Objective: Provide Information Necessary to Relate Customer Requirements and Expectations s5

Project Readiness Package Energy Bank Module for SESE Rev 16 May 2011

PROJECT SUMMARY The mission of the Sustainable Energy Systems for Education (SESE) family of projects is to design, develop, build, test, and deliver interchangeable sustainable energy technological solutions for use by future senior design teams and undergraduate engineering class projects in the KGCOE, beginning fall semester 2013. The SESE should represent an integration of the six core technologies: Capture/Collection, Conversion, Storage, Transmission, Management/Control, and Consumption. The objective is to provide opportunity for various technological solutions within the core functions to allow the execution of numerous modular SESE systems. All work produced should be in an open source / open architecture format, encouraging use of the technologies by others. The Energy Bank Module for SESE will have three of the six core functions; Conversion, Management/Control, and Storage. These three functions are critical so the energy captured within the system can be consumed by the end user. The mission for the Energy Bank team is to design, build, test, and deliver a controlled storage system to store the power coming from the Capture/Collect Module. This Capture/Collect Module is titled Wind Energy Collection for SESE. The Energy Bank team will need to take the energy and voltage outputs from the Capture/Collect team and convert them into a form which can be readily stored in a suitable NiMH or Lead Acid battery. The two possible batteries were chosen because they are the most suitable for this project within the next academic year. Future development may allow this Energy Bank to become a Li-Ion storage system.

The Energy Bank team should also research if batteries are capable of being overcharged and if this condition will harm the battery. If so, consider a Management/Control solution so the battery does not overcharge when it reaches its full storage capacity.

The Energy Bank Module must interface with the Charging Dock Module for SESE as well. The Energy Bank must have enough storage capacity so the Charging Dock can charge at least 10 SESE Power Supplies. The Charging Dock Module will also be in charge of preventing the Energy Bank from discharging to 0% power.

This project will require collaboration between various teams within the SESE family to determine and pass along Engineering Specification Values. This team should focus on the energy, voltage, and phase coming from the Capture/Collect Module to determine the storage capacity necessary to provide sufficient power to the Charging Dock Module. A primary focus should be high conversion and storage efficiencies; try to maintain 90% efficiency or better. This project should still be considered a success if other SESE modules fail or are not chosen as MSD projects.

ADMINISTRATIVE INFORMATION: Project Name: Energy Bank Module for SESE System Faculty: TBA Project Number: Industry Guide: TBA Project Track: Sustainable Systems Project Customer: RIT MSD LVE and WOCCSE teams Project Family: OS/OA Modular Sustainable Energy Project Sponsor: TBA Systems Project Budget: TBA Parent Roadmap: R12006 Planning Term: 2010-3 Start Term: 2011-2 (Winter) End Term: 2011-3 (Spring)

PROJECT CONTEXT: Page 1 of 10 Project Readiness Package Energy Bank Module for SESE Rev 16 May 2011

This project is one of the critical modules of the larger SESE roadmap mentioned above. Without a conversion system, it would be nearly impossible to consume the energy harvested by the collection systems. Also, without a storage device, most of the energy would go to waste as the user does not always want to consume the power at the time of collection. The SESE is a modular project aimed at developing a power source for the Land Vehicle for Education (R12005) and Wireless Open Source/Open Architecture Command and Control System for Education (R12003) systems.

This will start from the capturing of energy to storage and finally the consumption of that energy. The Energy Bank will be designed to take the electrical output from the Capture/Collect system and convert it. For example, if a wind turbine is outputting 120VAC and the battery storage system charges at 12VDC, the AC to DC conversion system would match the output voltage to the required 12VDC.

If the Capture/Collect team decides to have a system with both a wind turbine and solar panels, the Energy Bank team will need to design a conversion board, or boards, that will have capabilities to convert both power inputs at once. This is not likely for the 2011-2012 Academic Year, but will be further down the road.

