Traffic Signs Outlined by Solar-Powered LEDs (May06-06)

Traffic Signs Outlined by Traffic Signs Outlined by Solar-Powered LEDs Solar-Powered LEDs

(May06-06)(May06-06)

Team Members:Team Members: Alex BeecherAlex Beecher EEEE

Jason ChoseJason Chose EEEE

Jim KopaskaJim Kopaska EEEE

Matt TreskaMatt Treska EEEE

Client:Client: Senior DesignSenior Design

Faculty Advisors:Faculty Advisors: Professor John LamontProfessor John Lamont

Professor Ralph Patterson Professor Ralph Patterson IIIIII

April 24, 2006April 24, 2006

Presentation OutlinePresentation Outline

Alex BeecherAlex BeecherIntroductory MaterialIntroductory Material

Jason ChoseJason ChoseDesign ActivitiesDesign Activities

Jim KopaskaJim KopaskaTechnical ApproachesTechnical Approaches

Matt TreskaMatt TreskaResources and Resources and

SchedulesSchedules

DefinitionsDefinitions

DOT - Department of Transportation

PV – Photo Voltaic (refers to solar panels)

NiMH – Nickel Metal Hydride (type of battery)

Pb-SN – Lead-Tin (type of battery)

NiCd – Nickel Cadmium (type of battery)

NEMA – National Electric Manufacturers Association

NREL – Nation Renewable Energy Laboratory

AcknowledgmentsAcknowledgments

Thanks to Dr. Dalal for his expertise on Thanks to Dr. Dalal for his expertise on solar energysolar energy

Thanks to DOT for donating stop signThanks to DOT for donating stop sign Thanks to NREL for email communications Thanks to NREL for email communications

pertaining to solar calculationspertaining to solar calculations Thanks to various local electrical Thanks to various local electrical

companies for donation of partscompanies for donation of parts

Problem StatementProblem Statement

Create LED-illuminated traffic signsCreate LED-illuminated traffic signs Solar-Powered with battery backupSolar-Powered with battery backup User definable software toolUser definable software tool Produce a more reliable and cost Produce a more reliable and cost

effective design to an existing effective design to an existing productproduct

Operating EnvironmentOperating Environment

Adverse weather extremesAdverse weather extremes Outdoor temperature extremesOutdoor temperature extremes Road side usageRoad side usage

Intended UsersIntended Users

Operators: DOT staff, city officials End users: motorists, schools,

construction zones

Intended UsesIntended Uses

Supplemental warning systems for drivers Immobile: Once installed remains

stationary Location: Roadside applications

AssumptionsAssumptions

Signs will dim to match ambient light conditions

Unit shall be operational in the continental 48 states

LED will match background color of signs Intended user has access to Microsoft

Office and can use Excel Signs will be powered to accommodate

abnormal weather patterns

LimitationsLimitations Cannot account for weather patterns not

following historical data LED flashing rate must be between 50 and

60 times per minute Unit cannot be protected from all forms of

vandalism Sunlight data used in the software can

only be given to a nearest location Installation shall be governed by

appropriate DOT/municipal ordinances Final product must adhere to all applicable

state and federal regulations

End Product & Other End Product & Other DeliverablesDeliverables

PrototypePrototype A fully working testable system

Software A fully functional Excel program for

traffic sign selection Performs calculations for necessary

components of a given application

Present Present AccomplishmentsAccomplishments

ResearchResearch 100%100% Order PartsOrder Parts 100%100% DesignDesign 100%100% TestingTesting 100%100% Software DevelopmentSoftware Development 100%100%

Approaches Considered Approaches Considered HardwareHardware

LEDsLEDs BatteryBattery Solar PanelSolar Panel Flasher Dimmer ModuleFlasher Dimmer Module Flasher ModuleFlasher Module Timer ModuleTimer Module PV Charge ControllerPV Charge Controller

Hardware UsedHardware Used

PV Charge ControllerPV Charge Controller 12V Solar Panel12V Solar Panel 55,200mCandella LED Cluster55,200mCandella LED Cluster Flasher Dimmer ModuleFlasher Dimmer Module

Approaches Considered Approaches Considered SoftwareSoftware

C++C++ JavaJava Visual BasicVisual Basic Selection bookletSelection booklet Microsoft Excel SpreadsheetMicrosoft Excel Spreadsheet

