Report OPENLIGHT

OPENLIGHT waveNETv0.1 Arvid Jense a.jense@ student.tue.nl TU/e ID M1.1 sept 2013 – jan 2014 Coach: Cindy van Bremen

2

ABSTRACT A lighting installation is developed for OPENLIGHT. A net of lighting units will be laid in water where it will visualize the actual waves it is floating on. Initially the units would be powered by energy-harvesting technology, but after a feasibility analysis this was deemed not possible. The alternate concept makes use of accelerometers to the detect wave motion and is powered by an Arduino-programmable chip. A circuit board with surface mount components was designed and manufactured completing the personal goals of the author. The end result is a functional prototype, ready for production once funding is managed.

COLOPHON Research project within the Time, Light, Space, Move theme at TU/e ID Project: DPM85 – The OPENLIGHT project Student: Arvid Jense s135438 Coach: Cindy van den Bremen Assessor: Menno Stoffelsen Time period: September 2013 – February 2014 Publication date: 17-1-2014 All images by Arvid Jense unless otherwise stated.

3

CONTENTS Abstract......................................................................................................................................................................................................................................................................................... 2 Colophon ..................................................................................................................................................................................................................................................................................... 2 1. Introduction........................................................................................................................................................................................................................................................................... 5

a)

Design brief ..................................................................................................................................................................................................................................... 5

b)

Personal goals ............................................................................................................................................................................................................................... 5

c)

Planning............................................................................................................................................................................................................................................. 6

2. Concept ................................................................................................................................................................................................................................................................................... 9

a)

Inspiration ........................................................................................................................................................................................................................................ 9 i) ii)

b)

Wave patterns......................................................................................................................................................................................................................... 9 Energy harvesting ............................................................................................................................................................................................................. 10 Final concept .............................................................................................................................................................................................................................. 11

3. Feasibility of energy harvesting ...............................................................................................................................................................................................................................14 4. Technical design .............................................................................................................................................................................................................................................................15

a)

Prototypes ..................................................................................................................................................................................................................................... 15

b)

Components................................................................................................................................................................................................................................ 16 i) ii) iii) iv) v)

c)

Microcontroller ................................................................................................................................................................................................................... 16 Accelerometer .................................................................................................................................................................................................................... 17 LED ...................................................................................................................................................................................................................................... 17 Power regulator........................................................................................................................................................................................................... 19 Resistors and capacitors .............................................................................................................................................................................................. 19

PCB design ................................................................................................................................................................................................................................... 20 i) ii) iii)

Preliminary layout.............................................................................................................................................................................................................. 20 Footprint .................................................................................................................................................................................................................................. 20 Symbol .............................................................................................................................................................................................................................. 21

4 iv) v) vi)

Schematic ....................................................................................................................................................................................................................... 22 Board layout .......................................................................................................................................................................................................................... 23 PCB order ........................................................................................................................................................................................................................ 23

d)

PCB assembly ............................................................................................................................................................................................................................. 24

e)

Programming .............................................................................................................................................................................................................................. 25

f)

Waterproofing ............................................................................................................................................................................................................................ 26

g)

Lighting it up ................................................................................................................................................................................................................................ 28

5. Evaluation .............................................................................................................................................................................................................................................................................30

a)

Prototype evaluation............................................................................................................................................................................................................... 30

b)

Cost estimation .......................................................................................................................................................................................................................... 30

c)

Client feedback ......................................................................................................................................................................................................................... 31

d)

Recommendations .................................................................................................................................................................................................................. 31

6. Conclusion...........................................................................................................................................................................................................................................................................32 Acknowledgments ...............................................................................................................................................................................................................................................................33 Appendices....................................................................................................................................................................................................................................................................................

APPENDIX A

Feasibility report .................................................................................................................................................................................................

APPENDIX B

Feasibility inquiry ................................................................................................................................................................................................

APPENDIX C

Schematics ............................................................................................................................................................................................................

APPENDIX D

Code ...........................................................................................................................................................................................................................

APPENDIX E

SMD instructable................................................................................................................................................................................................

APPENDIX F

Reflection.................................................................................................................................................................................................................

APPENDIX G

Demo day poster ................................................................................................................................................................................................

5

1.

INTRODUCTION This document is the report of a first-year masters project (M1.1) at Industrial Design (ID) Eindhoven University of

Technology (TU/e). It had been executed in the period September 2013 to February 2014. All rights to this document and design are reserved to Arvid Jense and OPENLIGHT.

a) Design brief 1

OPENLIGHT has requested the design and creation of a novel lighting installation in a pool of water for the Luminale 2

3

2014 based on the relationship between water waves and light waves. The brief is inspired by a talk by Richard Feynman in which he illustrates the impressive amount of information a human can extract from light waves.

Feynman compares our perception to a busy swimming pool in which we dangle our feet to feel the waves touching our skin. The waves produced by all the people in the pool all mix and finally end up at our feet. If you could be able to reconstruct the origins of these waves, you would be able to ‘see’ where all the people in the pool are. This sounds extremely complicated, but it is analogous to how our vision works with light waves.

Deliverable of the project is the actual, functioning installation. If this is not possible within the available time, at least a fully functional prototype is expected. The installation will later be produced outside of the scope of this project. Budget is available for the creation of prototypes in consultation with client, OPENLIGHT leader Rombout Frieling. Requirement of the project is that OPENLIGHT is the official (co)author of the project.

b) Personal goals This project was chosen as the first project at TU/e by the author as it promised to be a project focused on the realization phase of the design process. The fact the design should be realized and placed at an art festival, means that the

1

OPENLIGHT is the creative lab of the Intelligent Lighting Institute of the Eindhoven University of Technology. The goal of OPENLIGHT is to make innovative and inspiring lighting concepts, often realized as lighting installations exposed at various international lighting festivals. More information can be found at: www.openlight.nl 2 Luminale 2014 is a lighting festival at the Frankfurter Messe in April 2014. It is held alongside the Light+Building trade fair and in meant to demonstrate artistic lighting concept alongside the commercial range of products shown at the trade fair. The festival does not have a specific artistic theme. More information can be found at:

http://light-building.messefrankfurt.com/frankfurt/en/besucher/events/luminale.html 3

http://www.youtube.com/watch?v=1qQQXTMih1A

6 concept-generation phase will have to be kept short in favor of the realization phase to ensure a professionally functioning end product. This doesn’t mean the design has to be simple, but there simply isn’t time to do a large number or design iterations.

