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Environmentally Friendly Backup Power Generator
Design Brief
Studies have demonstrated the need and desire among consumers for an environmentally friendly
electrical power backup system. The system should be capable of driving the heat or air
conditioning and refrigerator or freezer in an average house at intervals that result in no damages
to occupants or property. The generator should also be a “green” technology, in that its
manufacture, operation, and ultimate disposal are / can be done in a way that minimizes
negative environmental impacts.
1.0 Performance
1.1 The unit will be capable of delivering peak power of 8 kW.
1.2 The unit will be capable of delivering a steady power of 3 kW
1.3 The unit will supply a base load of 1 kW of power for 10 hours.
1.4 The recharge time shall be no more than four days.
1.5 The frequency tolerance shall be 1 Hz.
1.6 The voltage tolerance shall be -10/+3 Volts.
1.7 The overall cycle efficiency shall be at least 15%.
2.0 Environment
2.1 The unit will be mainly used in North American weather conditions.
2.2 Temperature Ranges
2.2.1 Energy Gathering Components: 0 – 110 F
2.2.2 Energy Storage Components: 20 – 85 F
2.3 The product may experience humid conditions.
2.4 Corrosion resistance may be considered by the use of special materials or surface
protection methods.
3.0 Life Span
3.1 The product shall have a life span of 10 years if out of service.
3.2 The product shall have an operational life span of 10 000 hours of service.
4.0 Pre-Sales
4.1 Shelf Life
4.1.1 The product should have a warehouse life of one calendar year.
4.2 Storage
4.2.1 The product shall be stored in a supplier’s warehouse before sale.
5.0 Target Costs
5.1 Goals
5.1.1 The goal of the Green Back generator is to remain competitive with existing
generation options, though we realize a premium will be paid for the
renewable generation method we provide.
5.2 Numerical
5.2.1 The target production cost shall be 2800 USD.
5.2.2 The target sale price shall be 3300 USD.
5.2.3 The target profit will be 500 USD.
6.0 Quantity
6.1 The initial production shall produce one prototype unit.
7.0 Maintenance
7.1 Maintenance should be performed on the power-capturing elements bimonthly.
7.2 Maintenance should be performed on the power-storage elements annually.
7.3 Maintenance of all components must be performed after every 500 hours of service.
7.4 Parts requiring lubrication should be reachable within 15 minutes.
7.5 The use of special tools or equipment should not be required.
7.6 Spare parts should be available for 5 years after the product is replaced with a new
model
7.7 Spare parts should be available by ordering on the internet.
8.0 Marketing
8.1 Target Market
8.1.1 The intended market for the Green Back system is homeowners, small
businesses, contractors, and outdoor leisure customers.
8.2 Target Purpose
8.2.1 The target purpose of the unit shall be the prevention of in-home power loss
during rolling blackouts, and other power loss situations.
8.3 Stores
8.3.1 The product shall be sold exclusively in Home Depot stores.
8.4 Projected Sales
8.4.1 Projected sales for the unit in 2008 will be determined based on testing and
final costs.
8.5 Sale Time
8.5.1 The product will be on the market for 2 years.
8.6 Competition
8.6.1 Overview
8.6.1.1 the Green Back system can certainly fill a niche in the market
that these competitors have not yet tapped; an extremely versatile
renewable energy generator dedicated to sustainable and
environmentally sound manufacture and operation.
8.6.2 Diesel and Gasoline Generator Manufacturers
8.6.2.1 Farymann
8.6.2.2 Honda
8.6.2.3 Isuzu
8.6.2.4 Kubota
8.6.2.5 Norpro
8.6.2.6 Yanmar
8.6.3 Renewable Electronics Manufacturers
8.6.3.1 Xantrex Technology
8.6.3.2 Power Air Corporation
8.7 Industry
8.7.1 The generator industry grew five-fold from 2000 to 2005, according to
Generac Power Systems, the nation’s largest generator manufacturer.
8.8 Consumers
8.8.1 The American public has shown increasing awareness and concern over the
environmental impacts of their consumption. Gallup's annual Environment
survey, updated Mar. 11-14, 2007, showed that 84% of Americans support
higher emissions standards for business and industry, and 86% of Americans
support spending government money to develop alternative fuel sources.
9.0 Packaging and Shipping
9.1 The unit shall be packaged in a way that prevents transport-related damages, but also
minimizes the amount of materials that must be thrown away.
