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ANGKOR LIGHT - University of Twente Student Theses

1. 30 22 DETICICNCIES OF TMS ro 31 COMCIISIONS 32 4 DESIGN OF THE ANGKOR IGHT 33 Arodu UO ana 33 42 General uu u 33 34 35 Aa Yi 35 36 37 se 37 ec 38 41 Mechanical conne dion Su l ua a ee haqa basis apa 42 42 212 sss 43 b J e 5 Bachelor Report Angkor Light 44 ON 45 ORDER 45 EPON 47 48 PE D 51 L INOC er una ee 51 5 51 SEVERE 51 ON COIN u uuu xu xuma uz 51 53 50 ProducHon proce aaa 55 56 S0 pri CGE ON 57 5 59 6 CONCLUSIONS ANID RECOMMENDATIONS uuu u u u uuu ua 60 61 Meetingthe requirements 60 i 62 T n u unun 64 ERA 65 C D O Bachelor Report Angkor Light 1 INTRODUCTION 1 1 BACKGROUND This report is the resu
2. ane 10 Daily need for electricity kWh FIGURE 10 SOLAR ENERGY COSTS VERSUS GRID EXTENSION COSTS between the existing grid and the area that needs to be covered Solar energy has no need for a large grid resulting in the same cost per kW independent at every location with the same amount of radiation Figure 10 gt 5 C 5 8 UJ Bachelor Report Angkor Light m m w N Irradiation in horizontal plane kWh m2 day gt FiGURE 11 MONTHLY AVERAGES INSOLATION IN 2 7 LIGHTNING IN RURAL CAMBODIA Lighting in the rural areas is a matter of improvisation and creative use of available resources At the moment several kinds of lightning solutions exist 2 1 1 TRADITIONAL CAMBODIAN LAMP The first one is the Traditional Cambodian lamp a simple tin fuel lamp Figure 12 Kerosene 15 available throughout the country and is therefore an easy way to get some light Besides a bad smell this solution has some other disadvantages e Little light is produced e These kinds of lamps are unsafe because the top part becomes too hot and can fall off easily At that moment a fire can arise The lamp is useless in rainy conditions e Burning fuel is polluting to the environment Due to the high fuel price the use of this kind of lighting is expensive Families using this kind of lighting spend 20 24 per year o
3. product should look and feel robust 6 13 THE PRODUCT SHOULD MEET THE DEMANDS OF THE PV GAP The on off switch should withstand cycle of 100000 times e Charge controller protect from damage from voltage under open circuit conditions e Protected against damage from reversal polarity conditions of battery and solar panel e The battery should be protected by a fuse This may be on the circuit board e Solar panel connection should withstand minimum of 1000 connection cycles battery capacity C2 shall not decrease over the testing period more than 10 of the initial battery capacity 2 lt 10 e The measured days of autonomy shall match or exceed the defined minimum days of autonomy as indicated by the manufacturer lamp shall operate undamaged according to the manufacturer specs At maximum battery volt and max radiation e The manufacturer shall specify the daily number of hours the system can service the load under test conditions e The product should be able to operate during rainy conditions a according to IP23 e The product should be able to withstand the shipping vibration test 6 1 4 ELECTRICAL COMPONENTS LIGHT light bulb should be visible Z 5 2 Bachelor Report Angkor Light light bulb should be able to be replaced The CFL should meet the PV GAP standard BATTERY The battery should
4. reflector does not stay in position when aimed to the front neither turned when aimed backwards 3 10 CONCLUSIONS During the tests and the analysis done with the prototype several deficiencies were found To fulfil the requirements described in 0 several adjustments to the design the production process need to be carried out Elements that make the Angkor Light unique should work properly extra attention should be given to these elements in the design process of the final product Also the cost price need to be more specific and should be reduced to make the product affordable for the target group 0 4 C ie JJ 2 5 5 9 3 UJ NO Bachelor Report Angkor Light 4 DESIGN OF THE ANGKOR LIGHT 4 1 INTRODUCTION The previous chapter dealt with several shortcomings of the current product In the following chapter the solutions to these problems will be presented Changes to several parts are summarized first followed by solutions to general problems At last a total cost price calculation is given FIGURE 32 SOLANTERN FIGURE 31 ANGKOR LIGHT 4 2 GENERAL PRODUCT LAYOUT The products consists of a internal frame wrapping around the battery and serving as a support for the casing and other components The following order will be used In this chapter see also Figure 33 Reflector Casing o Reflector Base casing Handle o
5. ie J 5 ic p 12 Bachelor Report Angkor Light 4 15 COLOURS During the basic user research of Stephen Boom several colour schemes were presented to the people All participants favour bright colours and like shiny materials Figure 58 A possible explanation for this fact is that most products available are not very coloured not shiny and look cheap especially most Chinese products People want to show off with the lantern and want a real quality appeal FIGURE 59 COLOUR CHOICE OUT OF THE USER TEST Boom 2005 All plastic parts can be made in a lot of bright colours because the availability of sheets is high The front plate however can be produced in one colour only Very high start up costs are required to produce them only when a second batch 15 ordered it can be changed Dark red is chosen because of the contrast with the base casing and because it matches best with all bright colours 4 16 COST PRICE Components Subtotal Total Getting a of the cost price of the Plastic components 3 77 product and bringing it down was of the most Important tasks of the assignment A lot of things Metal components 62 07 was were uncertain and based on rough estimations and Screws Nuts bolds etc 205 availability of parts in Europe Electronic parts 56 99 55 global part list was included the report of Solar panel 1782 Stephen Boom B
6. casing Front plate Internal frame casing Llabtsource o Base Casing Electronics e Handle e Front plate e Internal components o Internal frame o Light source o Electronics FIGURE 33 OVERVIEW OF THE ANGKOR LIGHT ie J 5 ie 5 UJ UJ Bachelor Report Angkor Light 4 3 REFLECTOR 4 3 1 REFLECTIVE LAYER The material chosen by Boom consists of a plastic PS sheet with a very thin reflective layer glued on top of it As seen in the previous chapter cracks develop very easy and make this material not really applicable Gluing a thin reflective layer on top of a plastic sheet will also cause problems tests revealed that vacuum forming 15 not possible because the layer 15 to stiff and will not form when it is glued onto the product afterwards seams will always be visible because it does not shape very well into double curved surfaces Reflector colour Some different brands of reflective paint available in the neighbourhood of Phnom Penh Without reflector two types of spraying paint and one type of paint in White plastic abs a can were found The chrome spray has much silver spray better reflective properties than the other ones 148 8 1635 even better than the original reflective layer see Mirorfim Chrome spray 716 0 Table 3 for the test results To prevent the layer from scratches an extra layer of clear paint
7. The first consideration was to use dieing to shape the frame but this technique has several drawbacks An alternative bending tool was developed taking away all of these disadvantages All the corners have a 90 angle only the distance between them varies so the tool has several positioning stops at the right distances It consists of locally available materials and is easy to manufacture A hydraulic cylinder be attached to the handle to make more productive Figure 64 Bachelor Report Angkor Light lot of dies are needed The dies are expensive to make Aligning the metal to the die is very difficult because the die pulls the metal into its form making the metal slide easily To verify if a die suites its purpose it hasto be actually made This results in high risk of losing the invested money if the die is imperfect The stroke of the available machine is not big enough contain the frame necessary for some bends FIGURE 65 TOP VIEW OF THE A rubber stop can be used to stop the handle at the desired angle BENDING TOOL 9 oy 4 7 S PA 53 WU gt 5 7 FIGURE 66 SECTION VIEW OF THE BENDING TOOL FIGURE 67 PROTOTYPE OF THE BENDING TOOL b NO Bachelor Report Angkor Light A bending tool was also constructed to get the right shape into the handle Aluminium is pretty easy to bend maki
8. FIGURE 20 PROTOTYPE IN STANDING AND HANGING POSITION Bachelor Report Angkor Light 3 4 PROTOTYPE TESTING In order to see if the product fulfils its requirements certain tests need to be performed Each test is preceded a description of the purpose and an evaluation at the and with any problems discovered 3 4 1 USER TEST A very simple user test with the prototype of Boom has been done therefore only basic information about the lantern at this stage 15 known The purpose for this test is to get more insight into the thoughts of rural people about the lantern in general about how they are able to use It and if they are capable and willing to pay the estimated selling price The most important conclusions of the user test are that the lamp is used by people as intended The function of the lantern with and without the reflector is understood well and things people want to do with it are exactly the intended ones FIGURE 21 USER TEST AT A FAMILY HOME WITH THE PROTOTYPE Disadvantages mentioned are the bad fixation of the reflector and the weight Three out of ten people are capable of and willing to pay the price of 50 but only if the quality of the product is very high and it will last long The other people want to buy the product for a price between 20 and 25 otherwise they cannot The complete questionnaire including literal answers can be found in Appendix 34 2 WATER TEST During this test an amount of
9. UJ Bachelor Report Angkor Light 7 LIST OF DEFINITIONS Rural population Country people with a low income of about 50 per month Solar Home Systems Autonomous solar energy installation powering a building This kind of installation is used when no power grid is available PV Abbreviation of Photovoltaics meaning technology based on solar energy Nil series Series of products made In mass production which 15 fully functional and user test could be performed with Compact fluorescent lamp CFL Also known as a compact fluorescent light bulb or an energy saving light bulb is a type of lamp designed to fit into roughly the same space as an incandescent lamp but with the advantages of a fluorescent lamp FOB Free On Board named loading port the classic maritime trade term Free On Board seller must load the goods on board the ship nominated by the buyer cost and risk being divided at ship s rail The seller must clear the goods for export Maritime transport only CIF Cost Insurance and Freight named destination port seller must pay the costs and freight to bring the goods to the port of destination The seller must procure and pay for insurance for the buyer Maritime transport only Glass Transition Temperature Tg The glass transition temperature is the temperature below which the physical properties of amorphous materials vary in a manner similar to those of a crystalline phase glassy state and above which
10. marks between the two parts are visible The effect described is almost impossible to avoid although the effect can be minimized by good timing of the pre stretch and ascend of the mould a good design of the product and heating up the mould to the plastic temperature FIGURE 18 CHILL MARKS CRACKS IN THE REFLECTIVE LAYER Vacuum forming the reflector revealed a serious problem it is almost impossible to form this part without making cracks in the reflective layer This is caused by the much higher stiffness of this layer compared to the plastic sheet More and longer heating and adjusting the pre stretch height offer no solution to this problem Once in a while a useful product was made but this is definitely no workable situation in a production environment Only adding a layer after vacuum forming of the part will be an option e g gluing a thin plastic layer on the reflector by using paint can be a solution 3 3 3 2 METAL CUTTING BENDING AND FIXING Forming the handle was a matter of alternately bending and measuring the aluminium strip The same process was performed while producing the inner metal frame Moulds are necessary to produce these parts in large quantities to ensure the right shape Rounding the endings of the strip was done with a grindstone in mass production cutting would be preferred Drilling and cutting should be done before bending because this requires less complicated alignment tools Because no s
11. 51 FRONT COVER WITH CONNECTIONS Due to this extra output connector a new hole must me made in the front plate To control the light intensity two more buttons were added causing the total button count to rise to three In the original design the connector was a separate part and not connected to the front plate directly but mounted on the circuit board Both connectors are mounted onto the front plate using a screw to make a waterproof connection 4 10 2 MEMBRANE SWITCH big difference with the SOLantern 15 the type of buttons used Instead of a micro switch mounted unto the circuit board membrane switch is used The big advantages of this kind of button are its very small size the ability to integrate it into the front cover its durability and the clustering of all connection threads into one strip Only one hole for this strip has to be made into the casing and because it is positioned in the centre 4 Z TREE of the cover it will be completely protected from water Another u problem solved with this kind of button 15 the absence of torque performed on the circuit board when the button is pressed Also the placement of the picture of the button will be exactly on top of the button itself Membrane switch 2 74 connector plugs FIGURE 52 MEMBRANE SWITCH COMPOSITION C 5 C 42 9 Bachelor
12. Bank Environment Department Environment at a Glance 2004 Cambodia Book 2004 Zeus Industrial Products UV Properties of Plastics Transmission amp Resistance Report 2005 9 Ul
