Integrating Solar and LED Technologies

1. Henry Harms Stevens Institute of Technology Integrating Solar and LED Technologies

2. Presentation Goals To describe how Stevens Institute of Technology and NJTEA have collaborated to develop the SAGE project To provide an overview of the project, instructional modules and short courses To explain Home Lighting module in detail To invite your active participation

3. Systems Engineering Systems Engineering (SE) focuses on the big picture and the relationships among the systems and subsystems of complex projects such as: Designing a Moon habitat Mass transit systems A family of new airliners E-vehicle service station network

4. Systems Engineers Money Magazine, November 2009: SE is the best job in America with great pay, superior growth prospects and meaningful work SE need good communication and leadership skills and an interest in other disciplines NASA is the largest employer of Systems Engineers

5. Global Engineering 3-D CAD and other software packages have made it relatively easy for firms to collaborate on design and engineering over long distances For example, the new Boeing 787 Dreamliner is being engineered and built by 50 companies located in 13 states and 10 countries

6. SAGE Teacher Participation Spring 2008: Six Lead Teachers worked in teams of 2 to develop 3 HS level instructional modules with a sustainability focus Twenty Pilot Teachers attended a 4-day PD workshop in August 2008

7. Module Topics Introduction to the Core Concepts of SE Home Lighting in Developing Countries Biodynamic Farming Water Purification Complete Details: www.stevens.edu/ciese/sage

8. Collaboration To simulate a systems and global engineering project approach, communication among participating schools is primarily electronic. This is facilitated through the use of our online system, Collaboration Central.

9. Module 101 An estimated 2 billion people do not have access to electricity for their homes. A multitude of alternative lighting and power devices must be developed to meet the needs of various regions and populations in an effort to both increase the quality of life and to lower energy use. A possible solution would be a lightweight and low cost system to that does not require the use of scarce fuel.

10. Module 101 Students can work together to identify problems or opportunities, explore alternatives, create models and test them. Students in each participating class will be assigned to one of the project-wide teams: Design Team, Prototyping Team, or Manufacturing Team. Each team will include students from multiple schools. Students in each team will collaborate to meet their team's goals and deliverables.

11. High intensity leds One of the key advantages of LED-based lighting is its high efficiency. High Brightness (HB) are readily available and relatively inexpensive

12. Solar cell How Solar Cells Work: • Photons in sunlight hit the solar panel and are absorbed by semiconducting materials, such as silicon. • Electrons (negatively charged) are knocked loose from their atoms, allowing them to flow through the material to produce electricity. Due to the special composition of solar cells, the electrons are only allowed to move in a single direction. The complementary positive charges that are also created (like bubbles) are called holes and flow in the direction opposite of the electrons in a silicon solar panel. • An array of solar cells converts solar energy into a usable amount of direct current (DC) electricity.

13. Online Resources • Equipment needed for the module. • http://www.ciese.org/curriculum/ledproject/equipment.html • Reference Materials • http://www.ciese.org/curriculum/ledproject/reference.html • http://www.ciese.org/curriculum/ledproject/glossary.html • Provided timeline – IMPORTANT! • http://www.ciese.org/curriculum/ledproject/schedule.html • Lesson Plans • http://www.ciese.org/curriculum/ledproject/lessons.html • Collaboration Central • http://www.ciese.org/curriculum/ledproject/collab.html

14. Your typical sage school • Classes included: • Technology/Engineering • CAD • 2 AP Physics • Varying levels of concentrations and skills • High Level Physics Classes (Honors) • 2nd Level Mechanical Drawing Class • 2nd Level Electronics Course • Engineering Design Class

15. Week 1 Reviewed the Design Brief Investigation and Research Discussed Appropriate Technology Examined Garden Lights

16. Project introduction • Framing questions? • How can we relate electricity and lighting to the development of society? • What is appropriate technology?

17. Cherokee SAGE – Class roles • Website and Collaboration Central Team • Responsible for reporting on and updating collaboration central and our website. • Manufacturing Team • Responsible for constructing a model of the light. • Electronics Team • Responsible for researching and developing the circuitry. • Marketing and Communications Team • Responsible for creating marketing materials and content for the website.

18. Website and collaboration manager http://sites.google.com/site/cherokeesage

19. Collaboration Central Tour http://www.ciese.org/curriculum/collaboration_central/

20. manufacturing • Handles construction of the light container. • Experiments with mirrors and LEDs. • Designs, constructs, tests and redesigns base/housing enclosure. • Integration of electronics components and solar panels. • Coordination of documentation with collaboration manager.

