Project Plan Presentation
P0842X – LED Lighting
Technologies
COURTNEY WALSH (ME)
IAN FRANK (ME)
MATT BENEDICT (ME)
SHAWN RUSSELL (ME)
WIN MAUNG (ME)
NARESH POTOPSINGH (ME)
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  150-200
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 62-91
Incandescent bulb  100
Metal Halide  ~85
HPS  22
http://lighting.sandia.gov/XlightingoverviewFAQ.htm
 Color Temperature




Degree warmth or coolness of a light
source
LED  5000-7500 (cool white)
Metal Halide  3000 K (very
yellow) to 20000 K (very blue)
HPS  2700 K
 Lifetime



LED  100,000 hours
Incandescent  1000 hours
Fluorescent  10,000 hours
Efficiency Comparisons
http://www.iolighting.com/efficacy.htm
Project Breakdown Comparison
Outdoor
 HPS: Shawn
 Metal Halide: Courtney
Indoor
 T8 Tube: Naresh
 CPL Replacement: Win
Developing
Nations
 Ian
Power Module
 Matt
Start Term: 2007-2 for MSD1
Start Term: 2008-2 for MSD1
End Term: 2007-3 for MSD2
End Term: 2008-3 for MSD2
Preliminary Work Breakdown Structure
Person
All
Week 0 - 1
(03 Dec 07)
Establish team values and norms
Three Week Project Plan
Week 1 - 2
(10 Dec 07)
Understand customer needs
Week 2 - 3
(17 Dec 07)
Present individual "research" to group
Review and understand the project
Meet with customers to establish any additional needs
Participate in brainstorming session
Meet with faculty guide and consultants
(or Brainstorm any additional needs)
Team building exercises/ice breakers
Participate in benchmarking session
Identify and gather any additional benchmarking
materials
Introduce project to team
Help team get up to speed
Arrange the necessary meetings
ME 1
Schedule a meeting with all team leads to
coordinate projects
Review CAD package tutorials
ME 2
EE 1
EE 2
Review Fatigue analysis package for deformation,
stress, and thermal (heat transfer) analysis
(Or lead needs brainstorming session)
Lead benchmarking session
Focus on human interface portion of benchmarking
session
Record and publish results from benchmarking and needs
evaluation
Focus on materials and mechanical analysis portion of
benchmarking session
-
Look into possible interface options and prepare
report
Lead brainstorming
Help others when/where needed
Look into possible materials and prepare report
-
Review EE analysis programs
Focus on power supply portion of benchmarking session
Look into power supply options and prepare report
Review chosen control language
Focus on power storage and light emitting portions of
benchmarking session
-
Look into storage and lighting options - prepare
report
-
Review EE analysis programs
Review MATLAB
ISE 1
Arrange meeting with customers
Determine product target specifications
-
Review CAD tutorials
Review sustainability guidelines
Focus on manufacturing, sustainability, and environmental Look into sustainability and DFM options - prepare
concern portions of benchmarking session
report
-
-
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 Level
Senior Design I
Senior Design II
D
Have completed concept development for
Have multiple concepts in the works with
at least two of the original concepts and
a semi-clear plan for executing at least
have a project production plan for one of
one of them
the concepts
C
Have a concept singled out and in the
process of being completed
B
Have a working concept nearly developed Have finished the bulk of product
A
Have finished concept development and
are ready to proceed with fabrication
Have finished concept development and
begun working on the final project
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
 2007-2 for Senior Design I
End Term
 2007-3 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


Color Temperature


85
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
Industrial and Systems 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
Develop light fixture
Integrate parts together
Develop CAD package
3
Electrical Engineers
1
Electrical Engineer 1
Primary electrical engineer
Determine power source
Develop interface to power source
LED integration
Any computer programming
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
a potential business plan to manufacture product
Create
Customer Needs
Target Specifications
Metric
Importance (Stars)
Units
Target Value
Production Cost
4
US $
~$400
Usable Temperature Range
5
Degrees (F or C)
-10-100 F,
(-25-40 C)
Water-Proof
4
Binary
Yes
Heat/Cold Resistant
4
Binary
Yes
Vandal Resistant
4
Binary
Yes
Lifetime
5
Hours
100,000
CRI Level
1
No units
85
Energy Efficient
5
lumen/watt
85
Standardized
4
Binary
Yes
Weight of Light (Mass)
3
Lbs (kg)
~10
Future Plans