13. after a fall of 50 cm walking height and table height on earth ground LIST OF PREFERENCES The product should made be out of local materials which are easy provided The production of the product should fit with the main objective to contribute to the development of Cambodia by offering local labour Users can easily take the lantern and solar panel to their work rice field or marketplace The product should be easy to repair The product should fit all lighting categories The product should have a connection to supply power to other products e g a mobile phone e Z O 9 C O gt Bachelor Report Angkor Light 6 2 RECOMMENDATIONS Some requirements for the redesigned Angkor Light have not been tested yet These tests should be Incorporated into the field test planned for the nil series The following list needs to be checked product should have a modern western look and feel product style should fit with the mood board made by Stephen Boom the colours should be bright and powerful the Cambodian way The product should express stability The product should able to withstand the shipping vibration test The minimum illumination level should be at least 20 lux at a distance of 1m e Users can easily take the lantern and solar panel to their work rice field or marketplace The following requirements are not met The selling price should
14. amorphous materials behave like liquids rubbery state Tuk Tuk A tricycle used for the transportation of people and goods see Figure 87 Insolation The incoming solar radiation that reaches the earth and the atmosphere Ballast An electrical ballast is a device intended to limit the amount of current flowing in an electric circuit FIGURE 88 A TUK TUK IN PHNOM PENH 1 http en wikipedia org wiki Compact fluorescent light bulb 2 http en wikipedia org wiki Incoterm i http en wikipedia org wiki Glass_transition temperature 9 5 5 7 Bachelor Report Angkor Light 8 LITERATURE Boom Stephen Affordable lightning for people living in rural areas of Cambodja Report Delft University 2005 Economic Consulting Associates World Bank Cambodia The country and its RE context Report 6 11 World Bank 2002 Formech International Ltd Vacuum Forming Guide Book 2001 Gordon Raymond G Jr Ethnologue Languages of the World Book 2005 see also http www ethnologue com Heerink Jony Development of training materials for micro entrepreneurs in solar energy for rural Cambodia Report 2007 Hil Erik van de New electronics for the Angkor Light Report 2007 Institut de Technologie du Cambodge Renewable energy technologies in Asia Book Phnom Penh Regional Energy Resources Information Center RERIC 2002 Kamworks Kamworks homepage O
15. down into several sub assemblies making it possible to complete one part at a time The process can be managed and optimized according to work capacity and possibilities The complete assembly process can be seen in Figure 84 FIGURE 85 ANGKOR LIGHT ASSEM BLY CHART Production UI LO Bachelor Report Angkor Light 6 CONCLUSIONSAND RECOMMENDATIONS 6 1 MEETING THE REQUIREMENTS After te redesign it has to be checked if the requirements defined at the beginning are met Colour codes are used to mark in which level the requirement is met in the following way e Green mains requirement met e Orange partially met not checked yet Red not met When a requirement 15 partially or not met an explanation 15 given with recommendations to meet it in the future Also ways to determine how requirements that are not checked yet can be verified will be given in the recommendations section 6 1 1 PRODUCTION e Vacuum forming should be used as production technology for the plastic parts e Final assembly should be in Cambodia 6 1 2 AESTHETICS e The product should have a modern western look and feel e product style should fit with the mood board made by Stephen Boom the colours should be bright and powerful the Cambodian way e The product should express stability e Make people feel proud to own a product like this Refer to the Cambodian look and feel e The product should have a quality appeal and consist of plastic parts
16. is very useful to analyze the difficulties in this process Not only problems regarding the product itself are discovered also the complete production environment is tested The problems experienced are described in the next paragraphs with a direction in which the solution can probably be found 3 3 3 1 VACUUM FORMING At Kamworks the 3 plastic parts are made using the vacuum form machine Vacuum forming is a process in which thermoplastic materials are formed on top of a mould through which the air is sucked out of the space between those two The complete process is explained in Appendix L together with applications for the Angkor Light DIFFERENT MATERIALS Several materials with varying thicknesses are used because PC the material selected by Boom was not avallable Using these materials revealed some potential problems In general thinner sheets are formed better than the thicker ones and higher or vertically varying shapes create more variation in the wall thickness PS and ABS are very easy to thermoform acrylic and PC on the other hand are more difficult PLASTIC DELIVERY Thick plastics which are not very pliable like Acrylic were not formed very well using high shapes because not enough plastic could be delivered in the lower corners Figure 17 Using sheets with higher thicknesses enlarged this effect A solution would probably be a bigger vacuum pump resulting in more suction but this is not feasible given the hi
17. not exceed the maximum of 50 De high selling price 15 discussed in previous chapters and changes In margins for the retailer and the company should be reconsidered by Kamworks to lower this amount FIGURE 86 ABSOLUTE PRICE INCREASE PER COM PONENT OF THE ANGKOR LIGHT COMPARED TO THE SOLANTERN The increase in price can be analysed by looking at the increase in price per component compared to the SOLantern Figure 85 The increase of the profit and overhead in combination with the decrease in price of the distribution and marketing can partially be explained by a redistribution of these budget items the items profit and overhead are combined to be able to make a comparison with the SOLantern When all these costs are added to each other a total decrease of almost 2 can be seen Marketing will be done via the market stalls which use a different way of funding The profit and overhead together are still 2 7 higher than the SOLantern despite the advise of the MIT research to lower this costs MIT Sloan GLab team 2007 It should be considered to find ways to lower the overhead e g by sponsorships or more local and cheaper employees This implications however are out of reach of this assignment and should be investigated by the company itself 19 Z 5 2 NO Bachelor Report Angkor Light The extra money for the retailer was a decision made by Kamworks in order to give
18. products have a cap blocking light at the top side some of them also have bars to support this cap prevent light to pass in some horizontal directions The other advantages not seen at any other product are the ability to use a optional reflector to converge the light if necessary and the possibility to turn and fixate the lantern to aim downwards or forwards FIGURE 26 THE LIGHT DISTRIBUTION AROUND THE PRODUCT IN AN ANGLE OF 110 DEGREES MEASURED FROM THE VERTICAL AXIS LOWER HEMISPHERE NO Technical analysis of the SOLantern Bachelor Report Angkor Light FIGURE 29 TYPICAL PETING FIGURE 29 EXTRA CONNECTION FIGURE 29 VERY SMALL AND SOLAR LANTERN FOR POWER OUTPUT LIGHT WEIGHTED The most important advantages of competing lanterns are e One product featured an extra connection to charge mobile phones or other small devices e Some lanterns are very light weighted size of some lanterns is very small If possible these features should be incorporated Into the new design 3 6 STANDARDS Several standards were used to check and to show the quality of the product Guaranteed quality is very important in the Cambodian market situation due to the existence of a lot of Chinese products of inferior quality Together with the existence of known selling points the trust of the consumer can be acquired 3 6 1 INGRESS PROTECTION RATE To satisfy the need of checking the level of being water proof the Ingres
19. save energy by pushing the button 4 Increase the light by pushing the button 3 Aim the solar panel directly at the sun for optimal performance Attach reflector facing upwards for a focussed beam of light The battery indicator C will show the state of the battery and charging status as shown in the table on the right During charging with the solar panel the indicator will continuously be on Maintenance Keep the lamp and the solar panel clean and store the lamp in a dry place free of dust Keep the Angkor Light out of bright sunlight and hot places Do not turn the lamp on and off repeatedly for a long time Bring the product to your local reseller in case of malfunctioning Do not leave the battery uncharged for londer then XX days Specifications Battery 4 5 Ah 12V Lamp 5W CFL The amount of autonomy XX hours Solar Panel 4Wp 12V The lamp will burn for 4 hours from the charge of one good day 5 full solar hours Angkor Light Game rules 2 4 players play time 10 20 minutes all ages The aim of the game is to collect as many Watts as possible before the first player reaches the finish of the game Watts can be earned or lost by playing side games Every player needs a small stone to indicate his or her position in the game Everybody will throw the dice once the person with the most pips on the dice will start the game To play you throw with the dice one time and move your stone forwa
20. supporting frame behind it a lot of torque is applied every time a connector is plugged in The circuit board might be damaged after time The lantern is designed for CFL including a ballast instead of a CFL with separate ballast interface for the new electronics is available 3 9 3 PRODUCTION e The edge of the painted and the transparent area of the top casing Is frayed The paint comes off at the contact points between the top casing and the base casing 3 9 4 AESTHETICS picture of the on off button is not exactly placed above the button itself e When the on off switch is pushed it sometimes does not work because of the stiffness of the plastic in front e The on off switch works unnaturally in an outward position the lantern is turned on an inwards position it is turned off light of the lamp shines through the lower casing revealing the threads and other inner parts giving the product an shabby look colours chosen in the prototype do not reflect the taste of the Cambodian population 3 9 5 COSTS The price of 62 71 see Table 2 is much higher than the target price of 50 3 9 6 OTHER PROBLEMS e When the lantern is placed at an downward angle the lantern is not balanced e The handle is cutting into the users hand especially when the lantern is placed at an downward angle e Because there are 4 stability pins at the base casing It is overdetermined and not stable at a bumpy surface
21. the local reproduction of the prototype by performing several tests with this prototype and by the analysis of the competitors Also an examination about the availability of materials and a cost price analysis will be performed After gathering this data a redesign of the lantern will be performed to fulfil the demands b 5 e 5 CO Bachelor Report Angkor Light To produce a pre production series and a subsequent production of about 400 products the implementation of the production is carried out This will result in the production of this pre production series which will be used to perform some final tests The timeframe of this assignment will be three months 1 3 NAMING CONVENTION To make a clear difference between the product designed by Stephen and the redesigned one these two versions will be referred to as SOLantern and Angkor Light respectively The SOLantern is the name originally chosen by Stephen Angkor Light is the one chosen by Kamworks reflecting the Cambodian identity of the lantern and is also the name under which the product will be sold C D O Bachelor Report Angkor Light 2 GENERAL ANALYSIS 2 1 INTRODUCTION Because the project is carried out in a country with huge differences compared to the Netherlands a general analysis about the local situation is carried out This analysis consists of an exploration of the geographic situation the l
22. to cover more than 80 of the population because of the high costs and low gain The second type of power suppliers are Rural Electricity Enterprises REEs Relatively small generators supply power to one or two villages only making a large grid not necessary This type of power supply is suitable for rural areas but with the average price of 51 c kWh very expensive The third method consists of car batteries charged by local generator shops but this is also an expensive solution up to 3 5 per kWh Economic Consulting Associates World Bank 2002 The batteries are not charged with the right current and with very inefficient diesel generators causing very short battery life loss of energy and a lot of pollution 2 6 SOLAR ENERGY At the moment solar energy in Cambodia 15 a rare phenomenon Some small NGOs are installing Solar Home Systems in small villages supplying power to one to several small households to let them use some electrical lights and perhaps a small television if affordable These systems are often paid by foreign countries as a part of an aid project Solar Home Systems are an effective way to supply rural villages with electricity The costs are generally about 1 2 kWh Kamworks 2007 mainly because of the high material and installation costs Another option is to extend the electricity grid to reach these people This is even more expensive and the costs also depend on the distance 2
23. was TABLE 3 REFLECTOR COATING ILLUMINATION added unfortunately decreasing the extend of reflection with about 40 lux Because of the much longer lifetime of the reflector the choice was made to add the clear paint nevertheless 43 2 FIXATION The reflector does not stay in position when placed forwards or backwards It even falls off when the lantern 15 turned downwards This problem is caused by the shape of the reflector and the base casing which are modelled to be able to be released by the mould The current solution with two rubber strips does not provide enough friction to fixate the reflector FIGURE 34 REFLECTOR FIXATION PROBLEM AND SOLUTION The reflector must also be able to be placed at the base casing upwards and downwards causing more problems because the connection point of the reflector has a draft and 15 therefore not symmetrical in de vertical direction Several options were drafted and tested on usability and makability The solution chosen consists of a click mechanism with rim making use of the flexibility of the plastic Figure 34 4 3 3 REMOVING OF THE REFLECTOR By adding a click mechanism to fixate the reflector the force needed to detach it will be higher Removing the reflector without adjustments 15 difficult therefore an extra rim was created Figure 35 The rim is easy to release from the mould and formed a regular shape making the mould not more difficult to produce FIGURE 35 RIM TO RE