Software UsedSoftware Used

Microsoft Excel SpreadsheetMicrosoft Excel Spreadsheet

Changes in Project Changes in Project DefinitionDefinition

Hardware component remained Hardware component remained unchanged throughout the project unchanged throughout the project

Software component was added and Software component was added and requirements adjustedrequirements adjusted

Research ActivitiesResearch Activities

Project ComponentsProject Components

Research Activities:Research Activities: PV Charge ControllerPV Charge Controller

Prevents over current and over voltage damage to PV panel, battery, and circuit

Handles battery charging and power distribution to circuitry

Research Activities:Research Activities:LED ClusterLED Cluster

LED selection based on operational requirements

55.2 Cd cluster used on night use only signs

102.4 Cd cluster used on 24 hour operation signs

Color specific for each sign

Research Activities: Research Activities: Flasher Dimmer ModuleFlasher Dimmer Module

Ensures flashing rate between 50 and 60 times per minute

Integrated photoresistor allows automatic dimming of LEDs to match ambient light levels

Research Activities: Research Activities: Flasher ModuleFlasher Module

Used on chevron sign in lieu of flasher/dimmer module

Maintains flashing rate between 50 and 60 times/min

Research Activities: Research Activities: Timer ModuleTimer Module

Used on school crosswalk sign Allows user defined hours of operation

Research Activities: Research Activities: Solar PanelSolar Panel

Utilized on all signs Operates at 14.2V to

provide sufficient energy for 12V system

Research Activities: Research Activities: BatteryBattery

Operates at 12V and 1.5A

Suitable for use throughout continental U.S.

Design ActivitiesDesign Activities

The designs constructed for this project The designs constructed for this project included a stop sign, school cross walk included a stop sign, school cross walk sign, and a chevron curve signsign, and a chevron curve sign

Only the stop sign was implemented as a Only the stop sign was implemented as a prototypeprototype

Software design work was also completed Software design work was also completed and implementedand implemented

Stop Sign DesignStop Sign Design

School Cross Walk SignSchool Cross Walk Sign

Chevron Curve SignChevron Curve Sign

Software DesignSoftware Design

Implementation DesignImplementation Design

Originally design was only meant for the 3 Originally design was only meant for the 3 applications designed aboveapplications designed above

After completion of software package, After completion of software package, made it possible to design any sign the made it possible to design any sign the user desireduser desired

Physical construction and parts were Physical construction and parts were implemented exactly as previously implemented exactly as previously determined by the project teamdetermined by the project team

Testing ActivitiesTesting ActivitiesAfter sign construction, various characteristics were evaluated: Physical Integrity was tested to ensure the prototype Physical Integrity was tested to ensure the prototype

would stand on its own and properly hold all would stand on its own and properly hold all componentscomponents

Battery run time was checked by fully charging the Battery run time was checked by fully charging the battery and running the sign with no sunlight presentbattery and running the sign with no sunlight present

Solar sensitivity was tested by operating the sign Solar sensitivity was tested by operating the sign outside on days with no, light, and heavy overcastoutside on days with no, light, and heavy overcast

Blinking rate was checked by counting cycles per Blinking rate was checked by counting cycles per minute and ensuring it operated within DOT minute and ensuring it operated within DOT regulationsregulations

Other ActivitiesOther Activities

An interesting side to testing found was An interesting side to testing found was that varying the light output of a regular that varying the light output of a regular incandescent light bulb using a dimmer incandescent light bulb using a dimmer switch varied the solar power generated switch varied the solar power generated by the solar cellby the solar cell

