P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture

1. P08428 LED Lighting Technologies for a Sustainable Entrepreneurial Venture Team Members Sponsor: RIT Facilities Management Services

2. Agenda • Project Description & High Level Customer Needs (Shawn) • Design Concept (Taylor) • System Design, Analysis and Testing • Light Output (David) • Fixture Lifetime • Color of Light (Arthur) • Manufacturing Plan (Christine) • Economic Analysis & Sustainability (Christine) • Remaining Improvements and Tasks (Shawn) • Questions

3. Project Description • Create a new walkway lighting system with the use of LEDs to: • Reduce power consumption • Increase replacement interval • Primary market is RIT Facilities Management Services • Current annual cost to maintain and power 125 residential lights: $10,020

4. Design Concept • Replace internal components of existing fixture with LED retrofit assembly • Use 5 individual circuit boards to angle the light where it is needed • Use simple design to direct light while minimizing component and assembly cost

5. Light Output Analysis • Ray-tracing software (TracePro) used to optimize design • Geometry of internal fixture components • Reflector design • Placement of LEDs • Lens configuration • Plot shows a minimum of 0.5 foot-candle over entire area. • Plot assumes three fixtures spaced 80’ apart.

6. Light Output Testing • Small scale tests with 1 – 5 LEDs to determine: • Number of LEDs • Wattage of LEDs • Optics • Verify software models • Photometry Testing • Individual LEDs and Lens combinations tested to determine validity of datasheets • Full scale light output on assembled prototype • Prove software models • Verify that specifications were met

7. Fixture Lifetime • Reduce maintenance costs • Two Components: • Fixture Lifetime • Corrosion resistant components used to prevent premature failure • Existing fixture housing re-used • LED Lifetime & Ease of Replacement • LEDs have a lifetime of 50,000 hrs • Each PCB can be easily removed when needed • Thermal, environmental, and vibration testing were completed

8. Light Color/CRI • Low color rendering index (CRI) indicates poor distinction between colors viewed under that light • Color temperature should be close to existing metal halide fixtures • Not too blue, not too yellow • Color temperature and CRI are properties of the LEDs, so LEDs were chosen with this in mind • A questionnaire was used to judge the CRI of the light from the LEDs and aesthetic appeal of the light color

9. Power Analysis & Testing • Current Metal Halide fixtures use 160 Watts • LED fixture uses 60 Watts

10. Thermal Analysis & Testing • Each circuit board was analyzed to determine the size and spacing requirements • Aluminum was laminated to the back of the boards to improve heat transfer • More surface area was added to the back plate to dissipate added heat • Transformers were placed on their own mounting plate, away from the LEDs to distribute heat • Thermal tests were performed to further optimize the design and prove the FEA models • Temperature measured at several points • Large changes in temperature were examined and corrected

11. Summary of Testing

12. Manufacturing Plan

13. Economic Analysis • Budget for prototypes • Total of 3 prototypes: $1802.83 + shipping • Initial prototype cost – one fixture • Initial investment per kit: $576.80 • Retrofit scenario – 125 fixtures • Approximate sale price per fixture: $430 • Total initial investment: $58,732 • Annual savings: $8,049 • Energy savings: $3,777 • Labor and material savings: $4,600 • Payback period: 7.3 years • Rate of return: 13.7%

14. Sustainability

15. Remaining improvements & tasks

16. Questions