24. water with a pressure between 1 and 2 bar 15 being sprayed over the product at a downwards angle Also water from the side and from below is sprinkled simulating rain splashing on the floor To determine if and where water is coming into the lantern paper tissues are placed against the casing and on top of the inner parts A complete test set up can be found in Appendix Unfortunately water is leaking into the casing at the following points holes used by the connection bolts between the top and the bottom casing holes used by the connection bolts between the bottom casing and the handle little gap between the to ends of the rubber on top of the bottom part FIGURE 22 WATER TEST This means that water is coming through every possible hole in the product The first two problems are very similar a solution can probably be found in the same direction NO Ul Q J C 0 e 22 WY gt 9 C p Bachelor Report Angkor Light 34 3 DROP TEST The requirement made by Boom concerning the height where the lantern could be dropped from was 50 cm This value was taken because almost every rural family has some combined tables couches in their home which have an average height of the assumed criteria Because a rural house always has a tamped down earthen floor and this will also be the hardest kind of foundation during outside use of the lantern this kind of surfa
25. will be done using a template of the curves 5 2 BENDING Bending 15 done by the tool design Because the hole on the top side 15 used to fixate the part it should therefore be drilled first 573 DRILLING In contradiction to the hole used for hanging the holes for the knobs to attach the handle onto the internal frame will be drilled after the bending process This is done to make sure that they are made at the right positions b UI Bachelor Report Angkor Light 5 8 PRODUCTION GUIDE All actions needed to produce a part are summarized in the following pages The assembly of parts that cannot be parted are also described in this section e g connections by welding 5 8 1 INTERNAL FRAME LOWER PART FRONT TO BACK AND SIDE TO SIDE FRAME 1 Cuta metal strip of 1 5mm thick galvanised steel to the desired length 2 Drill the holes using a drilling template 3 Bend the frame using the bending tool into the right shape 4 Check the precision of the frame using a reference template BOTH 5 Place both parts in the welding template and weld them together 6 Remove wired edges if necessary FIGURE 78 INTERNAL FRAME LOWER PART 5 8 2 INTERNAL FRAME UPPER PART FRONT TO BACK AND SIDE TO SIDE FRAME 1 Cuta metal strip of 1 5mm thick galvanised steel to the desired length 2 Drill the holes using a drilling template 3 Check the precision of the frame using a reference template 1 Place both p
26. 55 CRIMP TERMINALS ie 5 0 ic 12 NO Bachelor Report Angkor Light e Thesamewire isusedto connect the battery with the output controller The wire to the CFL holder is welded onto the circuit board and screwed into the holder e Small crimp terminals are used to connect a wire to the jack for the external device This wire is welded onto the circuit board e The wire from the user interface front plate is attached to the circuit board by a plug and socket connector Figure 56 FIGURE 56 FLAT PLUG By using a permanent connection at one side and a releasable one at the other side all components can be detached and replaced if necessary User interface Circuit board Charge Output controller controller External device B attery Solar panel FIGURE 57 ELECTRONICS IN THE ANGKOR LIGHT 4 13 BATTERY The battery chosen by Kamworks Is the Genisis NP 4 5 12 This sealed lead acid battery is has a current of 12V with a capacity of 4 5Ah The electronics developed prevent the battery to discharge more 6 than 50 At this rate the battery has a life expectancy of about NP4 5 12 12V 4 5Ah 550 cycles This amount increases quickly when discharged less at a discharge depth of 30 the expectancy rises to 1200 cycles The expectation is that people will use the light for an average of less than 4 hours a day making the expected life span ENERSYS I
27. Light FiGURE 64 ANGKOR LIGHT IN HANGING POSITION 5 0 C 22 9 Ul Bachelor Report Angkor Light 5 PRODUCTION 5 1 INTRODUCTION During the product development phase the production process was analysed Some problems encountered are used to redesign the product if possible others are used to change the production process itself This chapter deals with all production analysis aspects not described in the previous chapters and the implementation of the final product into a production environment suitable for Kamworks 5 2 PRODUCTION SITUATION Production in a third world country like Cambodia is completely different from a production situation in Western country Educational standards are low quality commodities are rare the country is very corrupt and the infrastructure is very bad On the other hand it has a lot of advantages labour costs are very low employees are easily available the local community is much easier reached and last but not least Cambodians are very patriotic and prefer real Cambodian products over foreign ones 5 3 EMPLOYEES Kamworks currently has four employees capable of operate almost all available machines Only the vacuum forming machine is unknown to them but it will be easy to operate because it will be programmed to perform a complete production cycle by its own More employees can be hired easily if necessary because of the high unemploy
28. MOVE THE REFLECTOR ie 5 ic 12 Bachelor Report Angkor Light 4 4 CASING The addition of the rim to the reflector also implies changes to the top casing Figure 34 The solution chosen for this part has four separate horizontal rims Instead of one big horizontal ring because this fits better into the design of the existing vertical grooves Tests with the prototype showed both a complete ring and separate rims provide a good solution to the fixating problem Another design consideration was the possibility to use a cavity to lower the FIGURE 36 Cavity screws attaching the upper parts onto the frame Figure 36 Lowering the screws is optically better but two big problems were encountered The first problem was the connection to the internal frame The cavity is rounded at the bottom side due to problems occurring during vacuum forming while using sharp corners The rubber ring between the internal frame and the casing had to be shaped according to the cavity this was not possible using the available material and tools The second problem was the precision required to position the top casing into the inner top casing In theory the depth of a cavity can be at most 75 of the width of the Opening on the surface excess thinning will occur beyond this depth Formech International Ltd 2001 Even shallow cavities will result into a thinner casing especially at these t
29. NC FORMERLY YUASA of the battery about three years MADE IN CHINA www enersysinc com FIGURE 58 THE BATTERY USED J ie J 5 ic p 12 Bachelor Report Angkor Light 4 14 MATERIALS 4 14 1 PLASTICS The materials possible for the plastic parts were tested using a drop test described in paragraph 3 4 3 Several other considerations were made during the selection of the appropriate plastic for the Angkor Light The characteristics are summarized in Table 6 Several inquiries have been carried out to obtain the price for all materials which are summarized in Appendix The choice for PS was made because of its low price its easiness to vacuum form its shiny surface look and transparency No other material has all these properties The only real disadvantage found is its UV sensitivity The lantern will only be used at night when it is kept away from the sun during day and while charging the battery the problem avoided The packaging should inform people about this potential problem The parts damaged by sunlight should be obtained very easy from the Kamworks store at a very low price Due to the low material costs and production costs this will be possible Material Price per piece Advantages Disadvantages 1 5x244x250mm Formech International Ltd 2001 Formech International Ltd 2001 see Appendix D 2 Zeus Industrial Products Inc 2005 Zeus Industrial
30. OP 41 gt 5 C 5 O 8 N Bachelor Report Angkor Light 2 5 ELECTRICITY IN RURAL CAMBODIA In the rural areas of Cambodia electricity is not an obvious presence Over 85 of the total population of Cambodia lives in rural areas Institut de Technologie du Cambodge 2002 and over 85 of the total population suffers of the lack of access to the electricity grid Together with electricity prices of 16 c kWh in Phnom Penh and an average of 51 c kWh in the rural areas Cambodia has one of the lowest electrification rates in Asia and among the highest electricity costs in the world Economic Consulting Associates World Bank OUTSIDE THE PROVINCIAL TOWNS POWER SUPPLY IS RARE AND MEAGER WITH ONLY ABOUT 6 PERCENT OF CAMBODIA S RURAL HOUSEHOLDS HAVING ACCESS TO ELECTRICITY SUPPLY AND ANOTHER 3 PERCENT OWNING SOME TYPE OF INDIVIDUAL POWER GENERATING UNIT OF THE REMAINING 91 PERCENT OF THE RURAL POPULATION SOME 55 PERCENT USE AUTOMOBILE BATTERIES COSTING US 2 0 3 5 KWH FOR OCCASIONAL AND LIMITED USE OR DO WITHOUT ELECTRICITY COMPLETELY 36 PERCENT WORLD BANK http go worldbank org C1KN2P 7M 0 2002 The electricity distribution differs from the distance to a city At the moment only 7 of the biggest cities have access to the national power grid supplying power generated by the national power company Electricite du Cambodge EDC It is very unlikely that this company will extend the grid
31. PROTOTYPING REDESIGN AND PRODUCTION PLAN FOR THE ANGKOR LIGHT A solar lantern for the rural population of Cambodia Martijn Kranen Industrial Design Engineering University of Twente October 2007 Mrs dr Ang le Reinders University of Twente Ir Henry de Gooijer Kamworks Arjen Luxwolda Kamworks Commissioned by Kamworks BACHELOR THESIS BACHELOR THESIS PROTOTYPING REDESIGN AND PRODUCTION PLAN FOR THE ANGKOR LIGHT A SOLAR LANTERN FOR THE RURAL POPULATION OF CAMBODIA Martijn Kranen Industrial Design Engineering University of Twente October 2007 Mrs dr Angele Reinders University of Twente Henry de Gooijer Kamworks Arjen Luxwolda Kamworks Commissioned by Kamworks Bachelor Report Angkor Light PREFACE This project really was an for me in different ways As a designer went to a world completely different from the one am used to live in and it therefore really required another view on designing For example efficiency was not a main priority contrary to the need to produce the product locally almost regardless of the amount of extra hours per product added Personally experienced that living in a poor country marks the relativity of the wealth of our Western world Our hunt for more and better things sometimes Intendsto overshoot in the materialistic direction People living in the most sober circumstances with great pleasure and joy point out that belong
32. Products Inc 2005 0 46 Very strong not brittle Expensive Transparent and highly shiny Hygroscopic Good resistance against weather influences ABS 0 21 Very shiny Not transparent Strong material Easy to paint and glue All colours available Difficult to vacuum form 0 28 Easy to vacuum form Expensive High transparency Bad UV resistance not used for Good recyclable durable consumer goods Stronger than acrylic 0 18 Transparent shiny surface look Does not withstand UV very well Cheap Easy to vacuum form APET 0 35 Easier to vacuum form than PETG Expensive Amorphous PET High transparency Bad UV resistance not used for Good recyclable durable consumer goods Stronger than acrylic TABLE 6 PLASTIC CHARACTERISTICS 4 14 2 METALS The metal for the handle selected by Boom was galvanised steel This material is hard to get in Cambodia and only as large sheets A possibility is to the cut the sheets into strips width the desired width but the tooling costs would be very high The borders are also very sensible for rust because they are not galvanised An alternative was found by use of aluminium instead This material is light weighted easy available in the right size and has a quality appeal The material costs are higher than the galvanised steel but this is compensated by the lack of extra tooling cost The internal frame is still made of galvanised steel these strips are less thick and cutting is therefore much easier
33. Report Angkor Light 4 11 MECHANICAL CONNECTIONS 4 11 1 PREVENTING ACCESS TO THE INNER PARTS Touching the inner parts is potentially dangerous because of the high current used to start the CFL In Cambodia the creative use of products is very common e g using the battery for other purposes without the power regulating electronics warranty is given by Kamworks so any undesirable use causing a broken battery should be minimized Access to the inner parts has to be restricted to end users but not to repair mechanics Sealing of one or more parts with for example plastic sheet will solve the problem partially The biggest problem is the connection of the CFL and the wiring to it from the electronics through which a voltage of about 300V will run when starting up the lamp for a short period Hil 2007 Another point of attention is the potential access to the connection from the battery to the electronics These electronics prevent the battery FIGURE 53 ToRX SCREWS from being charged or discharged too much but nothing should Interfere with them to make this work Because it is not necessary for end users to access any internal part these can be sealed using the casing A screw that can not easily be removed will be a good solution to this e g a Torx screw Figure 52 The drawback of this seal is that end users will not be able to replace the CFL themselves With a life expectancy of 3 yearsthe replacement of the CFL by a Kamworks