I have done a large number of projects in the past which did not come any further than the concept-generation phase.

Ad van Berlo said in one of the first lectures: “An idea is worth one, a concept is worth ten, a working prototype is worth a hundred and a marketable product is worth a thousand.” What he meant is that a lot of people have great ideas, but not many people possess the skills to turn that idea into something of value. And right here at this university is the place to acquire the essential skills before stepping into the ‘real world’.

As I’ll be working with a lot of electronics in my designs, I feel that it is very important for me to know how make rapid prototypes of these devices myself, instead of relying on a third party. For this, I have set a project goal of having designed and assembled a printed circuit board (PCB) with surface mount components (SMD). As a stretch goal I want have my design manufactured by an electronics manufacturer, which would lay the basis for being able to completely manufacture my own products.

Over the past years I’ve worked extensively with music and the sense of hearing. Being at a completely new environment, I’d like to take full use of the different kinds of expertise available at the TU/e. Being closely connected to Phillips and the city

of light, lighting is one major expertise. Through this project I hope to immerse myself in both the theoretical and practical aspects of lighting.

The M1.1 semester is designated as a research semester. As this is not inherent to the project brief, care will have to be taken to include a clear research aspect in the project.

While concepting and design have a lower priority than research and realization, it does not mean they can be disregard.

Care will have to be taken that all technical considerations are fed back to the concept. A concise concept will have to be chosen early on to avoid ending up with a broken concept.

c) Planning The project is to be executed in a limited time of ten weeks total. To ensure a satisfactory completion, a week planning was made as shown in

7 Table 2. The colors in this table coincide with the special circumstances in that week as explained in Table 1.

The project is divided into three increasingly long iterations (1 week, 2 weeks and 5 weeks) and two weeks of documentation. At the end of each iteration cycle, a prototype is presented to client and coaches. The feedback from the sessions is used to shape the next iteration. The first iteration is focused on creating a concise concept. The second iteration is focused on research. The third iteration is focused on the realization of the design.

Reality caused the project to be delayed through three unexpected time consumers. Heavy involvement with the GLOW presentation outside of the calculated RSDL time (week46), being forced to find new housing (week 48) and involvement with the commercialization of the GLOW project (week 2).

Otherwise the planning was followed thoroughly, with only a one week delay in getting the prototype to work.

Table 1. Legend of weekplanning table.

Legend Deadline at the end of the week Normal week Non-project week First iteration Second iteration Third iteration Documentation

8 Table 2. Weekplanning.

Week

Deadline

Activities

36

Project brief, pressure cooker

Concept generation, preliminary research, create a first prototype.

37

GLOW module

38

GLOW module

39

GLOW module

40

GLOW module

41

Process feedback, research, divert and converge on design variations.

42

Midterm demo

43

RSDL week/DDW

44

RSDL week

45

RSDL week

46

GLOW presentation

47

Crafting wearables

Create a second prototype, prepare for demo presentation.

Process feedback, expand on research.

48

Make final design decisions and design electronics.

49

Design electronics, order parts and PCB.

50

Create third prototype, program.

51

Final demo day

52

Vacation

1

Vacation

2 3

Process feedback and adjust prototype, write research report.

Report deadline

4 5

Make variations program to end up with functional prototype.

Final feedback

Document final prototype and write design report.

9

2.

CONCEPT The design brief is very board and could be filled with a lot a different concepts. Extensive brainstorming sessions were

held in the first iteration before ending up with the concept described in this section. First the direct inspiration for the concept is presented after which the final concept and its specification is laid out.

a) Inspiration i)

Wave patterns

The relationship between waves and particles is intriguing. Light has both a particle and a wave character, something that is not yet completely understood. Water on the other hand is a volume of H2O particles which interact to form waves as is illustrated in Figure 1. This visualization is mesmerizing, especially when animated. How little individually moving points of light form a complex structure when viewed together.

Figure 1. Visualizations of waves.

This principle sparked the idea: “What would happen if a grid of lights would visualize the actual waves in the pond at Luminale?� To explore this idea a number of simulations were made as shown in Figure 2. These were evaluated in a dark room where the animated visualizations were projected onto the floor, as to simulate the concept in its context. These experiments triggered very positive reaction from myself as well as the client and coaches.

10

Figure 2. A number of Processing simulations of a grid of lights visualizing waves. ii)

Energy harvesting

One of the other projects by OPENLIGHT is fLUMENS as shown in Figure 4. The project uses a large number small LEDequipped windmills which generate their own power from wind energy. This allows the installation to be completely independent from infrastructure as well as completely reactive to its environment. The concept of taking ‘wasted’ energy from the surroundings is called energy harvesting. This is very interesting concept to use for a lighting installation.

11 Pressure Difference

Wind power isn’t the only source of harvestable energy. Figure 3 shows a number of different sources. As we want the visualize waves, it would be very convenient to be able to use the kinetic

Ambient Lighting

Stray Radio waves

energy of the waves to power the lights. More information on energy harvesting techniques can be found in APPENDIX A.

Energy Harvesting

It should be noted that energy harvesting is a state-of-the-art concept and practical application have only recently been emerging. While this might give some problems in realization, it will make a technology-driven art project a lot more interesting.

Kinetic Movement

Temperature difference

Water Flow

Figure 3. Energy harvesting sources.