21. Marketing and communications Develops documentation for the Cherokee SAGE website and collaboration central. Develops a logo and other imagery items. Creates a commercial to spread awareness of the purpose of the product.

22. Electronics • Develops battery recharging circuit with solar panels. • Experiment with connecting solar cells in series and parallel • Experiments with diodes. • Experiments with battery consumption and charge cycles. • Develops LED circuit. • Experiment with series and parallel circuits • Integrate solar and LED circuits

23. Implemented “wash-ups” • At the end of every class period, the teams had to answer the following. • What was accomplished? • What did you learn? • What is tomorrow’s goal?

24. Week 2 • Manufacturing and Electronics • Reverse engineered solar yard lights • Marketing and Communications • Continued research on Appropriate Technology. • Developed a logo and trademark. • Website/Collaboration Manager • Introduced Cherokee to the rest of the SAGE schools. • Compiled our class “System Requirements Document” to share on Collaboration Central and the Cherokee SAGE website.

25. Week 3 Bottom and Left: Sample design for the solution developed by the Manufacturing Team • Manufacturing • Sketched design concepts for the reflectors and light housing. • Sent the sketched design to the Engineering Drawing class to have it drawn in CAD.

26. Week 3 • Electronics • Debriefed Garden Light Circuits. • Sketched schematic drawings for • Tested different light layouts • Marketing and Communications • Continued to develop log & user manual • Website/Collaboration Manager • Developed Cherokee SAGE website • Compiled manufacturing and electronics information for “Design Team Forum”

27. Week 4 • Manufacturing • Experiment with reflector mirrors. • Coordinate LED installation with the electronics team. • Electronics • Develop circuit schematics. • Continue battery tests. • Finalize switch circuit. • Solar panels are in series.

28. Week 4 • Marketing and Communications • Finalized Logo Design. • Submitted to Collaboration Central. • Began to Story Board Commercial. • Website/Collaboration Manager • Kept up with and reported on information posted to collaboration central. • Compiled Manufacturing and Electronics Doc into a technical sheet. • Continued work on Cherokee SAGE website.

29. Week 4 Cherokee SAGE Logo

30. Week 4 Storyboarded commercial.

31. Week 5 • Manufacturing • Received CAD Drawing back from the Cherokee Engineering Drawing class. • Began to construct final prototype. • Electronics • Updated the schematic. The solar panel circuit design finalized. • Manufacturing and Electronics found some problems with integration.

32. Week 5 • Marketing and Communications • Continued work on the commercial. • Website and Collaboration Manager • Kept up with and reported on information posted to collaboration central. • Updated technical sheet with new solar panel configuration. • Cherokee SAGE website

33. Week 5

34. Week 5 • Connecting the solar cells in parallel: • creates higher current. • IT = I1 + 12 • Voltage remains the same. • ET = E1 = E2 + - - + Take note of opposing poles within the charging circuit. Slide Switch (DPST):Position 1 – LEDs off, batteries charging. Position 2 – LEDs on and running off stored energy. The diode prevents the batteries from discharging through the solar cells over night. The charging is unregulated, so overcharging the batteries is possible.

35. Week 5 Prototype at the end of week 5. Housing is pretty much complete.

36. Week 6 • Manufacturing and Electronics • Manufacturing finalized the housing unit. • Electronics finalized their subsystem components and prepared jumpers for wiring the system. • Both groups integrated their subsystems. • Finished the week by running tests. • How long does the light last? • How long does it take to fully charge the batteries? • Is the system easy to maintain? Reliable?

37. Week 6 • Marketing and Communications • Completed commercial • Website and Collaboration Manager • Finalized parts of the website. • Continued to post on collaboration central. • Oversaw the integration of subsystem components.

38. Final graphics High Point HS’s Design Kittatinny HS’s Design Parsippany Hills NVOT’s Design

39. Final prototype

40. Final prototype Solar Panels Slider Switch Integration of Electronic Components Junction Point Wire Tube 3 Batteries totaling 4.5V Recessed LEDs

41. Short Course Topics An Introduction to Systems Engineering Reverse Engineering Home Lighting for Developing Countries Biodynamic Farming Water Purification

42. Year 3 Activities Encourage Global participation in the SAGE Project Finalize the modules and short courses Train additional facilitators Continue dissemination effort

43. You are invited toJoin the SAGE Project All SAGE Modules will run again in the fall of 2010 Contact Information: Henry Harms: henry.harms@stevens.edu www.ciese.org/sage