34. aging the casing Figure 42 This material is also very cheap and FIGURE 42 FIXATION KNOB easy available in rings A nut is welded onto the internal frame to provide screw thread for the bolt attached to the knob A rubber ring is also placed at the inner side of the casing to prevent harmful contact between the internal frame and the plastic casing and also to make the lantern waterproof 4 8 INTERNAL FRAME The internal frame is made of steel and is more capable of resisting shocks than plastic Therefore the support function of the casing for the heavy battery was decreased by transferring it to the frame To achieve this the frame was almost completely released from the base casing and rubber rings were placed in between to absorb the energy transferred from the frame to the casing Only the bottom part of the frame 15 still slightly connected due to height restrictions By adding a frame at the back the casing is stronger in general and the back of the product is also supported Only little weight is added by this alteration The nuts to attach the frame were repositioned to the height of the point of gravity to balance the lantern These are welded onto the frame to achieve a solid connection By unscrewing the knobs of the handle little adjustments of the rotation can be made very easy and the lantern 15 not tumbling any more The frame can be separated into two parts by FIGURE 43 EXPLODED VIEW OF INTERNAL FRAME unsc
35. all these lighting categories Table 1 Light distribution Light fixation General lighting Fixated on the ground Evenly distributed light around the lamp in horizontal plane General lighting Fixated at the ceiling Evenly distributed light around the lamp in horizontal plane Symbol General lighting Fixated at the ceiling Big bundle of light from above Task light Fixated at the ceiling Bright spot to see more details General lighting Mobile possible to carry in one hand Big bundle of light Spot light very bright spot Mobile possible to carry one hand TABLE 1 LIGHTNING CATEGORIES 2005 2 8 2 TARGET GROUP The target group defined by Kamworks are Poor people living in rural and developing areas without a reliable access to an electricity grid Poor people are those with an income of about 1 per day The first target market will be Cambodia because of the lack of electricity grid and the huge potential for PV products About 5 million rural people in Cambodia 1 1 million families belong to the target group onthly expenditures of these families for lighting vary from 1 3 per month Boom 2005 The product positioning is illustrated in Figure 16 41 S 5 C 5 O O gt 2 8 3 SELLING MODEL At the moment a Master thesis is written Miriam Reitenbach about the marketing of Kamworks solar products Several directions are being explored varying from fixed a m
36. anguage the market the energy and lightning situation At the end of the chapter the SOLantern is introduced and placed into the local situation 2 2 CAMBODIA Cambodia is a country in South East Asia bordered by THAILAND Thailand on the west and north Laos at the north and Vietnam at the east It has a population of almost 15 Sis5ph million people Population Reference Bureau 2007 ee giemr ab covering an area of 181 035 square km World Bank Wu Environment Department 2004 this is about 4 5 times Pouthisat 3 the size of the Netherlands country is located the anne tropics Cambodia has an average minimum temperature Prawn 4 of 23 and average maximum temperature of 32 with PHNOM almost no variation during the year The Weather Kong Channel 2007 Kampong Saam 5 country is mainly known to the outside world i 50 100 km n T AJ sxS gt 1m gt h because of the cruelties of the Khmer Rouge regime in P 2 the 70 led by Brother Number One Pol Pot Nowadays the country has still not completely overcome FIGURE 7 GEOGRAPHIC LOCATION OF CAMBODIA its history the leaders of the regime have never been prosecuted Pot died in freedom in 1999 and the soldiers of the regime are still walking around and could be anyone s neighbours without them knowing In two weeks after the Knmer Rouge was defeated by t
37. arket stall to altered tuk tuks driving between villages to sell the products The entrepreneurs selling will also be able to repair products and give information about PV to customers An educational program made by Jony Heerink providing general knowledge about solar energy and Kamworks vision is used to train these people Heerink 2007 2 8 4 SELLING PRICE Bachelor Report Angkor Light Complexity of the products High Business to business solar c mpanies SOLAR COMPANIES t 2 Electronic shops in bigger cities 100 200 Price of the products FIGURE 16 POSITIONING OF THE ANGKOR LIGHT BETWEEN THE EXISTING SOLAR PRODUCTS Boom 2005 The target price of the solar lantern made by Stephen Boom was estimated at 50 Several market researches confirmed this price as the maximum amount of money people are able to spend on this kind of product MIT Sloan GLab team 2007 Rotman 2006 The current price estimated by Stephen is almost 63 see Table 2 this is higher than the indication of the amount of money the target group can spend on a lantern Attention should be given to obtain an accurate prediction of the real cost price and the selling price and lowering it This can be done by enquiring a lot of companies to get the lowest price and comparing alternatives based on price during the redesign process 41 gt 5 C 5 O Bachelor Rep
38. arts in the welding template and weld them together 2 Remove wired edges if necessary FIGURE 79 INTERNAL FRAME UPPER PART b Bachelor Report Angkor Light 5 8 3 TOP CASING INNER TOP CASING AND BASE CASING 1 Vacuum form the casing with a 250x250mm PS sheet with the following thickness casing and base casing 1 5mm e Inner top casing 0 5mm 2 Remove the rest material 3 Drill the holes using the supports FIGURE 80 TOP CASING FIGURE 81 BASE CASING FIGURE 82 INNER TOP CASING Bend the frame using the bending tool into the right shape Check the precision of the frame using a reference template 584 HANDLE 1 Cuta metal strip of 2mm thick aluminium to the desired length 2 Round the edges 3 Check the precision of the edges using a reference template 4 Drill the holes 5 6 FIGURE 83 HANDLE b oF Ul OO Bachelor Report Angkor Light 5 8 5 REFLECTOR 1 Vacuum form the reflector with a 1 5x250x250mm PS sheet 2 Remove the rest material 3 Place the reflector in the paint support and paint a chrome layer 4 Place the reflector in the drying cabinet 5 After drying place the reflector in the paint support and paint a transparent layer 6 Place the reflector in the drying cabinet FIGURE 84 REFLECTOR 5 9 ASSEMBLY After production of the different parts required assembling them is the next step The assembly has been broken
39. but Kamworks is a commercial company and has to pay them The price of the solar panel is considered to be as low as possible after more than 25 inquiries comparison of the electronics of several other distributors by the electrical engineering experts can possibly lower the price of the electronics and the electronic parts e g the battery Margin for the retailer overhead and profit are determined by the Kamworks management when the product is put into practice it can be seen if these values are correct and reasonable TABLE 8 PRICE PER COMPONENT J C 5 Q C 42 9 4 17 PACKAGING Simultaneously with the redesign of the Angkor Light a packaging concept was developed by Stefan Ruiter as a bachelor assignment Ruiter 2007 The packaging together with the manual provides Information about the product as defined in PVGap it protects the product during transportation and makes clear what the product is used for and how when placed in a market stall 14 OBL V Bachelor Report User Manual Angkor Light How to use Charge the lamp by connecting the solar panel to the lamp at the power input connector 1 Connect a small external device to the power output connector 2 Turn the lamp on by pushing the indicated on off button 5 once Turn the lamp off by pushing the indicated on off button 5 once more Dim the light to decrease the output of light and
40. cavities and places where the material touches the mould last The ideal situation would be a mould where the plastic would hit the mould everywhere at the exact time To approach this situation the material is pre formed using a blower the amount of seconds required was tested and written down to apply in the production process By adjusting this pre bubble face the timing and wanted material thickness can be tweaked FIGURE 70 DRAFT ADDED b UJ Bachelor Report Angkor Light gt FIGURE 72 INSERTS TO MAKE THE CLICK FIGURE 75 MOULD OF THE REFLECTOR EXPLODED VIEW MECHANISM EXPLODED VIEW FIGURE 74 COMPLETE MOULD OF THE TOP CASING FIGURE 71 PROTOTYPE OF THE NEW CLICK MECHANISM Production UI D Bachelor Report Angkor Light 5 6 PRODUCTION PROCESS 5 6 1 ENERGY CONSUMPTION AND SUPPLY The power needed for production is produced by the existing solar panels and an additional generator During the prototype production the values were gathered to obtain an insight in the production situation The batteries of the solar system have a capacity of 19 2 kWh the generator is capable of producing an extra 15 kWh The vacuum form machine needs about 4 73 kW for heating and another 0 75 kW for all other operations All other machines are using only a fraction of this amount FiGURE 76 KAMWORKS SOLAR SYSTEM All costs required for the operation of these machines have been us
41. ce was add to the criteria Results of the test are listed below a complete report can found in Appendix H A casing made of acrylic was very brittle and was damaged easily PSand ABS have much better impact resistance partly because they are more flexible The damage mostly occurred at the point were the battery touched the casing This was possible because the upper casing and the frame did not fixate the bottom casing into its original shape during the collision The frame including its connections did not suffer from multiple drops PC although not actually tested will probably not be strong enough to withstand the same drop test FIGURE 23 DUMMY BATTERY AND POLYSTYRENE CASING FIGURE 24 RESULT USING THE ACRYLIC CASING C Q J Q C 22 gt C 0 9 P NO 3 5 COMPETITORS Several competing products are the market but most of them are not available in Cambodia An extensive examination of these products was performed by Stephen Boom including a comparison of the strengths and weaknesses One of the outputs of this research was a collage of the most important ones Figure 25 Most of these products have a cheap appearance feel cheap and are cheap Some are of a much better quality are much more expensive and are made for the western camping market The cheap ones cost as less as 10 the expensive ones have typical prices of 10 and more The characteristics of a ster
42. d a production plan was made Several tools including moulds and bending aids were designed and tested An scheme was made to describe the assembly of the total product RESULTS The results of this assignment are a prototype a complete redesign of the lantern and a production plan including the design of the tools needed C D O Ul Bachelor Report Angkor Light TABLE OF CONTENTS PREFACE 2 SUMMARY 4 T ADD O CONTENT 6 L INTI UID Lu 9 ne a ee SS u sS ES um 8 TI 9 NO mi CONV L 10 ER 11 A 11 11 OU 11 2A AGREE 12 2 5 Eleciidtyin rural Cambodia 13 259 13 ad CORO AE O aa E 14 8 bY uui u 15 3 TECHNICALANALYSIS OF THE SOLANTERN ayara usa kuwa ka 19 2 os o JPP ee eer 19 3 2 Recommendations and results out of previous 19 3 3 R producing the ee er ee er er Tr 20 34 0 06 25 ODS 27 Co 28 3 7 Changed boundary conditions 29 3 8 List of requirements of the Angkor Light
43. d these kinds of materials No other plastics for vacuum forming were avallable especially at the short term Some printed overhead sheets were used to make the front panel the button overlay This part was put onto the casing using two components glue 3 3 2 2 METAL M etal is widely available at local stores including large sheets and strips While producing the prototype not all strips with the right width were in stock so metal sheet was cut into smaller pieces Instead of RVS as material for the handle aluminium was used because of its availability and nice appeal 3 3 2 3 BUY PARTS Some identical 4 5 Ah batteries were available at the company with the desired voltage and size The connections were also positioned at the same place as the one used in Booms design so one of these batteries was used GFL U 4 C ie 4 0 2 5 5 9 3 H NO Bachelor Report Angkor Light The CFL used was a standard 5W light with a E14 connection submitting a bluish light The lamp holder used was a E14 fitting mounted onto the internal frame with two metal strips and some screws The original design consisted of a different connection not available in Cambodia 5 The knobs to attach the handle with the internal frame were taken from the Netherlands because it was known that they were not available in Cambodia 3 3 3 THE PRODUCTION PROCESS The local production of the prototype
44. e 40 Bachelor Report Angkor Light 4 10 FRONT PLATE front plate is the most important part for the user interaction with the lantern It must at least contain on off button and a solar panel connector Another requirement i that it has to be waterproof especially the connector s and the buttons are a point of attention because they are used a lot and pressure is applied to it 4 10 1 LAYOUT Due to the extra connection and the extra buttons the design of the front plate had to be redesigned and several new considerations had to be made Not all domestic appliances are suitable to be connected the external output e g television could Impossibly run on this kind of battery The connector of the solar panel may also not be put in the output Clear marking of the input and the output connectors will be the best solution but a shortage of space arose from the addition of all the new part leaving no room for clear icons The position of the connectors is considerably influenced by the position of the internal frame The frame is positioned vertically in the middle of the front plate and the connectors cannot be put in front of it without drilling holes and weakening the frame Repositioning the frame was no option therefore the connectors had to be placed at the side of the front plate By using two different connectors it will be completely prevented that users will choose the wrong connector by mistake FIGURE
45. ed to calculate the final product price 5 6 2 PLASTIC PARTS Production of the plastic parts consists of vacuum forming and finishing The vacuum forming step takes place using the moulds designed and the vacuum forming machine available To remove the waste material and obtain a nice upper edge several some finishing need to be done To investigate the local possibilities the following tools were tested e Knives hot or cold are working but it takes a lot of time Hot knives are a little bit faster A hot wire separates the plastic but also melts it together again Anangle grinder is much faster then a knife because it melts and removes the plastic the grinding process but is less accurate then previous methods hand saw is working but it costs lot of human power e A figure saw is very suitable but an often occurring problem is that the product is too big to fit into the machine The conclusion was that saws with fine tooth are in general the best solution to separate the product and the waste material To make a smooth upper edge a simple knife can be used to scratch the burs off To apply this method to mass production a band saw 15 most useful these machines are not very expensive and are available in Phnom Penh The holes needed are made with a column drill Several options to fixate the parts were investigated the problem encountered was the many double curved surfaces By making epoxy moulds described earlier the e