Figure 4. fLUMENS in Amsterdam. Source: www.openlight.nl

b) Final concept The concept is an installation (hereafter called the (proposed design) powerful in its effect, state-of-the-art in its technology and clear in its concept; A net of light devices is laid down in a body of water, when a person disturbs the water and creates waves, the shape of those waves will be translated into light. This is shown in Figure 5. This should be done through directly converting the kinetic energy of the wave into electrical energy to be used by a LED. Each lighting unit will need to be equipped with an individual energy harvester. This way the net is able to cut to size regardless of the context in which it is placed.

12

Figure 5. Scenario for the proposed design.

To realize this concept a big number of individually-operating light devices will have to be created as shown in Fig. 3.

These will individually be connected through a net. The amount of devices will be dependent on the amount of light generated by each device, but a number of 100 devices per square meter is desirable. A total surface of at least 4m2 is desired.

This information leads to a number of criteria. The concepted device’s should have a size of 1-25cm2 for the individual units. The big number of units requires that the component prices are low and that the production process should be simple to avoid high assembly costs. As a rough estimate, each unit should cost a maximum of ₏10 total, but preferably sub ₏1. To be able to function as a public installation, the entire net needs to be able to operate without maintenance for at least three months. It is also desirable to avoid complex mechanisms for installing the installation to its location.

The devices, as imagined consist of three main parts as shown in Figure 6: part A is the LED; part B contains the microcontroller and other electronics; part C is the energy harvester. These units are connected in a grid of wires and are deployed by simply throwing the net in the water.

The concept is meant for the context of a body of water within lighting festival. It is activated not only by user interaction, but also by wind and animals living in the body of water. It is recommended that the users are provided with objects to throw in the pool to active the installation.

13 While the installation is an interesting product by itself, it also holds potential to serve as a basis for developing commercial lighting products. Think of: a bicycle light that is powered by the bumps in the road; buoys guiding ships into a harbor which don’t need to be connected to a grid; a flashlight is powered by shaking or throwing it.

To feed back to the brief, this installation allows observers to make a translation between water waves and light waves.

The observer will experience how different waves interact with each other and how a still pool always contains movement.

The experience will be mesmerizing by itself and observers will discover the second layer of the energy harvesting technology when they read the information presented next to the installation.

A

B

C

Figure 6. Diagram of the proposed design.

14

3.

FEASIBILITY OF ENERGY HARVESTING As energy harvesting technologies are not commonly available, the research part of this project has been a feasibility

study which can be found in APPENDIX A. The summary of the research is as follows:

“For the creation of a lighting installation based on a large number of energy-harvesting units, six energy-harvesting technologies are analyzed; electromechanic, piezoelectric, induction, MEMS piezoelectric, MEMS electrostatic and MEMS electromagnetic. While the MEMS technologies are most suitable, the state of technology is not mature enough.

Piezoelectric and induction seemed to be decent alternatives, but failed to produce tangible results in experiments. It is recommended that this project will be continued without the use of an energy-harvesting technology.� (From APPENDIX A.) As using an energy harvester proved not to be feasible for this project, and it was no option to stop the project, an alternative need chosen. The alternate solution was to substitute the energy harvester with an external power supply and an accelerometer. This way the principle of visualizing waves could be demonstrated. Once energy-harvesting technology does become suitable to use, the device can simply be modified to use the new technology.

The letter which was send to potential partners can be read in APPENDIX B.

15

4.

TECHNICAL DESIGN With the concept clear, the functional prototype could be designed and manufactured. It was chosen to manufacture a

number of ten units, to allow the creation of a three by three grid and have a single unit left to allow for a failed board. This section will describe the entire process of going from a concept, to a functional electronics board.

a) Prototypes To get a sense of whether the device would work a concepted, a quick Arduino proof-of-concept, shown in Figure 7, was made with a Teensy3.0, MMA8452Q accelerometer (the big brother of the MMA8653FC used on the final board) and a 5mm RGB LED. After some wrestling with communications to the accelerometer, a basic working version was made. This device helped get the specification for the device in order. A diagram of the final design is shown in Figure 9. Requirements that came from this design are: •

5 IO pins needed: R;G;B;i2c data;i2c clock

•

Accelerometer needs to be set to 2g mode for best performance

•

Varying the color on tilt gives the most interesting resuklts

Figure 7. Arduino prototype.

16

Figure 8. Accelerometer output.

Accelerometer Vin

Power regulator

LED

Light

Microcontroller Lighting unit

Figure 9. Functional Diagram.

b) Components With a proof-of-concept, it is possible to select the components for the prototype. Mouser was chosen as supplier as their product range was wider and less expensive than those of competitors Farnell or RS-components. Having a single supplier made choice making for components a lot more manageable, as there is an enormous amount of variations available for each component. All components are chosen to match each other in voltage and functionality. i)

Microcontroller

The microcontroller is the part which connects all the other parts and contains the intelligence of the electronics. The main consideration for choosing this part is the difficulty of programming it, size and cost. To keep the programming manageable and to have access to extensive external libraries, it is desirable to be able to program in the Arduino language.

17 While an actual Arduino board would be too large for this project, there is a series of smaller chips which are programmable with Arduino; Atmel ATiny. A number of variation are available with subtle difference but in the same price range. Of these, 1

the ATiny85-SU was chosen as having an eight times higher program memory, yet only being 30% more expensive than the least expensive variation. If the final program proves to need less program memory, the ATiny85 can always be replaced with an ATiny13a or ATiny25, as these share the same pin-out and basic functionality. All of these boards can be programmed 2

with Arduino .

Important characteristics of the ATiny85-SU are: Voltage range 2.7-5.5V; 5 IO pins; i2c capability; 8 KB program memory; small footprint; 40mA max current on IO pins. ii)

Accelerometer

The main differences in accelerometers are the communication protocol and price. The three most commonly available protocols are i2c, SPI and analog, all possible to use with the ATiny85. Looking for the least expensive, the MMA8653FC

3

came out as winner. This device is coincidentally very similar the accelerometer used in the Arduino prototype, which makes programming a lot easier. A disadvantage is that the accelerometer is extremely small; 2x2mm. This is a challenge to solder, but it would be an enormous achievement to get it right.