Await PRP approval
High Pressure Sodium Lamp Replacement
This is a low pressure
sodium lamp
This is a spectrum of a high
pressure sodium lamp
A Basic design of a high pressure sodium lamp
Phase 0: Planning
Staffing Requirements
Mechanical Engineers
Industrial and Systems Engineers
3
Mechanical Engineer 1
Team Lead
Assign tasks to rest of the team
Keep in contact with team leads from other projects
Prepare deliverables
Contribute to mechanical design
Mechanical Engineer 2
Develop light dispersing lens
Conduct Heat Transfer analysis
Develop FEA package
Mechanical Engineer
Develop light fixture
Integrate parts together
Develop CAD package
3
Electrical Engineers
1
Electrical Engineer 1
Primary electrical engineer
Determine power source
Develop interface to power source
LED integration
1
Industrial Systems Engineer 1
Integration of the Design and Manufacturing process
Implement Lean Manufacturing processes
Observe ergonomic issues
1
Business Majors
Business Major 1
Marketing Campaign
Budget
Web page
Customer Needs
Target Specifications
Metric
Material Properties
Lifetime
Inexpensive materials
Simple design
Minimum output
Ballast efficiency
Color Temperature
CRI
UL codes and IEEE
standards
Light fixture mounting
Manufacturability
Low maintenance
Electrical connections
Efficiency
LED’s are powerful
Accepts AC and DC inputs
Bending Strength
Availability of parts
Importance (Stars)
2
2
1
2
2
2
1
1
Units
Binary
years
US$
Subj.
Ft-Candles
%
K
None
Target Value
Yes
30
700
Yes
1
95
2700
22
1
Binary
Yes
1
2
1
1
2
2
3
1
2
Subj.
Minutes
Subj.
Minutes
Lumens/Watt
Ft-Candles
Binary
kN
Subj.
Good
30
Yes
2
150-200
1
Yes
NA
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
Administrative Information
Project Name
LED Lighting Technologies
Project Number
P08426
Project Family
Sustainable Entrepreneurial Venture
Track
Sustainable Products, Systems, and
Technologies Track
Start Term
2007-2 for MSD1
End Term
2007-3 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
47@mail.rit.edu
Compact Fluorescent Lamp Replacement
 Commonly used in





www.botany.uwc.ac.za
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
3
10. LED is recyclable
4
11. LED does not generate excess heat
3
12. LED is adaptable on natural energy resources
5
Establish Target Specifications
Metric No.
Metric
Importance
1.
Efficiency
5
2.
Weight
1
3.
Lens Hardness
4
4.
Charge Time
4
5.
Lifetime
5
6. Light distribution drop height
4
7.
Rechargeable
5
8.
Production Cost
5
9.
Intensity of Light
3
10. Recyclable Components
5
11.
Storage Capacity
5
12.
Power Supply
5
13.
Power Drop Cycles
4
14.
Light Distribution
3
Units
hrs/charge
kg
Mohs
hrs
hrs
m
cycles
US $
Lux
Binary
mAh
Binary
cycles
delta lux/delta m
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: www.rit.edu
Estimated Budget: $2,500.00
Questions?
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
Industrial and Systems 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
Develop light fixture
Integrate parts together
Develop CAD package
3
Electrical Engineers
1
Electrical Engineer 1
Primary electrical engineer
Determine power source
Develop interface to power source
LED integration
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
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
Design Concept – Intelligent Power Module
277 VAC
Modular Enclosure
208 VAC
110 VAC
Power Conversion &
Conditioning
12 VDC
Power Controller/Switch
12 VDC
12 VDC
12 VDC
Power Storage
24 VDC
P0842X
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.
Incentives for Reductions in Peak Electric Demand
Permanent Demand
Reduction (PDR)
Con Edison
Rest of State
$600/kW
$300/kW
Demand Response
Load Curtailment & Shifting
Distributed
Interval Meters
(LC/S)
Generation (DG)
(IM)
Con Edison Rest of State
Con Edison
Everywhere
$200/kW
$50/kW
$150/kW
$1,500/meter
http://www.nyserda.org/programs/peakload/default.asp
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.
http://www.nyiso.com/public/webdocs/company/about_us/annual_report/nyiso_areport2006final.pdf
LED Project Philosophy
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…
Phase 0: Planning
Staffing Requirements
Mechanical Engineers
Industrial and Systems 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
Develop light fixture
Integrate parts together
Develop CAD package
3
Electrical Engineers
1
Electrical Engineer 1
Primary electrical engineer
Determine power source
Develop interface to power source
LED integration
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
Opportunities & Options for SDI
• 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
Future Plans
 Continue through list of potential faculty guides
 Conduct thorough patent search
 Refine project scope and determine design options
and expectations
http://www.nyiso.com/public/webdocs/company/about_us/annual_report/nyiso_areport2006final.pdf
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 nonpower-dependent source of light for developing nations.
Staffing Requirements
Mechanical Engineers
Industrial and Systems 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
CAD Work
Mechanical Testing
Mechanical Analysis
2
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
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
and Feasibility
Economic Efficiency
Customer Need – Engineering Metrics Matrix
Preliminary Metrics
#
Metric
Units
Importance (Stars)
Potential Value
1 Production Cost
U.S. $
*****
50
2 Has On-Board Power Supply
Binary
*****
Yes
3 Usable Temperature Range
°F or °C
***
(30-120)°F or (0-50)°C
4 Water-Proof
Binary
***
Yes
5 Heat/Sand-Proof (Air Tight)
Binary
***
Yes
6 Storage Capacity
mAh
****
6000
7 Recharge-ability
Cycles
*****
500
8 Lifetime
hrs
*****
100,000
9 Distribution of Light
(Δ Lux)/(Δ m)
**
10 Intensity of Light
Lux
**
11 Functional Drop Height
m
***
3
12 Drop Cycles
Lens Hardness (Resists
13 Scratching)
Cycles
Mohs
Hardness
***
50+
***
6+
14 Efficiency
Lumens/Watt
*****
15 Efficiency
hrs/charge
*****
60
16 Charge Time
hrs
***
≤4
17 Recyclable Parts
Binary
*
Yes
18 Environmentally Friendly
Binary
*
Yes
19 Aesthetically Pleasing
Subjective
*
Yes
20 Weight (Mass)
lb (kg)
**
<10lb (<4.5kg)
~0
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?