46. employing them to produce sustainable energy products In this way both the environment and the orphans gain profit The University of Twente is an entrepreneurial research university It offers education and research in areas ranging from public policy studies and applied physics to biomedical technology The discipline Industrial Design Engineering focuses on the design of mass produced consumer products The bachelor project is the final assignment of three years of the bachelor program C D O JJ OO Bachelor Report Angkor Light 1 2 ASSIGNMENT 1 2 1 BACKGROUND OF THE PROBLEM At this moment the rural population of Cambodia does not have a solution for affordable permanent indoor lighting Indoors and in improvised stores under their house people make use of kerosene lamps and lighting powered by generators and batteries Outdoor lightning solutions only consist of small torches powered by expensive batteries Although there is a demand for both permanent indoor and movable outdoor lightning no affordable products are available With five full hours of sun per day and a balanced distribution over the year Cambodia is one of the sunniest countries in the world Because of this fact the potential for successful solar powered products is very high To utilise this potential in 2005 Stephen Boom of Delft University of Technology carried out a M aster thesis with the goal to design a solar lantern In October of tha
47. entrepreneur will be sufficient 4 11 2 MAKING THE INSIDE WATERPROOF To solve the problems discovered during the water test multiple alterations to the design were made Rubber rings were placed around the screws and between the internal frame and casing preventing water to enter through the holes The front panel was replaced by a membrane switch covering the hole necessary for the wires to the on of switch Jacks with screws are used to create a watertight connection Rubber rings can be used as a seal if necessary Finally silicone kit is used instead of a rubber hose to fill the gap between the FIGURE 54 DC POWER JACK base and upper casing Silicone kit is more elastic and extra material can be WITH SCREW applied in corners to follow the shape of the casing more accurate 4 12 ELECTRICAL CONNECTIONS The charge and output controller are mounted on the same circuit board making the wiring easier Figure 56 The arrows in this figure represent physical wires between the components and are implemented in the following ways e wire attached to the solar panel is connected to the circuit board with a DC power plug and a normal DC power jack Figure 53 This jack is connected by welds on the circuit board and small crimp terminals at the side of the power jack Figure 54 e connection between the battery and the circuit board is made a wire weld to the circuit board and crimp terminals at the battery side FIGURE
48. eotypical lantern are Boom 2005 A big plastic handle to carry the product Top part with the on off switch This part can be opened to replace the light bulb A cap to give the impression that the light reflects downwards Semi transparent cap to cover the light bulb Inside M ostly it makes use of fluorescent tubes of 5 7W A solid base for lead acid battery or dry cells and electronics The base can be opened to replace battery An separate solar panel if included Bachelor Report Angkor Light FIGURE 25 COLLAGE OF COMPETITION Boom 2005 Chinese products are famous in Cambodia because of their lack of quality In accordance with this finding an important conclusion was made about these competitors to excel above their level a quality product with according look and feel should be made The new lantern should be able to distinguish itself on appearance and functionality from these stereotypical models with a bad reputation The risk of illegal copies by Chinese manufacturers should be taken In account during the design of the lantern Because this investigation took place in 2005 the products currently available could be changed Also a comparison between these products and the existing Angkor Light is possible to reveal the current advantages and disadvantages 3 5 1 COMPARISON The biggest advantage of the Angkor Light is its light beam shining more than the full lower or upper hemisphere Figure 26 All other
49. gh costs Also a bigger sheet and bigger frame could solve this problem but the company will end up with a lot of waste material Therefore this solution is also not FIGURE 17 PROBLEMS WITH THICK PLASTIC DELIVERY preferable PRE STRETCH FORM DISAPPEARS The pressure beneath the material is blow up the plastic into a bubble shape This is necessary to produce an equal wall thickness in the final product At the moment only one action at a time can be performed e g blowing and ascending the mould is not possible When the pressure pomp stops working the plastic shrinks back and the bubble shape is partially lost Blowing more air into the mould than desirable to compensate the shrinkage is one solution but the undesirable side effect is that the plastic will be stretched too much and wall thickness may vary in the final 0 4 C ie 4 2 5 5 9 3 NO Bachelor Report Angkor Light product A better solution is an adjustment to the machine to make it possible to perform multiple actions at one time CHILL MARKS After the pre stretch phase the mould starts ascending When the mould hits the material only a certain amount will be in touch with it the remainder will be touching only air Figure 18 This causes the plastic in touch with the mould to stay at the same place whilst the other part is stretched because the mould keeps ascending After the vacuum forming step chill
50. graduation project The complete design process was done in the Netherland exact for a field study of about 6 weeks The lantern had not been produced and tested locally and exact knowledge of the Cambodian situation was not always available during the design process This project started with a global analysis of the situation and the problem Next the existing prototype of the lantern was reproduced in Cambodia followed by a general analysis of the result and the production process Several tests were done with this prototype including a drop test a water test and a user test to determine deficiencies of the product REDESIGN OF THE LANTERN Using the requirements formulated by the company and the deficiencies found a redesign was carried out Every aspect was looked after but special attention was given to a low price for the product and the possibility to produce It locally Inquiries were done to obtain the lowest price for components used The product was altered to be waterproof to be more resistible against dropping on the ground and to be easier to produce at Kamworks b 5 e J Bachelor Report Angkor Light DESIGN OF THE PRODUCTION PLAN The production of a product in Cambodia differs a lot from a situation in the Netherland Production aspects like availability of machines and labour were examined and potential problems were investigated Based on the findings the design of the product was altered an
51. he Vietnamese in 1978 next the Knmer Rouge started a guerrilla war which finally ended after the peace settlement in 1991 In 1993 the first democratic elections were held but even today the country is not really a democracy because corruption and intimidation are every day s business Due to the economically and technical recession during and after this period and the lack of financial support of Western countries like neighbouring country Vietnam received Cambodia is still low developed country 2 3 LANGUAGE The Khmer language is part of the Austro Asiatic language group together with e g Vietnamese and Mon found in Thailand Cambodia Burma Vietnam and Lao Gordon 2005 These languages differ a lot from Western languages in sound and writing It has a completely 8 THE worD CAMBODIA IN different kind of alphabet and several other sounds are used see KHMER Figure 8 for an example of Khmer writing The English education is developing but at the time almost no one speaks it at a high level making communication with local people very difficult PWENLARMNG IPAS 41 gt 5 C 5 8 2 4 SITUATION 2 4 1 CORRUPTION Angkor Light Bachelor Report According to the Corruption Perceptions Index Cambodia was ranked 151 out of 163 meaning that it belongs to the 15 most corrupt countries in the world Transparency International 2006 Compared to the 9 place of the Netherla
52. he country by motorbike revealed a lot of things tourists C D O NO Bachelor Report Angkor Light normally don t see and meeting people who normally don t see tourists It was a beautiful way to explore Cambodia and its natural and cultural treasures want to thank the following people who helped me to complete this project Arjen for his help and endless patience while answering a lot of questions also want to thank him for the constructive discussions we had about the production process Henry for his support and critical eye while watching at a distance from the Netherland Leap for his endless smiles and stories about Cambodia and its people and for showing us around Sarin and Sita for their help in the workshop and a wonderful insight in the Cambodian way of living Last but not least want to thank Angele Reinders for her support from the Netherland especially helping to achieve things difficult to arrange at the University FIGURE 4 LEAP CAMBODIAN STUDENT TRANSLATOR AND FRIEND A special thanks goes to Loes and my family for their support and motivation while being far away from home Martijn Kranen a eee e lt gt lt 5 i q ee __ gt FIGURE 3 DAILY WASHING OF THE COWS Introduction UJ Bachelor Report Angkor Light SUMMARY INTRODUCTION This report is t
53. he result of a bachelor graduation project at the University of Twente commissioned by Kamworks a small Cambodian company founded by the Dutch charity foundation Pico Sol The company itself aims at the production and sale of affordable PV products for the rural consumer market in Cambodia The project coversthe prototyping the redesign and the design of the production plan for a solar lantern THE PROBLEM Cambodia is a country with limited power resources About 90 of the Cambodian households have no access to electricity infrastructure for reliable lighting These people are also very poor and live below the poverty line of less than 1 per day Needs like lightning are not obviously catered for because of this limited power avallability The alternative using a fuel lamp is very expensive because of the high fuel price Another problem Cambodia faces is the unemployment rate General wages are low and because of the turbulent history about 60 of the population is 20 years or younger Job opportunities for this group are very low ANALYSIS OF THE EXISTING LANTERN The project started at Kamworks aims to solve a part of both problems described In association with the Delft University the first version of a solar lantern has been developed delivering both an affordable lightning solution to the rural population and work opportunities to young Cambodians This version of the lantern was designed by Stephen Boom in 2005 as a result of a master
54. hnical analysis of the SOLantern and its functions Anew competitor analysis is made to determine the strengths and weaknesses of the product e Answers to these questions results from these tests and conclusions from the previous chapter used to determine a list of requirements and wishes for the final product This list of requirements will be a starting point of the concept development phase and is used to check if the final product fulfils its needs 3 2 RECOMMENDATIONS AND RESULTS OUT OF PREVIOUS RESEARCH Three reports have been written partially about the solar lantern The first one is the initial master thesis of Steven Boom about the SOLantern the second is the internship report of Mando Rotman about Product arket Combinations Cs in Cambodian rural areas and the last one 15 a market research project of the MIT about solar product and the marketing of them In all of these report recommendations and points of attention are written down for further investigation A complete list with answers can be found in Appendix The ones useful for the redesign of the lantern are extracted put together and sorted by way to acquire the answers 3 2 1 REPORT STEPHEN BOOM The graduation assignment of Boom Boom 2005 was to design the SOLantern His report is a reflection of the design process including a general analysis of the problem the technical aspects of the lantern and a small user evaluation at the end M ost of his cons
55. iderations regarding the design are written down making it a very useful document as a start of the redesign A lot of research is done in the Netherland so very few local available materials are listed Because this is necessary to know when starting mass production in Cambodia it will be an important part to investigate 3 2 2 REPORT MANDO ROTMAN Extensive field research was carried out by Rotman Rotman 2006 to determine possible PM Cs for Kamworks in the rural areas Useful data about people s earnings and willingness to pay where collected 3 2 3 REPORT MIT The research carried out by the Massachusetts Institute of Technology MIT Sloan GLab team 2007 was done to determine 0 4 C ie JJ 2 5 5 9 3 H CO Bachelor Report Angkor Light 3 3 REPRODUCING THE PROTOTYPE One prototype of the lantern is made in the Netherlands by Stephen Boom No tests with this prototype have been done in Cambodia only earlier prototypes have been shown to the target group Bringing the prototype to Cambodia is very difficult and therefore no option By producing the prototype with local machines advantages and problems will be known and can be taken into account while redesigning the product For these reasons the prototype is reproduced using local machines and locally available materials Because the first prototype was not fully functional and some boundary conditions have been changed some additi