Important characteristics are: Voltage range 1.95-3.6V; 2g/4g/8g range; i2c communication; 10 bit resolution. iii)

LED

The central part of the electronics is the LED. This is the part which all the other components are supporting and which is the thing visible to the observer of the installation. There are a few different parameters to consider when choosing a led, these are shown in Table 3.

Table 3. LED selection characteristics Characteristic

Consideration

Choice

Single or multicolor

While the initial concept used a single white LED, the fact that the microcontroller can only source 40mA per pin,

RGB for maximum flexibility.

1

http://nl.mouser.com/ProductDetail/Atmel/ATtiny85-20SU/?qs=sGAEpiMZZMtkfMPOFRTOlzm3F7l5sNgt

2

http://highlowtech.org/?p=1695

3

http://nl.mouser.com/ProductDetail/Freescale-Semiconductor/MMA8653FCR1/?qs=sGAEpiMZZMuJJ6wbRIs2btaRRQKJJnyc

18 means that for maximum brightness three pins can be used with an RGB LED. Forward voltage

The voltage on which the device operates, if this doesn’t match the operating voltage of the device, the voltage needs to be converted or limited.

Should be below 3.3V as the accelerometer function on that range.

Forward current

The current that flows through the LED when the voltage is applied, this needs to match the capabilities of the power source.

Can be a maximum of 40mA due to limitations on the microcontroller

Luminous intensity

A higher rating means more light, but this has a heavy relationship with the forward current.

The higher the better

Viewing angle

Viewing angles can vary from 1° to 180 °.

A bigger angle means the installation will appear bright from a wider area.

Price

Higher efficiency will be more expensive.

As low as possible

Footprint

This usually scales with intensity.

Any SMD package

1

Firstly the CLMVB-FKA was chosen as having the best price brightness ration with the forward current in the right range. But as the package arrived it was realized a mistake was made. The peak forward current was regarded instead of the forward current. This mistake would mean a serious risk of either blowing the LED or having an inferior light output.

2

After evaluation another search was made for the right LED and the LTRB GFSF was found. This LED in turn fits nicely within the current ratings of the microcontroller and is almost four times as bright as the alternative while being only 30% more expensive.

Important characteristics are: Forward current 40mA; Luminous intensity 160-1350lm; Forward voltage R=2V G.B=3.3V; viewing angle 120°.

1 2

http://nl.mouser.com/ProductDetail/Cree-Inc/CLMVB-FKA-CFHEHLCBB7a363/?qs=sGAEpiMZZMseGfSY3csMkUpOsDptuOJoLry98PTe3eU%3d

http://nl.mouser.com/ProductDetail/Osram-Opto-Semiconductor/LTRBGFSF-ABCB-QKYOZ/?qs=%2fha2pyFadugP6zMi8J3mpA0nzAIiXyd7hWEB4rpT9HY%3d

19 iv)

Power regulator

All the components function near 3.3V, so it is important that the circuit is powered at that voltage. Problem is, voltage drops when a current is transported over distance. This drop is dependent on the resistance of the wire and had a linear relationship with wire length. If a big net is made, with say a distance of 10 meter and the devices are fed with 3.3V, it might just be that the first devices gets 3.3V, while the last one only gets 2V, not enough to power the LEDs. To avoid this problem, a voltage regulator can be used to convert a higher voltage to a steady 3.3V. A good option is 12V, as it allows for a lot of losses and 12V power supplies are abundantly available in the form or PC power supplies, where other voltages would need a more expensive laboratory power supply. A disadvantage is that converting from 12V to 3.3V will mean that a lot of energy is lost and the power regulators might get hot.

To get a sense of the amount of possible heat, a small analysis is made. The power we’re dissipating is equal to the current times the dropped voltage. Taking the rough estimate from Table 4, the power dissipation would be an estimated maximum of 8.7 V* 0.145A = 1.26W. Table 4. Maximum power consumoption estimate.

Part

Maximum power consumption (mA)

LED (x3)

120

Acceleromter

5

atTiny85

20

Total

145 1

The supply of 3.3V regulators is huge; this mean the choice is mainly based on price. The AP1117 is chosen a power regulator with the right availability, price and characteristics.

Important characteristics are: 6.4V-18V input; Current limit 1.1A. v)

Resistors and capacitors

Three resistors and four capacitors are used on the board. The only choice to make here is the package size. A smaller package automatically means that the component is less resistant to overpowering. For this reason the relatively big 1206

1

http://nl.mouser.com/ProductDetail/Diodes-Incorporated/AP1117IE33G-13/?qs=sGAEpiMZZMsGz1a6aV8DcCIlKWhD2GibreMCbJvWdNw%3d

20 (3.2x1.6mm) package is chosen for the capacitors directly on the power line and the smaller 0805 (2.0x1.2mm) package is chosen for all the other components.

c) PCB design 1

Designing the PCB is done with the software package Eagle . This program is free to use for PCBs under 10x10cm and has the advantage that many manufacturers can directly work with Eagle files. As PCB manufacturing is expensive and time consuming, it is very important the this phase is done very carefully, so the PCB will be functional on the first try. i)

Preliminary layout

With the components specified, the next step could be made; creating the PCB. Using 3d modeling techniques, a few variations were made to get a sense of the actual board layout. While some variations in shape were tried in this stage, it was chosen to go for a square board to be sure that the manufacturer could deliver.