9.2 Packaging materials should be recyclable.
9.3 Packaging expenses shall be no more than 5% the unit’s cost.
9.4 The unit should be shipped via boat or ground transportation.
10.0 Size and Weight Restrictions
10.1 Cabinet: Small Size
10.1.1 Weight should not exceed 500 lbs
10.1.2 Depth should not exceed 15.25 inches
10.1.3 Width should not exceed 33.62 inches
10.1.4 Height should not exceed 34.00 inches
10.2 Cabinet: Large Size
10.2.1 Weight should not exceed 1000 lbs
10.2.2 Depth should not exceed 15.25 inches
10.2.3 Width should not exceed 33.62 inches
10.2.4 Height should not exceed 58.00 inches
11.0 Instrumentation
11.1 Outputs
11.1.1 Current current usage
11.1.2 Current amperage usage
11.1.3 Current power usage (Watts)
11.1.4 Current power remaining (minutes, based on current usage rate)
11.2 Style
11.2.1 Digital displays shall be incorporated.
12.0 Manufacturing Process
12.1 The unit should be assembled by hand.
12.2 The unit should be manufactured in the United States of America.
13.0 Government Incentives
13.1 Business Energy Tax Credit
13.1.1 Sectors: commercial, industrial
13.1.2 30% of expenditures for solar technologies
13.1.3 Original use of equipment must begin with taxpayer or be constructed by
taxpayer
13.1.4 Equipment must meet any performance and quality standards in effect at the
time the equipment is acquired
13.1.5 Energy property must be operational in year in which credit first taken
13.2 Clean Renewable Energy Bonds
13.2.1 Sectors: Local Government, State Government, Tribal Government, Municipal
Utility, Rural Electric Cooperative
13.2.2 Can be issued by cooperative electric companies, governmental bodies, or
lenders
13.2.3 Issued w/ a 0% interest rate- borrower pays back only principal of bond,
bondholder receives fed tax credits in lieu of traditional bond interest
13.3 Energy Efficient Mortgage
13.3.1 Sector: Residential
13.3.2 Government-insured through Federal Housing Authority or Department of
Veterans Affairs
13.3.3 Government certifies private lenders to provide them through EnergyStar- meet
EnergyStart standards/certification
13.4 Residential Energy Conservation Subsidy Exclusion (Corporate)- solar only
13.4.1 Sector: Residential, Multi-family residential
13.4.2 Corporate exemption: may receive a rate reduction from utilities or a
nonrefundable credit against price of electricity
13.4.3 Applies to dwelling units only- i.e. house, apartment, condo, boat
13.4.4 Applies to “installations or modifications that are primarily designed to
reduce consumption of electricity or natural gas, or improve the management
of energy demand”
13.5 Residential Energy Conservation Subsidy Exclusion (Personal)- solar only
13.5.1 Similar to above
13.5.2 States that energy conservation subsidies given by utilities are nontaxable
13.6 Residential Solar and Fuel Cell Tax Credit- solar only
13.6.1 Personal tax credit
13.6.2 Sector: Residential
13.6.3 30% tax credit up to $2,000 for purchase and installation of residential solar
electric (photovoltaics or solar water heating system)
13.7 USDA Renewable Energy Systems and Energy Efficiency Improvements Program-
solar, wind, biomass
13.7.1 Federal Grant Program
13.7.2 Commercial, agricultural
13.7.3 Maximum grant award is 25% of eligible project costs up to $500,000 for
projects
13.7.4 Maximum guaranteed loan up to 50% of project costs (max project cost = $10
million)
14.0 Environmental
14.1 Emissions
14.1.1 Maximum CO emissions: 200 grams / hour
14.1.2 Maximum CO2 emissions: 100 000 grams / hour
14.1.3 Maximum hydrocarbon emissions: 100 grams / hour
14.1.4 Maximum particulate matter emissions: 50 grams / hour
14.2 Recyclable components
14.2.1 Batteries
14.2.1.1 The batteries used in the unit shall be recyclable at costs no more
than 20% their original manufacturing cost.
14.2.1.2 The batteries used in the unit shall be rechargeable.
14.2.2 Metal
14.2.2.1 The metals used in the unit shall be at least 90% recyclable.
14.2.2.2 The metals used in the unit need not originally be made of
recycled material.
14.2.3 Plastics
14.2.3.1 The plastics used in the unit shall be at least 90% recyclable.
14.2.3.2 The plastics used in the unit need not originally be made of
recycled material.
15.0 Quality and Reliability
15.1 Quality should be such that the product does not generally fail within 5 years, and
that only 1 in 100 fail within the first year.
