P08428 LED Lighting P08428 LED Lighting Technologies for a Sustainable Technologies for a Sustainable

Entrepreneurial VentureEntrepreneurial Venture

Team Members

Sponsor: RIT Facilities Management Services

Shawn Russell Project Manager

David Eells Mechanical Engineer

Taylor Shivell Mechanical Engineer

Arthur Deane Electrical Engineer

Phil Pietrantoni Electrical Engineer

Christine Lagree Industrial Engineer

AgendaAgenda

• Project Description & High Level Customer Project Description & High Level Customer Needs (Shawn)Needs (Shawn)

• Design Concept (Taylor)Design Concept (Taylor)• System Design, Analysis and TestingSystem Design, Analysis and Testing

– Light Output (David)Light Output (David)– Fixture Lifetime Fixture Lifetime – Color of Light (Arthur)Color of Light (Arthur)

• Manufacturing Plan (Christine)Manufacturing Plan (Christine)• Economic Analysis & Sustainability (Christine)Economic Analysis & Sustainability (Christine)• Remaining Improvements and Tasks (Shawn)Remaining Improvements and Tasks (Shawn)• QuestionsQuestions

Project DescriptionProject Description

• Create a new walkway lighting system with the use of LEDs to:Create a new walkway lighting system with the use of LEDs to:• Reduce power consumptionReduce power consumption• Increase replacement interval Increase replacement interval

• Primary market is RIT Facilities Management ServicesPrimary market is RIT Facilities Management Services• Current annual cost to maintain and power 125 residential Current annual cost to maintain and power 125 residential

lights: $10,020lights: $10,020

Customer Needs Engineering Specifications

Provide as much light as current system

Minimum of ½ ft-cd on walkway (spread of 80’x12’)

Long lifetime of fixture Design for 30 years

Color temperature & CRI comparable to metal halide

Color temperature between 3500K-5400K, CRI > 70

Design ConceptDesign Concept

• Replace internal Replace internal components of components of existing fixture with existing fixture with LED retrofit assemblyLED retrofit assembly

• Use 5 individual circuit Use 5 individual circuit boards to angle the boards to angle the light where it is light where it is neededneeded

• Use simple design to Use simple design to direct light while direct light while minimizing component minimizing component and assembly costand assembly cost

Light Output AnalysisLight Output Analysis

• Ray-tracing software Ray-tracing software (TracePro) used to (TracePro) used to optimize designoptimize design– Geometry of internal Geometry of internal

fixture componentsfixture components– Reflector designReflector design– Placement of LEDsPlacement of LEDs– Lens configurationLens configuration

• Plot shows a minimum Plot shows a minimum of 0.5 foot-candle over of 0.5 foot-candle over entire area.entire area.

• Plot assumes three Plot assumes three fixtures spaced 80’ fixtures spaced 80’ apart.apart.

Light Output TestingLight Output Testing

• Small scale tests with 1 – 5 Small scale tests with 1 – 5 LEDs to determine:LEDs to determine:– Number of LEDsNumber of LEDs– Wattage of LEDsWattage of LEDs– OpticsOptics– Verify software modelsVerify software models

• Photometry TestingPhotometry Testing– Individual LEDs and Lens Individual LEDs and Lens

combinations tested to combinations tested to determine validity of determine validity of datasheetsdatasheets

• Full scale light output on Full scale light output on assembled prototypeassembled prototype– Prove software modelsProve software models– Verify that specifications Verify that specifications

were metwere met

Fixture LifetimeFixture Lifetime

• Reduce maintenance costsReduce maintenance costs• Two Components:Two Components:

– Fixture LifetimeFixture Lifetime•Corrosion resistant components used to prevent Corrosion resistant components used to prevent

premature failurepremature failure•Existing fixture housing re-usedExisting fixture housing re-used