Figure 10. Solidworks tests for compoent layout and board size. ii)

Footprint

Because the chosen parts are not present in the Eagle part library and to learn how to use Eagle, custom footprints were mad for all the components. The creation of a footprint is basically recreating the suggested footprint from the component’s datasheet in Eagle. As Eagle doesn’t have the most user friendly interface and the datasheet references the measurements

1

http://www.cadsoftusa.com/

21 differently than Eagle, this is a very tedious task. A mistake made in this part might mean that a component does not fit later on.

Figure 11. Dataheet information (left) and Eagle footprint (right) iii)

Symbol

Eagle also needs a symbol next to the footprint. This is a schematic representation of the part and is used for making the schematic later on. While there aren’t any subtle mistakes to make as in the previous step, care should be taken to make a logical layout. This will help a lot later on.

Once the symbol is doen, the symbol and footprint have to be matched to form an functional Eagle part. All these steps are repeated for all the parts.

22

Figure 12. Dataheet diagram (left) and Eagle symbol (right)

iv)

Schematic

With the components correctly loaded into Eagle, the schematic can be made as it was in the Arduino prototype. See for the full schematic in APPENDIX C.

Figure 13. Eagle schematic.

23 v)

Board layout

Next step is making the final layout for the PCB. Eagle places the components of the schematic on a new canvas and draws ghost wires indicating which pads are connected. First the components need to be placed as they were in the Solidworks mockup. Then it is a puzzle of trying to make the most efficient connections.

Once a satisfactory layout was made, the board was checked with the design rules of manufacturer Eurocircuits. Luckily, this is an automated process and no errors were found. See full circuit in APPENDIX C

Figure 14. PCB layout vi)

PCB order

With a finished PCB, a manufacturer had to be given the order to manufacture the PCB. The choice was between 1

2

Eurocircuits and V-PS as these were the two manufacturers recommended to me by fellow students and teachers. After inquiring with both on prices, it became apparent that V-PS was almost twice as expensive and didn’t offer many redeeming features. So Eurocircuits was chosen as the manufacturer. As the startup price for PCBs is very high, it didn’t make much of a difference in price to order a single PCB or dozens. For this reason I ordered 30 PCBs.

1

www.eurocircuits.com

2

http://v-ps.com/

24

Figure 15. The PCBs as they arrived from Eurocircuits.

A week later, the PCBs arrives as seen in Figure 15. The quality was better than expected, even on the miniature pads for the accelerometer. Some of the printed text did not come out as good, but this might be a helpful reference in the future.

d) PCB assembly With the PCB and all the parts the boards could be assembled. I expected a lot of problems in actually assembling the tiny parts on the tiny board. But starting with few parts to test, then add more as I went, everything went really well. More details on the soldering process itself can be found in in APPENDIX E. After the boards themselves were soldered, I connected them together in a net with insulated wire to form a small net.

A few problems that occurred during soldering were double connected pads, but these were easily fixed after reheating.

A major problem though was that after the net was finished and functional, I wanted to switch from the lab power supply and use an unregulated 14V adapter. While within the range of the regulator, this proved to be a fatal mistake. Four of the boards somehow stated to flicker in a way that wasn’t correct. I quickly disconnected the power supply but I was too late. When connecting it to the lab power supply again, those four boards had blown the power regulator as well as the accelerometer.

Despite this accident, the microcontroller and LED still worked on the blown boards. Instead of having one 3x3 net, I opted for the following setups: •

2x2 boards fully functional net

•

2x2 boards silicone encased demo mode net (accelerators of these are blown)

•

2 boards independent to use for experimenting with the programming

25

Figure 16. Soldering the board on a hotplate.

Figure 17. The finished but blown testing net.

e) Programming While the Arduino program already contained most relevant code, there were two specific challenges to be dealt with for these boards. Both stem from the fact that the aTiny85 is a much more limited device than a normal Arduino. The first problem was getting i2c to function. The aTiny85 didn’t make the right communication with the accelerometer. At first it was though the problem lay in the share i2c and programming lines. But after test with an oscilloscope, a show in Figure 18, it was diagnosed the communication was working right, but the protocol wasn’t implemented correctly in the Arduino library. After I dived into the unfamiliar C++ code, I found the source of the problem and made a fix, after which the microcontroller and accelerometer communicated perfectly. The fix is communicated to the authors of the library.

26

Figure 18. Debugging i2c with an oscilloscope.

The second issue lay in the fact that the aTiny only has two PWM channels. This means only two colors of the LED could be dimmed smoothly, the third LED could only be in an on or off state. To regain the use of the third LED, I wrote a software PWM extension which makes use of timer compare interrupts. While a lot less accurate than the hardware PWM, it does allow the third LED to be smoothly dimmed. This extension will be shared open source to the Arduino community.

f) Waterproofing As the PCBs need to be placed in a body of water, they need to be waterproofed. The most suitable solution was to encase or coat them in a clear plastic. As shown in Figure 19, there was a large number of materials suited, to make to good choice a few requirements were regarded for the coating: •

Transparent

•

Waterproof

•

Affordable

•

Simple application

•

Floating

27

Figure 19. Options for waterproofing.

Of these the HT33 two component silicone excelled both in price as in mode of application. The board boar either be dipped in a bath of silicone or be encased though a mold. Figure 20 shows a test for the effective waterproofness of the silicone. A piece of MDF was encased in silicone. When dried it was put in water overnight. No swelling of the MDF occurred, indicating the it was completely watertight.

For the demo net, two of the boards were coated with the silicon and two boards were encased, to see the differences.

Both formed a nice surface around the board, but the quality of the coated boards was insufficient. The silicone came off on the edges and gravity pulled some off the silicone of the highest components. A second coating might fix these problems.

28

Figure 20. Waterproofing test.

Figure 21. Encasing the PCBs.

g) Lighting it up With the coating present, it was time to check how the boards looked. Interestingly the lighting effect through thick layer of silicone was very different from how the coated boards looked. See for an impression in Figure 22

29

Figure 22. The boards lighting up!

30

5.