16.0 Standards and Specifications
16.1 To be determined, based on exact parts yet to be decided.
17.0 Company Constraints
17.1 None.
18.0 Processes
18.1 All components to be of metric form and comply with ISO 4900 for limits and fits.
19.0 Safety
19.1 Operating Temperature
19.1.1 The cover / shroud over any part of the device that is open to human contact
should not exceed the surface temperatures indicated in Table 22.1.1 while in
operation.
Material Temperature
(C)
Uncoated metal 65
Painted metal 83
Enameled metal 74
Ceramics, glass, 80
stone
Plastics 85
Wood 110
Table 22.1.1: Safe operational temperatures
19.2 Hazardous Materials
19.2.1 Any hazardous materials used in either energy generation or storage should be
marked with labels on the unit.
19.2.2 To prevent exposure to these materials, which are most prevalent in battery
storage, batteries must be placed in a protective casing and careful
maintenance instructions must be displayed.
19.2.3 Maintenance of most batteries must be performed regularly to prevent corrosion
or even possible explosion of the casing, thus leaking hazardous materials to
the environment.
19.2.4 In the case of batteries with acid, a bottle of ammonia should be provided to
neutralize spills should they occur.
19.2.5
19.3 Fire Safety
19.3.1 The device must comply with UL Standard 1741 and 1778. Underwriters
Laboratories (UL) is a highly regarded source for generating safety standards for
commercial and personal machinery.
19.4 Zoning Restrictions
19.4.1 Zoning laws regarding green energy generating devices are still in the process of
being defined more explicitly across the United States (e.g. Nantucket and wind
turbines).
19.4.2 As such, restrictions in Durham, NC regarding wireless antennae will be used
as a benchmark for the issue as far as zoning is concerned.
19.4.3 If the device is attached to the building, it may not exceed 20 higher than the
building.
19.4.4 If the device is freestanding, it may not exceed 60 feet in height.
20.0 Testing
20.1 Testing is to be carried out on 100% of units.
21.0 Legal
21.1 Possible litigation lies in the users injuring themselves through electrical shock.
22.0 Human Factors
22.1 Installation: Wired into Home
22.1.1 The unit should be installed by an electrician or by a DIY homeowner in
under 6 hours.
22.2 Installation: Portable
22.2.1 The unit should be able to be installed by any homeowner in under 2 hours.
22.3 Initialization
22.3.1 The unit should not require more than 3 steps to bring online.
22.4 Noise
22.4.1 The unit should not produce more than 50 dBA at a distance of ten feet.
22.5 Aesthetics
22.5.1 The unit should be aesthetically pleasing with a dedicated design theme,
which exudes reliability.
22.6 Ergonomics
22.6.1 The unit should possess grips or handles for ease of portability.
22.6.2 The steps to bring online should be numbered, color coded, in large font, and
clear to the operator.
22.6.3 The status of the unit should be displayed on a backlit, easy to read screen.
22.6.4 The number of buttons and words should be kept to a minimum.
23.0 Documentation
23.1 Product shall be supplied with user manual covering operation and maintenance.
23.2 Suppliers and installers require maintenance and repair manual.
24.0 Sources
24.1 Example product design specification. (2007). Blueprint Web Site. Retrieved on
January 27, 2008, from
http://www.ider.herts.ac.uk/school/courseware/design/pds/example.html
24.2 Federal incentives for renewable energy. (2007). DSIRE Web Site. Retrieved on
January 27, 2008, from
http://www.dsireusa.org/library/includes/SeeAllFederal.cfm?Search=federal&federal=fed
eral&state=federal¤tpageid=1&ee=0&re=1
24.3 Portable gas powered generators: best values. (2007). Alternative-Heating-Info.com
Web Site. Retrieved on January 27, 2008, from http://www.alternative-heating-
info.com/Portable_Generators_PartII.html
24.4 Household appliance wattage chart. (2007). Alternative-Heating-Info.com Web Site.
Retrieved on January 27, 2008, from http://www.alternative-heating-
info.com/household_appliance_wattage_chart.html
24.5 Residential wind power facts. (2007). Alternative-Heating-Info.com Web Site.
Retrieved on January 27, 2008, from http://www.alternative-heating-
info.com/windpower_residential.html
24.6 Temperatures of touchable surfaces – a personal burn hazard. (2007). RoSPA Web
Site. Retrieved on January 27, 2008, from
http://www.rospa.com/productsafety/articles/temperatures.htm
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