56. ings are not always the way to happiness Severe poverty on the other hand makes life extreme difficult and having some products to help during the daily activities really can make a FIGURE 1 CHILDREN FROM THE VILLAGE difference My motivation to start this project was to go abroad to a total different country in the first place Also the ability to contribute to a sustainable product was a big consideration During the project my view on the best way to help third world countries changed a little We can and should provide the knowledge to help these people but should not judge the culture of a country from a strictly Western point of view Trying to understand why people act the way the do really helps in this process and providing education can help them to develop themselves and their country Working with local people and attending a class at the University of Leap was a nice way to get acquainted with the Cambodian culture At the start was overwhelmed with the attention given to all western people everyone was looking at us and in the more rural areas people are even waving and shouting especially the children After a while got used to this phenomenon but it was nice to see that was not the only one seeing new things FIGURE 2 THE STUDENTS AT KAMWORKS EXCEPT BAS had real fun with the Cambodian employees of Kamworks with the other students and the kids at the orphanage who were always smiling Exploring t
57. internal frame are visible This is done by painting the plastic on the inside temporary covering the part that should pass trough the light Because of the difficult form of this part taping off is very difficult and paint easily flows to places where it should not be An easy to use temporary seal should be made or a FIGURE 19 FRAYED PAINT OF THE TOP CASING replacement of the paint should be found SCREW CONNECTION TO ATTACH THE HANDLE The bolts used to connect the handle with the internal frame were attached to it using an electrode welding machine The intense heat and the thick electrode caused the metal inside the bolt to melt and to make the screw thread disappear A tap was needed to reconstruct the thread again which of course is not preferable when producing in large quantities FRONT COVER A silicon foil was intended to be cover the power switch a thin printed plastic sheet was used instead Double components glue was used to attach the cover onto the casing but the power switch could not be used anymore because of the stiffness of the sheet Attaching only the upper and lower part of the cover solved this problem U C J 5 0 gt 5 9 NO UJ Angkor Light 3 3 4 THE FINAL REPRODUCED PROTOTYPE The result of the reproduction is a completely functional prototype representing the last design made by Boom with a few minor adjustments to the local production situation
58. ion principally with IEC Technical Committee N 82 Solar Photovoltaic Energy Systems and certification with the IEC Quality Assessment System for Electronic Components IECQ By obtaining a PV GAP mark the product can be distinguished from the bad Chinese product available on the market The standard consists of several documents called PV Gap Standard Specifications covering product specifications for the both the electronics and the general design PV GAP 2004 3 7 CHANGED BOUNDARY CONDITIONS Several additions to the lantern have been requested by Kamworks due to problems encountered during the design of the electronics Implications will be described during the design phase The alternations are new boundary conditions for the redesigned lantern and consist of bigger battery with more capacity 4 5Ah instead of 3Ah ACFLwith separate ballast e Different electronics U C J 5 0 gt 5 9 NO Co Bachelor Report Angkor Light 3 8 LIST OF REQUIREMENTS OF THE ANGKOR LIGHT During the previous design stage performed by Stephen Boom a list of requirements was formulated Boom 2005 A lot of these requirements are in line with the findings presented in this chapter The list 15 extended with the changed boundary conditions and requirements from the company A direct reference is added if available 3 8 1 3 8 4 LIGHT PRODUCTION Vacuum forming sho
59. l radio The electronic controller already supported power output control preventing the battery from being discharged too much This new function can therefore easily be integrated in the existing system The connection also reduces the risk of people opening the casing to connect a device to the battery directly FIGURE49 PHONEJACK The connector chosen is 2 5 mm phone jack normally not associated with power output The intention with this choice was to prevent people from plugging In external devices without knowledge about the possibilities of the lantern Only after consultation of the vendor a very cheap converter switch can be bought This method is necessary because of the very limited knowledge of electrical devices of rural people 493 LIGHT INTENSITY BUTTONS AND LED INDICATORS Due to the extra function to dim the CFL some extra buttons had to be added LEDs are used to indicate the State of charge of the battery and to indicate if the solar panel is connected correctly In the ideal situation this will be indicated by to separate LEDs but unfortunately this is not possible because of the shortage of connections on the microcontroller as a result of the extra light intensity buttons The microcontroller has 14 connections which are used in the ways explained in Table 5 A choice had to be made between the use of 1 set of extra buttons to adjust the light intensity and one LED indicator 2 A single power light intensit
60. light TABLE 4 ILLUMINATION LEVELS BY SCHREUDER 2005 AS FOUND IN Boom 2005 FIGURE 46 LIGHT DISTRIBUTION OF 3W CFL LAMP KAMWORKS 2007 J C 5 42 C 9 UJ CO Bachelor Report Angkor Light A 3W CFL has a light distribution of at least 20 lux in the horizontal direction measured at a distance of 1m Figure 45 and is very energy efficient The alternative an array of led lights is not as efficient as a CFL and its light distribution characteristics are far less suitable for general lightning purposes A led with a capacity of about 10W is needed to match a 3W CFL Boom 2005 Because the light intensity at the top side of the CFL does not fulfil the requirement of 20 lux for general light Instead of the 3W variant a 5W CFL has been chosen This CFL has an intensity of 20 x at 1m see Appendix J for light measurements tests The costs for a 3W or 5W CFL are almost the same and by using the electronics dimming of the light will be possible when the extra light output is not needed FIGURE 48 CFL WITH AND WITHOUT BALLAST FIGURE 47 CFL AND HOLDER J C 5 Q 42 C 9 UJ WO Bachelor Report Angkor Light 492 CONNECTION FOR EXTERNAL DEVICE A big advantage of one competitive product was the ability to connect an external device to the battery see 3 5 1 This can be very useful for charging mobile phones or powering a smal
61. lt of a bachelor project at the department of Industrial Design Engineering of the University of Twente It covers the redesign of a solar lantern for the rural population of Cambodia The project was commissioned by Kamworks a small solar company in Cambodia 1 1 1 KAMWORKS Kamworks is a young Cambodian PV company with Dutch founders This initiative arises out of Pico Sol an also Dutch independent charity organization which makes an effort to help the small scale application of solar energy in third world countries The company itself aims at affordable PV products for the rural consumer market in Cambodia About 90 percent of the population of this country has no access to electricity The goal of Kamworks is being expressed in their mission statement Affordable energy for sustainable development At the moment the main focus lies on installing so called Solar Home Systems at orphanages churches schools etc These activities will be extended with the production of commercial consumer PV products FIGURE 5 THE KAMWORKS BUILDING AT THE ORPHANAGE Kamworks is located in a village named 5 Ampil 40 km south east from Phnom Penh on the grounds of an orphanage see Appendix O One of the problems these orphans come across 15 finding a job when they are leaving the orphanage Cambodia is mainly a traditional agricultural society and children usually continue with the business of their parents Kamworks tries to establish some jobs by
62. ment rate in the country An educational level of grade 9 comparable with 274 class of the Dutch secondary school will be a good starting point for an internal training The children at the orphanage will complete at least this grade making it possible for all of them to work at the company in theory Payment is a fraction of labour costs in Europe good paid workshop workers earn about 80 a week In addition to the salary Kamworks also provides additional health and industrial disability insurance services making them above average employers A problem observed while making the prototype was the lack of accuracy of these employees now and then In Cambodia a lower quality standard compared to western countries is commonly used This is not acceptable while producing the Angkor Light in mass production Checks for each critical part should be provided after production as well as quality checks concerning the complete product performed at random 5 4 PRODUCTION EQUIPMENT Several basic machines like the a drilling machine and a hand press brake are available see Appendix produce the Angkor Light some parts need to be made by a third party e g the vacuum forming moulds To ease the production process some tools were designed making the time required to produce a part lower and the accuracy higher b 5 oF Ul 541 TOOL DESIGN The internal frame consists of a metal strip bend in angles of approximately 90
63. more financial support the local entrepreneurs It also has to be considered if this addition will be the best way to earn more money considering the lower returns Previous market research done by the MIT MIT Sloan GLab team 2007 and Mando Rotman Rotman 2006 suggests giving a profit to the entrepreneur depending on the amount of items sold Target price point IDE s Paul Pollak Estimates of Cambodian Maximum VTP per WTP per Chamrouen Mando Rotman report Vichet GERES IFC IDE Estimated price range Current selling price Angkor Light ProSeed s ANDS Light Estimated price in Cambodia Thrive s LED light FIGURE 87 PRICING RANGE OF THE ANGKOR LIGHT INDICATED BY SEVERAL STUDIES MIT SLOAN GLAB TEAM 2007 A comparison of the electronics of several other distributors by the electrical engineering experts has to be considered to lower the price of the electronics and the electronic parts e g the battery The product should be sold as one integrated package containing the solar panel determined in mobile lighting unit and instruction guides The considerations made by Stefan Ruiter are 1 The solar panel size is approximately 400x500mm this will not fit in one casing together with the lantern in an easy way 2 Apackage for the solar panel is already provided by the manufacturer A Kamworks sticker will be added Ruiter 2007 9 5
64. n fuel MIT Sloan GLab team 2007 FIGURE 12 TRADITIONAL CAMBODIAN 2 2 FLUORESCENT TUBE Some kind of electric lighting is available Light bulbs are very energy consuming and are therefore not used Fluorescent tubes are used instead but little is known about electricity and its safety aspects and very bad wiring and fixation of these lights is used often Besides this increase of the risk of short circuit and fire several other problems with this kind of lightning exist e Batteries are used carelessly with the result of damaged batteries and less capacity e Batteries are being charged with the inefficient generators The characteristics of these batteries are not taken into FIGURE 13 A HANGING FLUORESCENT account while charging resulting in overload and heavy wear gt 5 C 5 8 Bachelor Report Angkor Light e charging process is very polluting because of the very inefficient generators used 2 1 3 FISHERMAN S LIGHT A lighting product commonly used is the headlight for assistance by fishing or finding frogs and 15 powered by a small battery A different purpose 15 the use as lighting inside a house In this situation a car battery is used as power supply The biggest problem with this headlight is the weak light bulb User interviews performed by Stephen Boom indicate that the bulb needs to be replaced up to 3 times a day The fishermen spend about 10 dollar a month on charging of
65. nds it is obvious that trade is not as straightforward as in western countries A lot of regulations exists and officers in function don t hesitate to ask more money purely for personal gain to get things aranged Going higher up in the command chain will get around this problem but is time consuming This fact has certain implications for product development and production in Cambodia A longer period to get the necessary paperwork has to be taken into account and even unpredictable incidental higher costs for licensing and the import of products will be possible The gouvernment is aware of the corruption problem and is trying to organize things better for foreign companies especially because this in the interrest of the country But the same corruption is causing these things to change very slow 2 4 2 SELLING PRODUCTS Large electronic concerns do not exist in Cambodia instead little market shops are located in a lot of villages These shops sell a lot of different products varying from ventilators to gas stoves which make finding a certain product sometimes difficult Prices for products are always established by bargaining A big problem for buyers in general is the unknown quality of a product A brand name is no guarantee because the Cambodian market is flooded with fake Chinese products copying quality brands A big challenge is to develop a quality product and convince the people of this fact FIGURE 9 TYPICAL CAMBODIAN MARKET SH