EVALUATION a) Prototype evaluation •

The encased PCBs give a really nice effect; this should be exploited for the final design.

•

Each unit creates a lot more light than described for the energy-harvesting concept this is a good thing for the installation in its current form, but deserves some attention if an energy-harvesting technology would be integrated.

•

Bigger leads from Gnd-Gnd Vin-Vin are needed, as a significant resistance is measured between these points.

•

Power conditioning is needed to protect from short circuit and reversed polarity as the incident showed.

•

Powering the installation with AC instead of DC might save some of these issues, but does make the voltage regulator more expensive.

•

Voltage conversion loses 70% of the energy, a switching dc-dc convertor can be used to make the electronics more efficient.

•

No heat is generated by the lighting units, so no additional cooling measures need to be taken.

b) Cost estimation 1

When making multiples of thousands, prices at Mouser and Eurocircuits

2

Table 5. Price estimation per unit Component

Cost (€)

Microcontroller

0,55

LED

0,35

Accelerometer

0,45

Resistor x3

0,06

Capacitor x4

0,09

1

http://nl.mouser.com/

2

http://be.eurocircuits.com/shop/orders/configurator.aspx

31

Voltage regulator

0,15

PCB

0,45

Subtotal

2,10

Solder and assembly (10%)

0,21

Connecting wires

0,10

Silicone encasing

0,20

Miscellaneous (30%)

0,64

cost

Total

3,25

With a net of 2000 units, the cost would be approximately €6500,-

c) Client feedback The client is very satisfied with the work done in this project. Even without the energy-harvesting technology the installation is interesting and inspiring. Sadly funding for the Luminale is not certain, so the realization of this project is delayed to the Amsterdam Light Fesitval 2014-2015.

d) Recommendations While the design is functional as is, there are a few points that need extra attention before continuing the creation of the lighting installation: •

Encasing the lighting units works well, but how will this happen for thousands of units?

•

The connections between the boards need to be more secure and easily connected.

•

There are a lot of possibilities in how the waves are visualized. Time was too limited to explore a lot of option within the scope of this project, but a lot can be gained in this area.

32

6.

CONCLUSION The first project of my education at TU/e ID has been an extremely valuable experience; I’ve met my goals of learning to

manufacture PCBs and immersing myself in lighting technology. Even though the end product is not yet an actual deployed lighting installation, it is a realized prototype, ready for production. The research part gave guidance to the project even though it concluded that the initial concept was not feasible.

The project started from a design brief which requested the design and creation of a lighting installation which was to be put in a body of water at the Luminale lighting festival 2014. The brief stated inspiration form a talk by Richard Feynman in which he draws parallels between water waves and light waves.

Focus for the project was on research and realization, while the design phase has been kept brief. This coincided with my main goal; learning to design and manufacture surface-mount printed circuit boards. A second goal was to immerse myself in the world of lighting and vision to compliment my knowledge on sound and hearing.

The project was executed over a course of ten weeks, in which three progressively longer design iteration have been done. The first iteration focused on concept generation, the second iteration on research and the third iteration on the technical realization. The concept phase led to a clear concept which seemed feasible to develop in the remaining time. The research phase on the other hand caused some disturbance, as the result stated that it was not possible to use the intended energy-harvesting technology. An alternative was made which was the same working principle, but relied on external power.

The third design iteration focused on the technical design choices such as the choice of components and the functional mechanism.

At the end of the three iterations a working prototype was presented, ready for production. The project has taught me a lot on designing and manufacturing electronics, to the point that I am now able to create small series of electronic products.

The client and coach were both very pleased with my work. My personal reflection can be found in APPENDIX F.

33

ACKNOWLEDGMENTS A number of people have been essential during the course of this project. First of all my coach Cindy van Bremen and client Rombout Frieling have guided me through the process and provided me with invaluable feedback. Secondly Herman and the other people from the /d.search-labs for providing technical knowledge, feedback and tools. Thirdly Rob van Schaijk of the Holst Centre and Guus Rijnders of the University of Twente for the help with my inquiries into energy harvesting. Last but not least the fellow students and teachers who provided enormous feedback and input into the project.

APPENDIX A Feasibility report

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

Feasibility study for energy-harvesting floating lighting units Arvid Jense ILI OPENLIGHT, Eindhoven University of Technology Den Dolech 2, 5612 AZ Eindhoven, the Netherlands a.jense@student.tue.nl Abstract— For the creation of a lighting installation based on a large number of energy-harvesting units, six energy-harvesting technologies are analysed; electromechanic, piezoelectric, induction, MEMS piezoelectric, MEMS electrostatic and MEMS electromagnetic. While the MEMS technologies are most suitable, the state of technology is not mature enough.

Piezoelectric and induction seemed to be decent alternatives, but failed to produce tangible results in experiments. It is recommended that this project will be continued without the use of an energy-harvesting technology.

Keywords— Lighting installation, Harvesting, Wave Energy Convertor

Feasibility,

Energy

I. INTRODUCTION Energy harvesters are a state-of-the-art technology with a huge potential. Their capability of converting ‘wasted’ energy, like vibrations and heat, into small amounts of electric energy, promises to free electronic devices from wires and batteries.

Imagine a mobile phone charged just by keeping it in your pocket while walking. Current research is trying to create small sensor networks with this technology, truly creating an Internet of Things [1].

In succession of the OPENLIGHT project fLUMENS [2], a lighting installation is proposed in which energy-harvesting floating lighting units visualize the waves made in a body of water. As there are quite a few different types of energy harvesters, this document will take a look at which one is most suited for this project. The question this document attempts to answer is: what is the feasibility of using an energy-harvesting technology for use in floating lighting units? As well as: which energy-harvesting technology is most suitable to use in floating lighting units?

The document will start with a brief explanation of the concept and related technologies. This is supplemented with a quantitative analysis of the power requirements. An overview will be given of the six identified energy-harvesting technologies which will be linked back to the requirements.

