Sponsor: U.S. Environmental Protection Agency P3 Design Competition Grant

Aiding Organizations: SOIL & H.O.P.E.

Affordably provide clean, reliable, high-quality lighting

Market: People in developing nations without clean/healthy lighting

Key High Level Customer Needs/Engineering Specs

Low Purchase Cost Light Module Cost < $40Power Module Cost < $160

Long Operation Time Storage Capacity @ 100 Lumens > 4hrsBattery Lifetime > 3 yearsBase Unit Lifetime > 10 Years

Universal Applicability Useable Temperature 4.5°C-38°CSurvives 3 meter dropWater Resistant to IPX Std. 3Value Added in Local Economy >25%

Bike

Trainer

Generator

Power Module Box

Charging Leads

Dimmer Knob

Charging JackLED/Diffuser Plate

Tin/Aluminum Can

Handle

Final cost over production target cost ($40)

Current LM Materials Cost $35 – this leaves only $5 for workL

ED temperature exceeds operational range Conservative thermal analysis shows that this shouldn’t be a

problem Test plan in place to thermally test system as soon as all

necessary parts are inS

ubsystems do not behave as expected Test plans in place to test individual subsystems ASAP

Mechanical testing to verify power Bread-boarding to verify circuits

Once subsystems are verified complete system verification

SLDR

Served to answer open questions about batteries, power conditioning, materials, and overall design (bike vs. treadle)

DDR

Mechanical Electrical Interface was not well defined Problem was solved by looking into the drive system and

creating a mounting bracket Light Stand – How are people going to use the light?

Stand and mounting options defined BOM was incomplete with regards to some pricing and

outdated components Updates made and prices found for prototype and at quantity

Needs and Specs not completely revisited/updated Action taken to look into design and needs/specs to ensure that

everything agrees – final specifications set

Design Meets all Customer Needs

Design Meets all Engineering Specifications

Light Module Production Costs will be close to over as the materials alone are in the $35 range

Current Materials Costs for Products:

Power Module: $266 ($129 for production levels) Light Module: $158 ($35 for production levels)

Schedule: About 1 week behind on circuit verification, PCB design & order

Mitigation:

Continue looking into lower cost options for components All parts on hand by the end of Spring Break to be ready for

immediate circuit verification and final PCB Design

Significantly Under Budget

Supplies/Material Budget: $3,767 Concept/Benchmarking

Exp. $351 Prototype Materials Exp. $378

Total Expenses to Date: $729

Remaining Supplies and Material Budget: $3,038

CategoryPlanned Actual

Itemized Total Itemized TotalRIT Indirect Cost (40.5% Rate) 2,883 2,883 2,883 2,883Travel to DC        

Vehicle 600    237  Gas 100      Hotel 1000    1,347  Food 500      Misc 800      

Total   3,000    1,584Supply        

Benchmarking 500   351.06  Power Module 750   265.48  Lighting Module 750   121.17  

Other Prototypes for Field Testing 1767      Total   3,767   737.71

Contractual        Poster Printing 200      

Prototype Shipping 150      Total   350    

Grand Total 10000    

23 February – All ordering Complete (Final Design)

09 March – All parts in House

13 March – Alpha Prototype Assembled

23 March – EPA P3 Documentation Due

27 March – Design verification testing complete, initiate design revisions

10 April – Design verification complete

14 April – Poster complete and printed

17 April – EPA P3 Design Expo, Washington D.C.

05 May – Documentation finalized: DHF & Formal Paper

10 May – MSD II Project Review