The image below is a SESE system block diagram for all of the modules. This Energy Bank Module is colored purple. You can see that the Capture/Collect’s power goes to the Energy Bank Regulator Board which converts the power to the designated D/C Power in order to store it in the Energy Bank. These color coded modules are used throughout R12006 documents and roadmap. For more information on the larger project into which this system will be integrated, search for on the EDGE website for R12006, the Sustainable Energy Systems for Education roadmapping page. Link provided below. (http://edge.rit.edu/content/R12006/public/Home)

of 10 Project Readiness Package Energy Bank Module for SESE Rev 16 May 2011

PROJECT HOUSE OF QUALITY: (NO COLOR CODING)

Energy Collection Energy Sustainable Energy Systems for Education / Energy Energy Distribution / Capture Conversion Energy Storage Transmission Energy Control Peak energy output Correlation Codes Average Rate of Energy Output + + + + Very Positive Conversion Efficiency (%, Joules In/Joules Out) + + - Negative Rate of Energy Conversion + + -- Very Negative Packaging + + Storage Capacity + + Maximum/Average Energy Charge Rate + + + + Maximum/Average Energy Discharge Rate + + Rate of Energy Degradation + Number of Storage Cycles + + + + + + + + Packaging + + + + + Maximum Distance Between Collection/ Conversion/ Storage/ Consumption + + Transmission Efficiency + + + + Packaging + + + + n

Maximum Energy Threshold + + + + o i t

Maximum Power Threshold + + + + p + + m

Cost Per Watts Produced + + + + + + + + + -- + u + + + s n

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E n E n n r i l e s r l i i n i u u u u u e m l H r e f f l e m e g e g g g - C m e e h o g m m o m m m P b a b o a a a s o i c i i i i r v c t k a a t o r k k k e n e e t x i s r x x x x a e m n s t t n c r l c c c a a v a a a a i e o u v u o a e a o r i a a o o t a P C A C R P S M M R N P M T P M M C B P S L M n n n Preferred n n n w w w w w w VOC - Affinity Groups CN# VOC - Customer Objectives Direction p p p p o p p p o p o o p o p p o U U U U D U U U D U D D U D U U D CN1 Able to power WOCCSE and LVE 3 9 9 1 3 3 3 1 1 3 3 3 3 3 3 1 2 2 CN2 Operational in environmental conditions 3 3 3 2 4 Power Range of users from developing countries to freshmen and 32.2% 3 2 3 4 2 CN3 graduate students CN4 Easy/minimal maintenance 3 3 3 3 3 1 4 5 2 Packaging CN6 Design priority to LVE 15.3% 3 9 9 1 1 1 1 CN7 Must be scalable 9 3 3 3 3 2 1 3 1 Usage 10.2% CN8 Individual weight considerations 3 9 9 9 2 3 CN9 Total battery lifetime 3 3 3 1 3 3 End-User Needs CN10 Battery runtime 11.9% 3 9 3 1 9 9 3 CN11 Recharge time 9 3 3 3 1 1 1 CN12 Voltage/Amperage 9 1 9 1 2 5 Benchmark CN13 Power required 9 9 1 9 2 2 5 20.3% Specifications CN14 Phase 3 1 9 3 3 CN15 Power to weight ratio 3 3 CN16 Improving ease of use for end user 3 3 3 3 3 2 4 5 2 Future Motives 3.4% CN17 Look beyond traditional energy solutions 3 1 1 5 3 Measure of Performance JoulesWatts% Jin/JoutWattsin & lbJoulesWattsWattsWatts# in & lbMeters% Jin/Joutin & lbJoulesWatts$/Watt Nominal Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Marginal Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Benchmark is Much Better Than Proposed 5 1 1 4 3 3 1 1 5 4 3 3 3 3 A) Portable High Power-Density Energy System Benchmark is Somewhat Better Than Proposed 4 2 2 3 3 5 3 1 5 4 5 3 3 3 5 B) Solio Classic Universal Portable Solar Charger Benchmark is About the Same as Proposed 3 5 5 5 4 5 4 C) Livecell Batteries Benchmark is Somehwat Worse Than Proposed 2 5 5 5 2 D) Micro-Hydro Generator Benchmark is Much Worse Than Proposed 1 3 7 2 8 3 2 7 2 2 5 7 8 8 7 9 0 7 3 3 5 5 9 0 3 3 9 9 0 5 1 9 6 Raw score ...... 1 4 4 0 1 1 0 1 0 0 2 0 1 1 3 0 1