66. ng it possible to do this by hand The strip is fixated onto the tool using the hole used for hanging the lantern To form the material a metal cylinder is used possibly coated with rubber to prevent scratches The aluminium strip can be turned 180 to make a symmetrical shape This tool is also operated by hand and 15 therefore using no electricity FIGURE 69 BENDING TOOL SIDE FIGURE 68 BENDING TOOL PERSPECTIVE To fixate the plastic parts during the drilling of the holes several supports were designed and tested A frame made of Fiberglas and epoxy built upon a metal construction turned out to be the most accurate and strong solution The metal construction was used to attach the support to the column drill Only a metal frame did not work because the frame could not be shaped correctly due to the double curved shape of the casings 5 5 MOULD DESIGN Several considerations were taken into account during the design process to ease the vacuum forming of the plastic parts The new material thickness was implemented and tested to reveal potential problems The changes in the design of the lantern considering the vacuum forming process consisted of adding drafts to all vertical faces to ease the release of the parts Figure 69 New ideas like the click mechanism to fixate the reflector were tested using prototypes see Figure 70 and Figure 71 Vent holes were added to aid the plastic shaping process These holes are placed in
67. ngthen the casing identify the front panel and reflect the shape of the top casing The number of stability pins has been decreased from four to three making the connection with the ground not overdetermined anymore These pins are placed as far as possible to the outside of the product to provide as much stability as possible Drafts to ease the release of the part from the mould were missing in the original design and were added FIGURE 41 BOTTOM LAYOUT WITH STABILITY PINS The battery support nodes were kept to absorb the energy of the battery in case the lantern will be onto the ground 5 Q te 4 O UJ Bachelor Report Angkor Light 4 7 HANDLE 4 7 1 HANDLE FIXATION The handle needs to be turned into a certain direction and must be able to be fixated in that position Heavy clamping of the casing has to be prevented when the handle 15 turned see 3 9 1 Several concepts have been developed to eliminate this problem all with several advantages and disadvantages The main considerations are to ability to produce it locally and the expected lifespan By limiting the rotation to a certain degrees the problem arises that not all lightning function can be fulfilled After testing of several possibilities the most basic one turned out to be the best a rubber ring made of an old car tire will fixate the handle in every desirable position without dam
68. nline 2007 April 2007 http www kamworks com Kamworks Solar energy costs 2007 MIT Sloan GLab team Presentation about investigation marketing stategy Kamworks 2007 Plas Robert van der Rural PV Lighting Opportunity Lost Online IAEEL newsletter 2 98 1998 http iaeel org IAEEL NEWSL 1998 tva1998 LiRen_a 2 98 Population Reference Bureau Cambodian population Online 2007 05 11 2007 http www prb org DataFind prjprbdata wcprbdata7 asp DW DR amp SL amp SA 1 PV GAP PV GAP Recommended Specification PVRS Book 2004 Rotman Mando Exploratory research for appropriate Product M arket Combinations in Cambodian rural areas Report University of Twente 2006 Ruiter Stefan The design of the packaging user manual and educative game for the Angkor Light Report 2007 Samy Sat et al A solar start PV in Cambodia Journal Renewable Energy World 2005 pp 82 87 Schreuder Duco Verlichting thuis voor de allerarmsten Conference NSVV Nationaal Lichtcongres 2005 The Weather Channel Monthly Averages for Phnom Penh Online 2007 11 05 2007 http www weather com outlook travel businesstraveler wxclimatology monthly CBXX0001 Transparency International Corruption Perceptions Index Report 2006 http www transparency org news room in_focus 2006 cpi_ 2006 1 table World Bank Developing International Power arkets in East Asia Report 1998 World
69. not make contact with the electric system when stored The battery should have a minimum capacity of 2 5 Ah at 12V After purchase a fully charged battery should be able to operate the product 3 hours without being recharged in between The battery should be protected from direct sunlight The user should be able to obtain information when the battery is almost empty The user should be able to obtain information about the charging status of the product The battery should be able to be replaced The battery should meet the PV GAP standard SOLAR PANEL The panel should be able to take inside the house The panel should be able to be fixated and aimed at the sun The product should operate on 12 Volts The panel should meet the PV GAP standard OTHER The selling price should not exceed the maximum of 50 The product should be sold as one integrated package containing the solar panel determined in Boom 2005 3 4 4 mobile lighting unit and instruction guides USE The product should be able to be carried by the user The lighting product should be able to stand on a rough underground like stones and sand and mud lighting product should be able to be hanged The light should shine evenly distributed in an angle of 110 degrees measured from the vertical axis around the product The minimum illumination level should be at least 20 lux at a distance of 1m Components that are irreplaceable like casing and frame should be able to operate
70. ons are made abigger battery is used causing the bottom part to be larger e aconnection to attach the solar panel is made not implemented in the first prototype 3 3 1 AVAILABLE MACHINERY Cambodia is a development country and therefore it is not possible to easily get every imaginable machine to produce the product It is helpful to know which kinds of machines are available at the moment at Kamworks this can be taken into account in the design process to make the product producible Kamworks is able to buy some second handed machines when needed The available machinery at Kamworks is listed in Appendix The power needed is produced by the existing solar panels and an additional generator The batteries of the solar system have a capacity of 19 2 kWh 1800 Wp the generator is capable of producing an extra 15 kWh The vacuum form machine needed about 4 73 kW for heating and another 0 75 kW for all other operations other machines used only a fraction of this amount Because of the high start up power needed by the vacuum forming machine and high energy use the generator must always be used during production with this machine 3 32 MATERIALS 3 3 2 1 PLASTICS During the reproduction period non transparent polystyrene and acrylic with a thickness of 1 5 mm where available at the company Transparent acrylic 2 mm and an acrylic like material with a thickness of 1 mm were found in Phnom Penh almost the only place in Cambodia to fin
71. oom 2005 but it was not Subtotal 42 64 containing all parts used Also a lot of suppliers were sa w unknown This list was used as a starting point and Packaging 5950 extended with other all parts used for the product Bree 93 After the redesign of the lantern all items in the list POS tare turned out to be replaced by new parts Overhead 5624 The costs of all parts used in the product have been Profit O analysed obtain several possible distributors of Subtotal 12 74 components and get different price indications Margin retailer 650 many inquiries have been performed Using these Subtotal 6 50 inquiries an accurate estimation of the product price Selling price 65 01 could be made The list with suppliers is also useful J le 5 ic p 12 Bachelor Report Angkor Light to decide which alternative can be chosen in case of a conflict with the current one or increased cost prices total cost price breakdown including the complete part list can be found in Appendix The total cost price Table 7 marks the problem found during this process the product price is 65 after Intensive research for cheap suppliers The price per component chart Table 8 reveals the share of each main part of this total amount A big problem are the import taxes The government collects about 10 VAT and 35 import tax An exemption is made for NGOs
72. ort Price Reference 2 7 Westward com 7 56 Conrad electronics 0 09 PM 1 29 2 10 5 Chinese supplier amworks Chinese supplier apital costs machinery ssumption abor ssumption ransport packaging breakage 15 2 49 Business plan Kamworks 3 2 Ing 14 56 05 Business plan Kamworks rofit 20 usiness plan Kamworks iler 10 usiness plan Kamworks AT 10 4 32 Business plan Kamworks lastic components lectronics crews Nuts bolds etc 5 Subtotal D gt D 5 Q s 5 lt olar panel 519 50 Kamworks Chinese supplier Total 62 71 TABLE 2 THE 5 BREAKDOWN SOLANTERN Angkor Light 41 gt 5 C 5 8 OO Bachelor Report Angkor Light 3 TECHNICAL ANALYSIS OF THE SOLANTERN 3 1 INTRODUCTION After a general analysis of situation presented in the previous chapter a technical analysis of the existing lantern will be carried out This will be done in the following steps e Recommendations from previous reports about the lantern are analyzed questions are formed based on these recommendations e Theprototype isreproduced locally to doa user test a drop test and a water test o analyze deficiencies of the product o analyze problems in the production process e Tec
73. pot welding machine was available the internal frame was put together with bolts The advantage of this method is the possibility to separate the parts when necessary a disadvantage is the amount of extra Space required and the extra costs 3 3 3 3 CFL HOLDER A standard CFL holder was used to attach the lamp the connection with the frame was made of the same metal By the use of a standard holder the construction was very solid and reliable and should be seriously considered as a possibility in the final product Another kind of fitting will be used because the ballast of the lamp will be manufactured in house but these holders are available all possible variations and mountings 3 3 3 4 FINISHING PLASTIC PARTS U 4 C fe JJ 12 2 5 9 NO NO Bachelor Report Angkor Light The difficulty of removing the plastic scrap from the vacuum formed plastic depends on the material used Polystyrene is easy to cut and to plane away so is ABS Acrylic is very difficult to cut and to sand because it cracks really easy A solution is to use a high speed grinder making which melts the material Drilling reveals the same problem PS and ABS are easy to work with and only a high speed drill can be used in case of acrylic PAINTING THE TOP CASING The top casing needs to be transparent because the lamp needs to shine trough it but the bottom part of it should be coloured otherwise the battery and
74. rd the number of pips the dice indicates The game board on the packaging consists of a day side sunny and a night side stars the sunny side you can earn Watts on the night side you can lose Watts day side is everything on the left side of the dashed line the night side is everything on the right side of the dashed line A player can not have less then 0 Watts The white circle the middle is the finish a player will have to land exactly on the white spot and in case of more pips on the dice the extra steps have to be taken backwards Once playing there are six options Your stone lands on a 1 at the day side it means you play day game 1 Your stone lands a 2 at the day side it means you play day game 2 Your stone lands on a 1 at the night side it means you play night game 1 Your stone lands on a 2 at the night side it means you play night game 2 Your stone lands on a0 this is a resting spot you don t play a game the next person throw the dice Your stone lands on the white circle the middle you get 5 bonus Watts and the game is finished everybody counts their Watts and the person with the most Watts wins battery status indicator table 0 5 blink every 0 5 second 5 25 blink every 1 second 25 50 blink every 3 seconds 50 75 blink every 6 seconds 75 100 blink every 9 seconds Day Game 1 Aim panel at the sun more
75. results with the requirements several deficiencies of the product can be summarized Solutions to the problems to meet the requirements will result in the final product presented in chapter 4 The following problems were found 3 9 1 CASING handle touches the top casing causing scratches knobs used to hold the handle into position are heavily clamped when the handle is turned and damaging the casing this happens because of the turning in combination with the screw thread side of the base casing is weaker then the other parts no frame is behind the plastic 0 4 C ie JJ 2 5 5 9 3 H Bachelor Report Angkor Light e casing is damaged due to the pressure performed by the internal frame during use casing is not watertight especially at the separation between the two ends of the rubber and the opening for the bolts connecting the top casing with the internal frame e casing is not large enough to contain the bigger battery 3 9 2 ELECTRONIC COMPONENTS e Users can easily open the product and access the electronics producing approximately 300V during start up of the CFL Hil 2007 e Users can easily access the electrodes of the battery and or detach the battery itself to use it in other ways Causing battery exhaustion and illegitimate warranty claims e Because the power connector is placed on the circuit board and because it has no
76. rewing four bolts making it possible to ie 5 ic p 12 C Bachelor Report Angkor Light change the battery Each part consists of two strips welded together after being bended Two strips are added to the top part to support the CFL holder FiGURE 44 BALLAST OF A NORMAL CFL FIGURE 45 COMPLETE INTERNAL FRAME 4 9 ELECTRONICS Simultaneously with the development of the Angkor Light new electronics were designed by two students of the Haagse Hogeschool The goal of this project was among others to design an external ballast having several advantages over a commonly used internal ballast The external ballast developed is able to dim the CFL ballast will be separate of the CFL giving more design opportunities e The ballast designed will be more power efficient Beside the development of this ballast a new controller for the CFL and a charge controller for the battery type used were designed making the lightning and loading much more efficient 491 CFL By quantifying the lighting categories in which the lantern need to be used the sufficiency of the light output of the final product can be checked These values stated in Table 4 are based on the recommendation of Duco Schreuder Schreuder 2005 on lighting for very poor people 12 x lm Type of light Illumination level Orientation light General light 25 Ixat 1m General light 2 Task light Spot