The conclusions are tested after which a recommendation is given.

The information gathered for this feasibility report originated from articles found through academic search engines as well as conversations with experts from the Holst Centre and the University of Twente.

A. Concept The concept is an installation (hereafter called the ‘proposed design’) powerful in its effect, state-of-the-art in its technology and clear in its concept; A net of light devices is laid down in a body of water, when a person disturbs the water and creates waves, the shape of those waves will be translated into light. This is shown in Fig. 1 and Fig. 2. This should be done through directly converting the kinetic energy of the wave into electrical energy to be used by a LED. Each lighting unit will need to be equipped with an individual energy harvester. This way the net is able to cut to size regardless of the context in which it is placed.

To realize this concept a big number of individuallyoperating light devices will have to be created as shown in Fig. 3. These will individually be connected through a net. The amount of devices will be dependent on the amount of light generated by each device, but a number of 100 devices per square meter is desirable. A total surface of at least 4m2 is desired.

This information leads to a number of criteria. The concepted device’s should have a size of 1-25cm2 for the individual units. The big number of units requires that the component prices are low and that the production process should be simple to avoid high assembly costs. As a rough estimate, each unit should cost a maximum of €10 total, but preferably sub €1. To be able to function as a public installation, the entire net needs to be able to operate without maintenance for at least three months. It is also desirable to avoid complex mechanisms for installing the installation to its location.

Fig. 1 A visitor throws an object into a still body of water.

Fig. 2 Waves of light appear.

Fig. 3 Diagram of the proposed design.

B. Wave power The proposed installation could be regarded as a miniature version of a wave energy convertor (WEC). These are machines that harvest the mechanical power of waves to be used as electric energy in the general electricity grid. [3] While these are regarded as a high-potential renewable energy source, they have not yet reached the level of efficiency and wide-spread deployment of for instance solar or wind power.

Fig. 4. Wave energy convertors. Source: http://www.alternative-energynews.info

An actual full scale parallel to the proposed design is the WEC sensor buoy [4]. While different in their purpose, these devices are meant to be deployed somewhere in a body of water, where it will take measurements for an extended period of time, without needing maintenance. At this point, WEC sensor buoys are expensive devices, but the proposed design might serve as a prototype for a new generation of miniature sensor buoys. The application field would be in data gathering for scientific research as well as low cost marker buoys for the maritime industry.

C. Energy requirements To get a sense of what the actual power requirements are for the proposed installation, a short analysis will be made.

The installation will be placed in a dark urban environment.

As such, the surrounding area will have an ambient luminance of approximately 0.1 lux [5]. For the installation to be visible, it should produce about 1 lux at peak level to the visitors. This luminance is in the range at which the human eye’s photopic vision regime just starts, meaning the installation can be seen clearly and without adaptation issues [6].

A typical low energy LED produces about 5 cd/W [7]. To get the desired amount of light with such LEDs, about 20ÂľW/cm2 at peak is needed.

The number of LEDs used in the installation is dependent on type used. If the LED with the lowest power consumption of 1mW and a light output of 5mcd is used, 2000 lights per square meter would be needed. While a more intense light using 20mW generating 100mcd would be needed for the concepted 100 lights per square meter.

White LEDs function at 3.6V DC, meaning either the energy harvester will need to generate this voltage, or power conditioning has to be used to get this voltage. Different power conditioning methods are available to drive the LED, but all of these have energy loss. We’ll estimate the efficiency of power conditioning at 50% [8], bringing the energy requirement up to 40¾W/cm2.

D. Wave energy The amount of energy present in the waves we’re creating in the pool is many times smaller than the sea waves used by WEC’s. The predicted frequency range of the waves created is 0.1-10Hz with a height of 1-20cm. To get an indication whether our small waves contain enough energy, we take a look at the wave energy equation [9] shown in Equation 1.

With P being the wave energy, W being width of the wavefront, Ď being the density of water (≈ 999 kg/m3 at 16ÂşC), g being the gravitational acceleration (≈ 9.81 m/s2), T being the wavelength and Hs being the significant wave height. The significant wave height is defined as the average height of the highest third of the waves. đ?‘Šđ?œŒđ?‘”2 đ?‘‡đ??ťđ?‘ 2 đ?‘ƒ= 64đ?œ‹ Equation 1. Wave power equation

Simplifying this equation, we can calculate the wave energy flux in an area (W/m2) as show in Equation 2, which is easily compared with the energy requirements. đ?œŒđ?‘”2 đ??ťđ?‘ 2 = 478.2 đ??ťđ?‘ 2 đ?œ™= 64đ?œ‹ Equation 2. Wave energy flux

This means that even with a significant wave height of only 10cm, the wave energy flux would be about 4.8W/m2 = 480ÂľW/cm2. This one order of magnitude above what we estimated to be needed for our installation. While the available energy is not extremely abundant, it does seem to leave enough leeway for inefficient energy processes.

II. CRITERIA/CONSTRAINTS To be able to make an educated decision between the different types, a list of criteria for the energy harvesters is made. This is shown in Table 1. These will be referenced in making the final decision.

TABLE I CRITERIA

1.

2.

3.

4.

5.

Integrable on a 1-25cm2 device Price <€10 (preferably <€1) Simple assembly (preferably automatable) Needs to produce >40µW/cm2 at 0.1-10Hz (preferably >40µW per unit) Preferably a simple mode of deployment

B. Induction Similar to electromechanical systems, the principle of induction can be used to convert motion into electric energy.

As shown in Fig. 7, the device consists of two parts, a coil and a magnet which moves inside of the coil. This is a lot less completed for assembly than electromagnetically systems. It is, on the other hand, more demanding on power requirements, as it does not produce a stable stream of electricity. To safely power delicate electronics, a robust energy management system is needed, adding complexity.

III. OVERVIEW OF AVAILABLE OPTIONS This section gives a brief overview of the six main options for energy harvesters. A more in-depth comparison of the MEMS techniques is written by Mitcheson et al [10].