Relative % %

Weight % 3 2 % % % % % % % % % % % % % % 3 1 1 1 4 4 3 3 1 1 8 3 3 4 9 3 5

VOC to VOE There is no relationship between VOE & VOE There is a weak, indirect relataionship 1 There is a linear relationship 3 There is a stronger than linear relationship 9

CUSTOMER NEEDS ASSESSMENT: (NO COLOR CODING)

Need # Affinity Group Name Importance Customer Objective Description Measure of Effectiveness SESE power supply provides both high power and high fidelity DC power CN1 9 Able to power WOCCSE and LVE through converters CN2 3 Operational in environmental conditions Passes drop tests conducted at 3 ft Power Range of users from developing countries to freshmen CN3 1 Survey on user friendliness and graduate students No more than 10 user steps per session (disconnect, removal, charger CN4 3 Easy/minimal maintenance connection & visa versa) CN6 Packaging 9 Design priority to LVE System will be tailored to LVE dimensions as the primary customer CN7 3 Must be scalable Size: 2AA (WOCCS), 6AA (LVE), 5AA (ThmStv) Usage CN8 3 Individual weight considerations Weight: <1/3lbs (ThmStv), 4x578g(UAVE) CN9 1 Total battery lifetime 5 years for MT at 8 hours per day, 5 days per week, 52 weeks per year CN10 End-User Needs 3 Battery runtime 8hrs (MT), 30min (UAVE), 2-3days (UVWT), 2hrs. (LVE) CN11 3 Recharge time 4hrs (UAVE), 10hrs (MT), 2hrs (WOCCS & LVE) (MT: A, >5V, 8hr) (WOCCS: <3A, 2.5-4.2V) (UAVE: 10,000mA*hr, V, 0.5hr) CN12 3 Voltage/Amperage (CellPhone .7A, 5-6V, hr) (UVH20: 3.3A, 12V, 72hr.) (LVE: A, V, 2hr) Benchmark CN13 3 Power required 4W (ThmStv), 40W (UVH2O) Specifications CN14 3 Phase DC Power CN15 3 Power to weight ratio >50W/lb (UAVE) Reduce installation time, packaging space, and complexity of Interface from CN16 1 Improving ease of use for end user Gen1 system Future Motives Research current prototype solutions for energy collection and conversion by CN17 1 Look beyond traditional energy solutions conducting patent searches ENGINEERING SPECIFICATIONS:

PROJECT INTERFACES: (COLOR CODING APPLIES)

This Energy Bank Module will need to interface seamlessly with the Capture/Collect and Charging Dock Modules. This will allow future upgrades to be implemented very easily. Included below is an image showing the interfaces between the modules that are integral to the Energy Bank. Also included is an interface internal to the Energy Bank project; the interface between the Regulator Board and the Energy Bank itself.

1. The Capture/Collect module(s) will output power from a female Molex connector to a male Molex connector on the Energy Bank Regulation board. The Regulation board will need to have as many Molex connectors as there are Capture/Collect modules. The two teams will need to discuss the length and quality of this wire.

2. The Energy Bank Regulation Board will output the converted power from a female Molex connector to positive and negative leads (+/-) that connect to the Energy Bank (battery). This means the wire between the board and the bank will have a male Molex connector on one end, and +/- leads on the other.