Resources and ScheduleResources and Schedule

Final Personal Effort Final Personal Effort ChartChart

Task Name Alexander Beecher

Jason Chose James Kopaska Matthew Treska Total Hours

Select Signs 5 5 5 4 19Select LEDs 4 20 3 4 31Determine Electrical

Parameters

34 33 42 37 146

Select Solar Panel, Battery,

and other Hardware

35 37 39 37 148

Design Circuit 8 9 11 9 37Plan Construction 17 15 21 16 69

Construct Prototype

30 23 35 28 116

Test and Refine Prototype

32 33 (software) 35 31 131

Finalize Prototype 7 5 (software) 11 3 26

Documentation 18 18 17 19 72Poster 6 6 6 5 23

Software Development

16 39 21 22 98

Website Creation 15 2 2 2 21Updating Website 12 1 1 1 15

Total Hours 239 246 249 218 952 

Final Time and Capital Final Time and Capital CostsCosts

Item Team Hours Other Hours Cost

Stop Sign 8 0 Donated

LEDs 13 0 $80.00

Battery 25 0 Donated

Solar Panel 28 0 $20.00

Project Poster 21 0 $25.00

Software 24 0 None

Mounting Hardware 10 0 $40.00

PV Charge Controller 12 0 $87.50

Flasher/Dimmer 10 0 $57.00

Total 151 0 $334.50

Final Project CostsFinal Project Costs

Item Cost Without Labor

Cost With Labor

Parts and Material Items:

a. Signs Donated Donated

b. LEDs $80.00 $80.00

c. Battery Donated Donated

d. Solar Panel $20.00 $20.00

e. Software None $264.00

f. Mounting Hardware $40.00 $40.00

g. Flasher/Dimmer $57.00 $57.00

h. PV Charge Controller $87.50 $87.50

Subtotal $284.50 $548.50

Labor at $11.00 per hour:

a. Alex Beecher $2629.00

b. Jason Chose $2706.00

c. Jim Kopaska $2739.00

d. Matt Treska $2398.00

Subtotal $10472.00

Total $11020.50

Final Project ScheduleFinal Project Schedule

Final Deliverable Final Deliverable ScheduleSchedule

Closure MaterialsClosure Materials

Project EvaluationProject EvaluationAll initial and additional milestones accomplished

Most part selections met or exceeded design Most part selections met or exceeded design expectations, though some parts were not obtained expectations, though some parts were not obtained on timeon time

Construction milestones were mostly met, though Construction milestones were mostly met, though the LED mounting deadline was missed due to late the LED mounting deadline was missed due to late parts and inaccessibility to a rivet gunparts and inaccessibility to a rivet gun

Testing milestones were well met, though variable Testing milestones were well met, though variable testing conditions would have been favorabletesting conditions would have been favorable

Overall, the project well met design parameters and Overall, the project well met design parameters and drew out ideas for improvement on future modelsdrew out ideas for improvement on future models

CommercializationCommercializationIf placed on the market, the sign could be sold at a price between $350 and $400

Sign parts cost just under $250.00Sign parts cost just under $250.00 One person could construct the sign in four hoursOne person could construct the sign in four hours

At $11/hour, labor would cost $44.00At $11/hour, labor would cost $44.00 Without software, construction costs $294.00Without software, construction costs $294.00 Once software is produced, it takes minimal time Once software is produced, it takes minimal time

and resources to reproduce for each customerand resources to reproduce for each customer

Additional WorkAdditional Work

Since the sign is intended to work across Since the sign is intended to work across the continental U.S., the prototype would the continental U.S., the prototype would be tested in different localesbe tested in different locales

Given a larger budget additional Given a larger budget additional technology, such as wireless interfaces, technology, such as wireless interfaces, would be added for sign diagnostics and would be added for sign diagnostics and programming specific use eventsprogramming specific use events

Lessons LearnedLessons LearnedIf the project were to be repeated: Software design would start earlierSoftware design would start earlier Parts would be ordered earlierParts would be ordered earlier The prototype would be made to a smaller scaleThe prototype would be made to a smaller scale A different sign would be prototypedA different sign would be prototyped

Risk and Risk Risk and Risk ManagementManagement

Anticipated RisksAnticipated Risks Loss of a team member, failure to use Loss of a team member, failure to use

technologytechnology Unanticipated RisksUnanticipated Risks

Budget affected part selectionBudget affected part selection Team member illnessesTeam member illnesses Scheduling conflictsScheduling conflicts Loss of data due to digital storage failureLoss of data due to digital storage failure

Closing SummaryClosing Summary

The goal of the project was to create a traffic device that would save drivers’ lives.

This goal was met due to the team’s research into the parts and technology used in the project’s construction, along with constructing a reference program that allows users to obtain a sign catered to their sign’s uses.

Demonstration!!!Demonstration!!!

Questions?Questions?