cost
0
1
1
1 efficiency
0
1
1
1 size
0
1
1
1 weight
0
1
-1
-1

Iteration II
Power Source
1 Solar Panel
2 Li-ion Battery
3 Rechargeable Li-ion
4 Lead Acid Battery
Iteration III
Power Source
1 Solar Panel
2 Li-ion Battery
3 Rechargeable Li-Ion
4 Lead Acid Battery cost
-1
0
-1
1 efficiency
-1
0
1
-1 size
-1
0
-1
-1 weight
-1
0
-1
-1 cost
-1
1
0
1 efficiency
-1
-1
0
1 size weight
-1 1
1
0
1
1
0
-1

Iteration IV
Power Source
1 Solar Panel
2 Li-ion Battery
3 Rechargeable Li-ion
4 Lead Acid Battery cost
-1
-1
-1
0 efficiency
1
1
1
0 size
1
1
-1
0 weight
1
1
1
0

Materials
Stainless Steel
Injection Molded
Plastic
(Polyethylene)
Shock Absorbing
CONFOR Foam
Fiberglass (Silica based fiber)
Density(g/cm
3
)
7.85
0.935
930
2.33
E
0.45E
2E
0.96E
Thermal Expansion
Coefficient
17.3x10
-6
/K at 20
°C
13.0 x 10
20°C
-5
/K at
0.04/K at 20°C
Cost($)
$18.68 (304.8mm length)
$4.98 (152.4mm, with 3.2mm thickness)
$9.92 (50.8mm thick)
47,390E(at 5K) 0.05/K at 20 °C $18.72 (304.8mm)

McMaster Carr Supply Co. The Led Light, Inc
473 Ridge Rd.
Dayton, NJ 08810
(732) 329-3200
1617 Fairview Dr. Ste 27-28
Carson City, NV 89701
Telephone: 1-775-841-4490
FAX: 1-775-841-4491

 When the conductor activates an emergency break, a signal is sent to activate the lighting unit. The switch within the unit completes the circuit. The current is then drawn from Li-ion batteries connected in series. The batteries are placed within a three-layer compartment —outer layer of 1cm thick steel, 3mm of protective memory foam, and 3mm plastic. On the outside, they are covered by protective steel bars of 1cm thickness. The bars are removable so that the batteries can be replaced, as a typical Li-ion battery may discharge without usage over the period of five years. The current follows through insulated wires to the lighting units. Each lighting unit has a thick steel covering and steel bars protecting it. The reflector dish, which is made from highly reflective durable plastic, is further cushioned by memory foam. The reflector dish houses nine LED units.

 Over the LED units, reflector mirrors are placed, which reflect light emanating upwards from the LEDs back to the reflector dish, which in turn reflects the light back outside.
The light is then further scattered by a concave lens. This achieves, very roughly, 70-130 degree visible beam (the lens diopter amount can be calibrated to suit the design —higher negative diopters will give a higher light beam angle, while positive diopters (making it a convex lens) would concentrate the beam is necessary), up from the 45 degrees that is provided by the LEDs utilized in this design. The bars themselves have a reflective paint painted on their underside so that any extra light that strikes them is reflected back into the reflector dish and then outside, conserving light. A manual shut off is accomplished by breaking a second switch within the circuit



The LED lights used in this design come from www.theledlight.com online store. According to the website’s specification (PDF format) for 5mm 7000mcd
40-50 degree angle white LED, the LED operates at
3.2 V with 20mA current. A 4.5 V source per design is assumed.
POWER:
According to www.ledcalc.com LED calculator for nine
LEDs connected in parallel (each LED drawing 61 milliwatts of power), a 68 ohm resistor is necessary
(each drawing 25 milliwatts of power) . The total power usage for this configuration of 9 LED, per single light unit, is then .774 (all power usages added together).

 BATTERY CAPACITY:
According to http://www.techlib.com/reference/batteries.html , Li ion battery utilized in this design supply 1100 mAh of energy. According to www.ledcalc.com, the total usage for the 9 LED unit is 172.1mA. Multiplying this number by 5, which is the number of lighting units in the design, it is seen that 860 mA total will be drawn from the batteries. 1100 mAh/860 = 1.28 hours of lighting time, exceeding the 20 minute requirement by a large amount.



LIGHTING (LUMENS):
The 5mm LEDs utilized in this design are white, are 6000-
7000mcd, and have a view angle of 40-50 degrees.
Utilizing 6500 mcd, 45 degrees, these numbers can be converted to candelas. According to http://led.linear1.org/lumen.wiz , this degree-mcd combination yields 3.109 lumens per one LED. To convert to LUX, total area covered is needed.
AREA COVERED BY LIGHTING UNIT:
Assuming 70 degree light dispersion using the mirrorreflector-lens combination used in the design, and applying trigonometry, then the circular area under the lighting unit will have a diameter of 1.4 meters. The total area, using the area formula, is then 6.16 m^s.

 LIGHTING (LUX):
Using the 3.109 lumens figure derived above, the total LUX can be calculated. First, a total amount of lumens from 9 LEDs needs to be calculated. 3.109 x 9 =28.0 lumens. Tutal LUX can now be calculated 28.0 lumens / 6.16 m^2
= 4.54 LUX. Since the lighting coverage of the lighting unit is so large, an overlap from other units will also be present, and the LUX in certain areas will be even higher.

CAD Final Design Circuit Board

Qty
Description Catalog Number Vendor
24 Socket Cap Screws, 2.5mm stock, 8mm height,
5mm head diameter
91294A0196 McMaster Carr
The Led Light 48 LED Lights – 5mm, white, 460-555 nanometer wavelength
LED5 40-50DG WH
11 Multipurpose Stainless Steel (Type 304/304L)
304.8mm Length, 4.7mm diameter
8457K22
3 Mirrored Plastic Sheet, 304.8mm x 304.8mm,
4.7mm thickness
8574K27
3 Wear Resistant Stainless Steel Cubes (Type 412)
606.9mm height, 152.4mm width, 3.175mm thick
9524K292
6 Slow-Recovery Super-Resilient Polyurethane
Foam, 304.8mm length, 304.8mm width,
6.35mm thickness
86195K316
3 Transparent Plastic Sheets, 1.6mm thickness,
304.8mm x 606.9mm
8754K121
McMaster Carr
McMaster Carr
McMaster Carr
McMaster Carr
McMaster Carr
Total Cost
Total Cost
$5.00
$65.76
$40.37
$27.87
$323.82
$32.46
$32.82
$528.10

 The total cost of the entire lighting system would be $851.92 which is a reasonable price. That includes 5 lighting units and the battery casing.
Also the units themselves are not large and easily installed in the designated locations.

After going through a thorough design process we feel that we came up with a quality product. As a group we conducted detailed background research, a customer needs assessment, a hierarchal customer needs list, and weights of importance for each main category of redesign.
We then gathered ideas and used several techniques such as Pugh charts and a morphological chart to come up with the best overall design idea. After finalizing our design idea, we constructed several 3D models using
SolidWorks.

 These models show the assembly of the individual parts as well as the overall mount design. We also built a prototype of our lighting system. Although the quantity and quality of the lights used in the prototype are not accurate to the actual product, it accurately represents how our system operates, and outlines all of the technologies used. Our system meets all requirements specified by GE and we believe it is the most efficient, and safest possible method of lighting for this locomotive.