3. The Energy Bank will send its power from +/- leads to a male Molex connector on the Charging Dock. The wire that connects the two (+/- leads to female Molex connector) is the responsibility of the Charging Dock team, but the Energy Bank should still be in discussion throughout its construction.

NOTE: The Energy Bank team will need to communicate with the Capture/Collect and Charging Dock teams to decide on which exact Molex connectors they will use. This will be largely based on the power that the Capture/Collect team can supply and the power that the Charging Dock needs to draw.

From (right) Energy Bank Capture/Collect Energy Bank To (down) Regulation

Capture/Collect

Energy Bank From ___ Molex Regulation to ___ Molex From ___ Molex Energy Bank to +/- Leads From +/- Leads Charging Dock to ___ Molex

STAFFING REQUIREMENTS: (NO COLOR CODING)

Position Title Position Description The individuals will be responsible for designing and testing printed circuit boards used to convert various electrical inputs. Input connections to the PCB will be specified however characteristics of the Electrical Engineer: electricity may vary (current, phase, etc…). Efficiency will be the primary focus of the design. PCB Designer The individuals should be pursuing a degree in Electrical Engineering. They should be well versed in (2 needed) the process of designing printed circuit boards, the various PCB components associated with power conversion systems and the procedures for testing such a product. Co-op experience in this field is highly desired. Required coursework: Power Electronics, Circuits II, Fields II, Electronics II The individual will be responsible for researching lead acid and nickel metal hydride batteries. The goal is to choose the better of the two (in terms of power density, storage capacity, lifetime, sustainability) and implement one into a system which provides intermittent power. After performing research, the individual will be tasked with interfacing the battery with the conversion system being Electrical Engineer: developed concurrently. If time allows, research lithium ion batteries to see if they are viable storage Battery Research systems. The goal for future MSD project modules for SESE is to provide a more energy dense (1 needed) solution to the classic lead acid battery while considering safe operation of the system The individual should be pursuing a degree in Electrical Engineering and should be passionate about power and storage systems. Required coursework: Power Electronics, Device Physics, Circuits II, Fields II This individual will have three key responsibilities. The first will be to manage the engineering teams that encompass the whole SESE system. Secondly, this individual should perform a thorough cost benefit analysis to determine the Return on Investment of the prototype as well as a mass manufactured system. Due to the sustainability aspect of this project, this individual will complete life Industrial Engineer cycle assessment and provide recommendations for material use and end of life options. (1 needed) Interest and experience with project management and sustainability is preferred. Interest is sustainability and renewable energy would be beneficial. Applicable courses include: Engineering Economy, Life Cycle Assessment, Design for Environment, Engineering Management, Design for Project Management One option is available to this individual based on the direction of the project. If the system is to be integrated somewhere in the Engineering Building, this person could design and develop a stand or support system for the Energy Bank battery and its Regulation Board. The wires could be routed from the Capture/Collect module to the Energy Bank. This individual could also work with the Charging Mechanical Engineer Dock ME to assist in designing and fabrication of that system as well as interfacing with that system. (1 needed: If the Energy Bank and Charging Dock are not indoors, these systems will need to either be housed or potentially) withstand the elements. General fabrication and experience in design is preferred. Interest is sustainability and renewable energy would be beneficial. Applicable courses include: Design of Machine Elements, Circuits I, Materials Processing, and Engineering Design Graphics.

Position Title / Disc Skill Notes About This Skill - For example, what kind of experience Engineering Discipline Skill Description Discipline Name Number would this student likely have had in the past? ME1 Machining and Fabrication of Components Intermediate Machining Lab ME2 Basic Circuits Skills Circuits I Mechanical Engineer ME3 Perform ANSYS Finite Element Analysis of Structural Integrity ACT ME4 Develop Simulink Model of Device Dynamics System Dynamics ME5 Create Pro-Engineer Solid Model of the Device Package Engineering Design Graphics EE1 Circuit Board Design - Regulator & Converter Boards Basic EE Course Curriculum Electrical Engineer EE2 Fabricating Circuits Experience Designing, Fabricating, and Testing Circuits Develop Test Plans for Noise, Regulation & Degradation for EE3 Applicable Components Advanced Circuits/Electronics Industrial Engineer IE1 Matrix Management of Projects Basic IE Course Curriculum