77. s Protection rate is used The IP rating defined in international standard IEC 60529 and classifies the level of protection that electrical appliances provide against the intrusion of solid objects or dust accidental contact and water The one used 15 23 standing for the protection against FIGURE 30 THE PV GAP MARK e Objects of 12 5 and bigger fingers or similar objects e Water falling as a spray at any angle up to 60 from the vertical rainwater To determine if the product complies with this standard tests need to be done 3 6 2 PVGAP ANDIEC PV GAP Global Approval Program for Photovoltaics is a not for profit international organization dedicated to the sustained growth of global photovoltaics PV markets to meet energy needs world wide in an environmentally sound manner Its mission is to promote and encourage the use of internationally accepted standards quality management processes and organizational training in the design fabrication installation Sales and services of PV systems To this end it partners with PV related industries international organizations testing laboratories government agencies financing institutions non governmental organizations and private foundations in developing and developed countries Technical analysis of the SOLantern 28 Bachelor Report Angkor Light PV GAP co operates closely with the International Electrotechnical Commission IEC in respect of standardizat
78. sing a separate part This extra layer blocks the light normally shining through the base casing and is used to colour the lantern The part can also be painted by artists to make a special collectors item or can be decorated with stickers The extra costs to produce this part are partially by the lack of a layer of paint and the added quality appeal to the lantern FIGURE 39 EXAMPLE OF A DESIGN 4 6 BASE CASING The total shape is adjusted to the bigger battery which is about 1 5 times higher than the old one and has therefore been rotated 90 to lower the point of gravity and make the lantern more stable Still it has effect on the height and the required strength of the base casing because of the increased overall weight and volume The drop tests described in 83 4 3 revealed that PS with a thickness of 1 5 mm was needed instead of 1 mm in the original design Vacuum forming test with this material showed that sharp corners and deep cavities could cause problems The new design was adjusted to fit the Cambodian style together with the top casing More curves are used compared to the SOLantern this was possible because FIGURE 40 BASE CASING WITH HOLES FOR the frame was used to position the battery instead of the casing itself Rounded corners also facilitate the vacuum forming process and these curves make it less obvious that it Is a casing for the rectangular battery The indentations were kept because they stre
79. stem can service the load under test conditions The product should be able to operate during rainy conditions a according to IP23 The product should be able to withstand the shipping vibration test ELECTRICAL COMPONENTS The light bulb should be visible The light bulb should be able to be replaced The CFL should meet the PV GAP standard BATTERY The battery should not make contact with the electric system when stored The battery should have a minimum capacity of 2 5 Ah at 12V After purchase a fully charged battery should be able to operate the product 3 hours without being recharged in between Boom 2005 3 5 4 0 C J 9 gt 5 O 9 3 LJ Bachelor Report Angkor Light e The battery should be protected from direct sunlight user should be able to obtain information when the battery is almost empty user should be able to obtain information about the charging status of the product e The battery should be able to be replaced battery should meet the PV GAP standard SOLAR PANEL e The panel should be able to take inside the house Boom 2005 2 2 3 3 e The panel should be able to be fixated and aimed at the sun e The product should operate on 12 Volts Boom 2005 3 4 1 e The panel should meet the PV GAP standard 3 0 OTHER e selling price should not exceed the maximum of 50 e The product should be sold as one Integrated package con
80. sun more power DA 7 1 23456 Watts 1 2 3 3 2 1 Night Game 1 Dim the light Less light less power Dice 3 21 3 15 16 Watts 1 1 2 2 3 3 Angkor Light Day Game 2 Clean the panel Less dirt more power Dice1 23456 Watts 3 3 2 2 1 1 Night Game 2 Connecta device small device less power 0 1 2 3 4 56 Watts 1 1 2 2 3 3 FIGURE 60 USER MANUAL RuITER 2007 Angkor Light 1 FIGURE 61 PACKAGING DESIGN RUITER 2007 the Anckor Light f To aKO Des Bachelor Report Angkor Light 4 18 THE FINAL PRODUCT The Angkor Light is the redesign of the SOLantern made by Stephen Boom It is a solar lantern designed for the rural population of Cambodia and is characterized by its sustainability its suitability for multiple lightning situations and low costs on the longer term Possible reparations can be done by entrepreneurs educated by Kamworks against very low repair costs The lantern will be produced in Cambodia itself with as much materials local available as possible FIGURE 63 ANGKOR LIGHT DURING OPERATION FIGURE 62 EXPLODED VIEW OF THE ANKOR LIGHT J X 5 Q C 12 9 Bachelor Report Angkor Light C 5 Q 42 C 9 WO Bachelor Report Angkor
81. t year he finished this project resulting in the SOLantern At the moment a prototype of this lantern is made but it is not ready yet for mass production 1 2 2 ASSIGNMENT DESCRIPTION The goals of this assignment are to redesign the SOLantern to make it useable and affordable for the target group and make it producible in Cambodia The assignment consists of the analysis of the current design the redesign of the lantern and the production plan At the completion of the assignment a pre production series of about 20 pieces must be able to be produced using the designed production plan Next extensive user tests can be performed with these products by the company 1 23 SITUATION To get a good Idea of the local situation the end users and the production capabilities the assignment will be carried out in Cambodia A team of 6 students will be working on different parts of the lantern and its distribution system see Appendix for more information 1 2 4 FRAMEWORK The approach that will be followed consists of several parts Figure 6 Technical analysis Redesign General analysis FIGURE 6 PROCESS OF THE PROJECT The general analysis consists of reading lecture and papers concerning the lantern e g the reports of Stephen Boom Boom 2005 and ando Rotman Rotman 2006 Also the local situation in Cambodia will be explored and the rural population will be questioned about the prototype The technical analysis will be done by
82. taining the solar panel determined in Boom 2005 3 4 4 mobile lighting unit and instruction guides 3 8 0 USE e The product should be able to be carried by the user Boom 2005 3 3 2 e lighting product should be able to stand on rough underground like stones and sand mud Boom 2005 3 3 2 lighting product should be able to be hanged Boom 2005 2 2 3 1 and 3 3 2 e light should shine evenly distributed in an angle of 110 degrees measured from the vertical axis around the product The minimum illumination level should be at least 20 lux at a distance of 1m e Components that are irreplaceable like casing and frame should be able to operate after a fall of 50 cm walking height and table height on earth ground Boom 2005 3 3 2 3 8 LIST OF PREFERENCES e The product should made be out of local materials which are easy provided production of the product should fit with the main objective to contribute to the development of Cambodia by offering local labour e Users can easily take the lantern and solar panel to their work rice field or marketplace e The product should be easy to repair product should fit all lighting categories The product should have a connection to supply power to other products e g a mobile phone 3 9 DEFICIENCIES OF THE PRODUCT After analyzing the recommendations reproducing the prototype and performing a user a drop and a water test and comparing the
83. the battery and replacement of the light bulbs This product is a multifunctional by removing the reflector the headlight is FIGURE 14 FISHERMAN S LIGHT transformed into an ambient light usable for indoor lightning This principle is used in the development of the SOLantern 2 8 THE SOLANTERN The lantern developed by Stephen is a sustainable solar product aimed at the needs of the rural population Because a rechargeable battery and a solar panel are used no extra costs are needed to keep it working The lantern should replace the two current polluting and inefficient lighting solutions the traditional Cambodian lamp and the fluorescent tube The chosen materials and production methods are supposed to make it possible to produce the lantern in Cambodia This is not tested yet and no local manufactures are located at this moment At this moment only a basic prototype of the design is produced in the Netherlands Several requirements formulated by Stephen are not evaluated yet FIGURE 15 PROTOTYPE OF THE SOLANTERN gt 5 C 5 8 Ul Bachelor Report Angkor Light 2 8 1 PURPOSE OF USE The product can be used inside the house for reading cooking and talking and outside the house for walking and tasks like finding animals Several general lightning categories can be determined when these tasks are analysed Plas 1998 To fulfil all demanded purposes the product should be able to comply with
84. uld be used as production technology for the plastic parts Final assembly should be in Cambodia AESTHETICS The product should have a modern western look and feel Boom 2005 2 3 3 1 The product style should fit with the mood board made by Stephen Boom Boom 2005 3 6 3 the colours should be bright and powerful the Cambodian way Appendix P The product should express stability Boom 2005 2 2 3 1 Make people feel proud to own a product like this Refer to the Cambodian look and feel The product should have a quality appeal and consist of plastic parts The product should look and feel robust THE PRODUCT SHOULD MEET THE DEMANDS OF THE PV GAP The on off switch should withstand cycle of 100000 times Charge controller protect from damage from voltage under open circuit conditions Protected against damage from reversal polarity conditions of battery and solar panel The battery should be protected by a fuse This may be on the circuit board Solar panel connection should withstand minimum of 1000 connection cycles The battery capacity C2 shall not decrease over the testing period more than 10 of the initial battery capacity C0 C2 C0 lt 1090 The measured days of autonomy shall match or exceed the defined minimum days of autonomy as Indicated by the manufacturer The lamp shall operate undamaged according to the manufacturer specs At maximum battery volt and max radiation The manufacturer shall specify the daily number of hours the sy
85. wo points where the top casing connects to the frame this is very unwanted The shape of the top casing was altered to make it visually more consistent with the lower part M aking the top casing rounder also has several advantages FIGURE 37 TOP CASING The chill marks encountered during the production of the prototype will be minimized because the plastic 15 stretched less at the top see 3 3 3 1 total shape resembles Angkor Wat better making it more recognisable as a Cambodian product e The top of the part will be stronger because there will be less stretching of the plastic making it less thin 4 5 INNER TOP CASING One problem discovered after the production of the prototype was that the light of the CFL shines trough the base casing revealing a lot of the inner parts This effect is unwanted because it looks very cheap Two more problems encountered were the frayed painting of the top casing and the paint coming off at the contact points with the base casing Several test where done to obtain a straight paint line like using paper tape a removable plug and even some fluids preventing the paint to stick to the plastic No solution was found making it both possible to produce the product locally and being also a solution usable in a production process FIGURE 38 INNER TOP CASING UI Ul J ie 5 0 ic 12 Bachelor Report Angkor Light All problems can be solved by u
86. xact internal shape of the parts could be reproduced The plastic parts can be places on the moulds very easy and the placement is accurate FIGURE 77 INNER TOP FRAME CUT SHAPE Cutting the hole of the inner top casing will be done using a die Because of the round shape of the die it can be made pretty easy while corners are difficult to produce see Figure 76 An epoxy mould will be used to position the part Ul Ul b Bachelor Report Angkor Light 5 METAL PARTS 5 7 1 CUTTING The internal frame consists of metal strips with a width of 20 mm and varying length Only metal sheet 15 local avallable making cutting it to the correct size necessary The guillotine shears in the Kamworks workshop are only suitable to cut sheet in 90 angles or into vary small pieces Sawing by hand is not possible because of the necessary tolerances machined sawing or cutting is not possible because no such machines are available at the workshop and buying them would be to expensive An external company capable of machined cutting was found in Phnom Penh the only drawback of outsourcing the cutting is the slightly higher cost but the quality is much higher The last option mentioned 15 used Aluminium for the handle was found with the right width as described earlier cutting it into the right lengths is done with a hand saw Rounding the edges can be done with a sanding machine or a grindstone both available Quality checks
87. y button and two LED indicators The first option was chosen because the use of one button as power switch and light intensity regulator is confusing to the user this effect was seen during tests with competitive products using this method To combine the battery state and the indication of the correct connection of the solar panel into one indicator the scheme defined in Figure 50 will be used A blink will be 0 5 seconds long making the indication of the almost empty state 0 5 a continuously blinking process To get some extra attention from the user when the battery reaches this state the CFL will also be flickering every second for a period of 5 seconds making it very clear that there will be no more light in about 10 minutes Nr Connection Blink every 0 5 second Battery current Pulse width modulation for buck converter CFL eBlinkevery second control 3 Solar panel current 4 Dimswith eg 3 seconds 5 Dimswitch 6 _ CFL control 2277222 6 seconds CFL control Fault detection CFL Wake up after connection of panel or external P P Loading eContinuouslyon 8 External connection 79 74711010 eBlinkevery 9 seconds ll IED C O connected On Off switch Power supply FIGURE 50 BATTERY STATE WITH LED Power supply INDICATION TYPE TABLE 5 MICROCONTROLLER CONNECTIONS mle al

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