– LED Lifetime & Ease of ReplacementLED Lifetime & Ease of Replacement•LEDs have a lifetime of 50,000 hrsLEDs have a lifetime of 50,000 hrs•Each PCB can be easily removed when neededEach PCB can be easily removed when needed

• Thermal, environmental, and vibration Thermal, environmental, and vibration testing were completedtesting were completed

Light Color/CRILight Color/CRI

• Low color rendering index Low color rendering index (CRI) indicates poor (CRI) indicates poor distinction between colors distinction between colors viewed under that lightviewed under that light

• Color temperature should Color temperature should be close to existing metal be close to existing metal halide fixtureshalide fixtures– Not too blue, not too Not too blue, not too

yellowyellow• Color temperature and CRI Color temperature and CRI

are properties of the LEDs, are properties of the LEDs, so LEDs were chosen with so LEDs were chosen with this in mindthis in mind

• A questionnaire was used A questionnaire was used to judge the CRI of the to judge the CRI of the light from the LEDs and light from the LEDs and aesthetic appeal of the aesthetic appeal of the light colorlight color

Power Analysis & TestingPower Analysis & Testing

• Current Metal Current Metal Halide fixtures Halide fixtures use 160 Wattsuse 160 Watts

• LED fixture uses LED fixture uses 60 Watts60 Watts

Thermal Analysis & TestingThermal Analysis & Testing• Each circuit board was Each circuit board was

analyzed to determine the size analyzed to determine the size and spacing requirementsand spacing requirements

• Aluminum was laminated to Aluminum was laminated to the back of the boards to the back of the boards to improve heat transferimprove heat transfer

• More surface area was added More surface area was added to the back plate to dissipate to the back plate to dissipate added heatadded heat

• Transformers were placed on Transformers were placed on their own mounting plate, their own mounting plate, away from the LEDs to away from the LEDs to distribute heatdistribute heat

• Thermal tests were performed Thermal tests were performed to further optimize the design to further optimize the design and prove the FEA modelsand prove the FEA models– Temperature measured at Temperature measured at

several pointsseveral points– Large changes in temperature Large changes in temperature

were examined and correctedwere examined and corrected

Summary of TestingSummary of Testing

Test Pass/Fail Comments

Light Output Pass

Environmental Pass

Thermal Pass

Light Color/CRI Pass

Power Consumption

Pass

Manufacturing PlanManufacturing Plan

Economic AnalysisEconomic Analysis

• Budget for prototypesBudget for prototypes– Total of 3 prototypes: $1802.83 Total of 3 prototypes: $1802.83

+ shipping+ shipping

• Initial prototype cost – one Initial prototype cost – one fixturefixture– Initial investment per kit: Initial investment per kit:

$576.80$576.80

• Retrofit scenario – 125 fixturesRetrofit scenario – 125 fixtures– Approximate sale price per Approximate sale price per

fixture: $430fixture: $430– Total initial investment: $58,732Total initial investment: $58,732– Annual savings: $8,049Annual savings: $8,049

• Energy savings: $3,777Energy savings: $3,777• Labor and material savings: Labor and material savings:

$4,600$4,600– Payback period: 7.3 yearsPayback period: 7.3 years– Rate of return: 13.7%Rate of return: 13.7%

CO2 Emissions

  LED MHkWh/year/fixture 262.80 722.70

kWh for 125 fixtures 32,850.00 90,337.50

Annual lbs/kWh/fixture 311.89 857.70

Annual lbs/kWh/125 fixtures 38,986.38 107,212.55 lbs/kWh for NY 0.86

lbs/kWh for Hess/RIT 1.1868http://www.eia.doe.gov/oiaf/1605/ee-factors.html

Fuel Sources:

HessBiomass <1%Coal 31%Gas 23%Hydro 11%Nuclear 23%Oil 12%Solar 0%Solid Waste <1%Wind <1%

SustainabilitySustainability

Remaining improvements & Remaining improvements & taskstasks

QuestionsQuestions