PROJECT CONSTRAINTS:

Regulatory Constraints  The design shall comply with all applicable federal, state, and local laws and regulations. The team's design project report should include references to, and compliance with all applicable federal, state, and local laws and regulations (see ISO Standards for Energy Collection)

 The design shall comply with all applicable RIT Policies and Procedures. The team's design project report should include references to, and compliance with all applicable RIT Policies and Procedures.

Economic Constraints  Each team will be required to keep track of all expenses incurred with their project.

 Purchases for this roadmap will be run through the Mechanical Engineering Office. Each team must complete a standard MSD purchase requisition and have it approved by their guide. After guide approval, the purchasing agent for the team can work with Ms. Venessa Mitchell in the ME office to execute the purchase and obtain the materials and supplies.

Environmental Constraints  Adverse environmental impacts of the project, such as the release of toxic materials or disruption of the natural wildlife, are to be minimized.

 Particular focus should be placed on resource sustainability (described further in Sustainability Constraints).

 Material Safety Data Sheets (MSDS) are required for all materials.

Social Constraints  Each team in this roadmap is expected to demonstrate the value and outcome of their project at the annual Imagine RIT festival in the spring.

Ethical Constraints  Every member of every team is expected to comply with Institute Policies, including the Policy on Academic Honesty, and the Policy on Academic Accommodations.

Health and Safety Constraints  Wherever practical, the design should follow industry standard codes and standards (e.g. Restriction of Hazardous Substances (RoHS), FCC regulations, IEEE standards, and relevant safety standards as prescribed by IEC, including IEC60601). The team's design project report should include references to, and compliance with industry codes or standards.

Manufacturing Constraints  Commercially available, Off-The-Shelf (COTS) components available from more than one vendor are preferred.

 It is preferable to manufacture and assemble components in-house from raw materials where feasible.

 Students should articulate the reasoning and logic behind tolerances and specifications on manufacturing dimensions and purchasing specifications.

Intellectual Property Constraints  All work to be completed by students in this track is expected to be released to the public domain. Students, Faculty, Staff, and other participants in the project will be expected to release rights to their designs, documents, drawings, etc., to the public domain, so that others may freely build upon the results and findings without constraint.

 Students, Faculty, and Staff associated with the project are expected to respect the intellectual property of others, including copyright and patent rights.

Sustainability Constraints  All raw materials and purchased materials, supplies, and components used in the roadmap must have a clearly defined Re-Use, Re-Manufacturing, or Recycling plan.

 This is intended to be a "Zero Landfill" project. This includes documents as well as project materials.

 Each team in the project family is limited to no more than 150 pages of printed documentation during MSD1 and MSD2 (not including the MSD2 poster and MSD2 technical paper). Teams may use an unlimited amount of electronic documentation, unless disk space becomes limited on the server.

 Each team must prepare an MSD2 poster and technical paper which is exempt from the paper constraint above.

REQUIRED FACULTY / ENVIRONMENT / EQUIPMENT:

Resource Available Category Source Description (mark with X) Faculty that specialize in power electronics and power conversion for EE RIT EE/ME Faculty questions. Mechanics and heat transfer (ME) faculty may be useful for X Departments some parts of the module. RIT Senior A designated place to work and store all materials necessary for project Environment Design X completion and organization Space RIT EE/ME Labs containing necessary hardware and software tools for designing and Equipment X Departments testing the module’s components Online and Materials local Batteries, PCB, PCB Components, Connectors, Wires suppliers Online and Other local Sheet Metal, Metal Stock, Hardware (if ME position needed) suppliers