Addison Ferrell

1
Katherine Danziger Matthew Campbell Seth
Sheldon Stephen Lewis

• Addison Ferrell
• Catherine Johnson
• Darby McEvoy
• Daniel Ryan

2
Background

• Problem
• Need for backup power
• Extreme cases- blackouts
• Inclement weather
• Current generators have negative environmental
  impact
• Goal
• Create green backup electricity source for
  residential use (Smart Home)

3
Specifications

• Environmental
• Zero carbon emissions
• Low environmental impact
• Safety
• Easily operable by average home owner
• High reliability
• Wide compatibility with most electrical devices
• Other
• Affordable
• Unobtrusive- low maintenance
• Reasonable charge time (lt20 days)
• High usable energy (7.2 kWh)

4
Gantt Chart
5
Energy Flow
6
System Architecture

• System architecture provides for
• Simple Installation
• Ease of Operation
• Infrequent Maintenance
• Indoor Use

7
The Battery

• AGM battery
• Compared to existing products, most power for its
  cost
• Cost 167.95
• Lifespan of about 7 years

8
Environmental Life Assessment- Battery

• Lead-acid batteries- high Eco-Indicator ranking
• Completely sealed system SAFE
• For its price, most environmentally-friendly
  option

Source http//www.e-mobile.ch/pdf/2005/Subat_WP5-
006.pdf
9
The Solar Panel

• Mitsubishi Electric 170W
• Polycrystalline solar panel
• Energy payback time of 1.5-2 years
• 13.5 efficiency
• Cost 840
• MOST EFFICIENT FOR ITS COST

10
Environmental Life Assessment- Solar Panel

• Our product
• Lead-free solder
• 5 reduction in energy during manufacturing
• Life-cycle emissions about 30g/kWh
• 1kWh GREEN POWER 1 LESS POUND OF CO2 EMITTED

http//img2.travelblog.org/Photos/17009/83653/f/51
9712-Pantanel--Sunrise-0.jpg
11
PV Cell and Stand
12
Cell and Stand Unit
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Cabinet Design

• Must hold 10 batteries, each weighing
  approximately 75 lbs.
• Charge controller and inverter must be in a
  compartment sealed off from batteries
• Allow for wiring inputs, outputs, and between
  components
• Mobility and accessibility desired

14
TRIZ Analysis

• Needed to have high precision without damaging
  the ease of operation
• Used an assembly line method of cutting parts
• Used the mill to make sure that each piece of
  similar aluminum tubing was the same length
• Cut one side of each, then the second side of each

15
Example Stress Analysis

• Horizontal Bolts
• ?max?581 psi
• Factor of Safety?60
• Vertical Bolts
• ?max?1016 psi
• Factor of Safety?34

16
Electrical System
Safe Efficient Easy
Stores 7.6 kWh _at_ 170 W Delivers 7.2 kWh _at_ 800 W

• 36 hours - TV
• 15 hours - Refrigerator

• Installed in sealed box
• Grounded

17
Electrical System Features PV Side

• Weatherproof Outlet on PV Module
• Modified 50ft 12 ga. cable
• Disconnect Switch
• 20 Amp Fuse
• Charge Controller

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Electrical System Features

• Battery Star Configuration

• Electrical Protection

• Battery Disconnect

• 200 Amp Fuse

• 3 Outlets

• 1/0 Gauge Wire

19
Prototype to Production

• PV Cell
• Use aluminum instead of wood for corrosion
  purposes
• Cabinet
• Weld, dont use fasteners (356 holes, 178
  fasteners, over 150 in the metal frame alone)
• Replace acrylic with sheet metal, except in
  compartment for inverter and charge controller
• Use steel, not aluminum
• Electronics
• More LCD displays detailing performance of the
  system

20
Aluminum vs. Steel Material Properties
Given analysis of 18 in member, which bears
highest stress of tubes in assembly.
21
Aluminum vs. Steel Weight and Cost
Unit costs are based on McMaster-Carrs catalog
and total cost is approximate
22
Testing
Calculations for 17 April 2008 Across day 9.340
kWh At 13.5 efficiency, this is 1.26 kWh At
8.32 c/kWh this is 10.5c / day
23
Testing
24
Budget
Total 5347.72
25
Emissions Benefit Offsetting Carbon dioxide
Our product offers a significant environmental
benefit by offsetting carbon dioxide, which is
the primary greenhouse gas.
Example Running our generator at 0.8 kW for 9
hours produces a total of 7.2 kWh of energy. A
typical gas powered generator will burn roughly
1.2 gallons of gasoline to produce 7.2 kWh of
energy.
Sources http//www.ecplaza.net/tradeleads/seller
/5036199/gasoline_generator_jl1000.html
http//www.greenuniversity.net/Green_Economics/car
bondioxide.htm http//www.fueleconomy.gov/feg/co2
.shtml http//www.trifuelgenerators.com/gasoline
generator.html http//www.fuelgaugereport.com/sb
savg.asp Photos http//www.ujr.ca/EN/KCG-3000G
_3000W_generator.jpg http//www.portable-electri
c-power-generators.com/images/generators/Robin/rgd
3300n_big.jpg http//yangkegenerator.en.ecplaza.n
et/1.jpg
26
Marketing GreenBack

• A demonstrated need for our product
• Natural disasters, aging power lines, heat
  waves, etc
• Creating a Green product
• Must be safe, clean, low maintenance,
  long-lasting, and durable
• Achieves all of this while staying
  environmentally friendly
• Consumer behavior towards Green
• 67 of consumers across 6 developed countries
  will pay premium for green energy, with Americans
  willing to pay a 20 premium
• IBM GBS, December 2007
• Costs
• We are confident that prices will drop
  significantly when producing on a larger scale
  based on significant discounts for bulk
  purchasing

27
Rollout Plan

• Florida California appear to have greatest
  potential for initial rollout
• Further expansion predicated on cost reductions
  and demand

28
Future

• Reliability?
• Mass production potential?
• New technologies
• Lower costs
• Increased demand

29
Conclusion

• Recommended for production
• Low charge time
• High delivery time
• Environmentally-friendly
• Easy installation
• Large target market

30
Thanks

• Dr. Josiah Knight chief engineering advisor
• Dr. Lincoln Pratson chief environmental advisor
• Dr. Michael Gustafson systems consultant
• Dr. Rhett George electrical consultant
• Dr. Robert Kielb technical consultant
• Patrick Mcguire- manufacturing consultant
• Milan Simonovic- manufacturing consultant

31
Questions?
32
QFD
33
Monte Carlo Simulation

• Work in progress