A. Electromechanical Conventional water energy convertor operate on the principle of capturing the motion of waves, mechanically transferring it to a (rotary) generator which in turn creates the energy. [3] The principle of this is shown in Figure 5.

Fig. 7. The principle of induction for energy harvesting. Source: Oregon State University.

Fig. 5. Four types of conventional wave energy convertor. [3]

These systems have found their use in large scale applications, but it is difficult to translate these concepts into a small scale version. An example of how this is done can be found in watchmakers territory. Self-winding watch mechanisms as shown in Fig. 6 effectively convert a rocking motion into usable energy, but the complexity is huge. An advantage is that it creates a relatively stable source of energy.

A big concern is the added difficulty of assembling a system like this in numbers of thousands.

Fig. 6. Millimetre scale motion energy convertor. Source: Seico Instruments Inc.

C. Piezoelectric A piezoelectric element is a device, often a thin plate or strip, which has the property of generating a voltage when bend. The bending principle could be used with the Attenuator (Fig 5.) principle, but without the complexity of a mechanical system.

Piezoelectric energy harvesters have the same power conditioning requirements as induction. They are commonly available in centimetre scale but less common in millimetre scale.

Fig. 8. Two common types of piezo. Source left: Rob van Heelsbergen.

D. MEMS Piezo The MEMS piezo technology works on a similar principle as the aforementioned piezoelectric elements, but on a microscopic scale. [11] Like all the other MEMS energy harvesters, it is still young technology. The devices work best if tuned to a specific frequency. Resonant frequencies of 1100Hz are possible, which nicely overlaps with our water wave frequency range. Similarly to the other MEMS technologies, the energy harvester can be packed into a chip

package, meaning they can be assembled on the lighting units’ circuit board with a pick-and-place machine, which makes assembly dramatically simpler.

The energy capacity is estimated at 10-100 μW/cm3 [12].

With a wave height of 10cm, that would give a potential of 100-1000 μW/cm2!

As these devices are not yet commercially available, a research partner needed. The researchers at the Tire-Road Consortium of the University of Twente have been doing research in this field and could be potential partners.

F. MEMS Electromagnetic As shown in Fig. 11, electromagnetic devices function on a similar principle has been described for induction devices, only on a micrometre scale. They are tuneable to single frequency and have experimentally achieved 0.61 μW for 14.9 m/s2 external acceleration at 55 Hz. [16] Again, this is not nearly sufficient for the needs of this project at this point in time, but the performance might improve in the near future.

Researches from the Holst Centre have been working with this technology and may be potential collaborators.

Fig. 11. Diagram of a MEMS electromagnetic energy harvester. [16] Fig. 9. Electron image of piezo MEMS generator. [12]

E. MEMS Electrostatic Electrostatic MEMS devices make use of a vibrating structure, which acts as a chargeable capacitor as seen in Fig. 10. They are especially suitable for frequencies <100Hz and experimentally managed to produce 36µW on a device of about 3x3x3cm. [13] This is at more than four times less than what is needed, but theoretically up to 40mW/cm2 with frequencies of 1-100Hz is achievable. [14] This means that this technology might become suitable in the near future.

Researches from the Holst Centre have been working with this technology and may be potential collaborators.

G. Conclusion The data gathered on the previously discussed technologies are presented in Table II. The table shows which criteria the technology matches, with a bold number if the criterion is matched very well.

TABLE II COMPARISON OF OPTIONS Specs Motion is connected to an electrical generator.

Advantages Proven technology.

Induction

A linear motion creates energy.

Well know principle.

Few parts.

Piezoelectric

A bending motion creates energy.

Theor

Commonly available.

Simple construction.

MEMS piezoelectric

Vibration creates energy.

Theoretic 1mW/cm2.

High voltages.

Vibration

Closed package Small footprint.

Electromechanical

Fig. 10. Diagram of a MEMS electrostatic energy harvester. [15]

MEMS

Well

suited

Disadvantages Complex to make on millimeter scale.

Many parts.

Very expensive.

Difficult to make waterproof.

High power conditioning needs.

Needs construction to ensure maximum flexion.

Large.

Immature technology.

Criteria 1

Immature

1,3,5

1,2

1,2,3,5

1,3,5

electrostatic

creates energy Theoretic 40mW/cm2 High voltages.

MEMS electromag netic

Vibration creates energy.

Tuned to single frequency.

Low voltages.

for the frequency range of pond water waves.

Small footprint.

Closed package.

Closed package.

Small footprint.

technology.

Immature technology.

Least common of MEMS technologies.

1,3,5

Comparing the properties of these energy harvesting technologies, no clear choice can be made, as no relevant data on the actual power yield was present. Hereto, an experimental evaluation has to be done.

The MEMS technologies seem to have the most potential, as well as the most uncertainty. As using these technologies would require a technical partner, contact will be made with researchers from UTwente as well as the Holst Centre to inquire on the current state-of-the-art and interest in collaboration. The biggest advantage is that the technology comes in chip form and as such can be easily integrated with the other electronic components.

The second most potential is the piezoelectric technology.

As it wasnâ&#x20AC;&#x2122;t possible to find relevant information on what the energy yield is some experiments need to be done to test the feasibility.

A third option would be induction. While the assembly of a device like this is a lot more complex than the other options and the energy yield is uncertain, experiments are needed to test the feasibility of using this technology.

The mechanical complexity en cost of a electromechanical system mean that it is no suited for this project.

This setup gave some results when tapped fiercely with a nail or pen, but failed to provide results when bend at 1-10Hz. To be sure of these results, measurements were taken with an oscilloscope under similar conditions. This showed that indeed a tap with a hard object would create a significant amount of energy, but that simply bending the object did not.

Better results might possibly be achieved with more specialized elements, but those were not available in the timespan of this research.

These results of these experiments show that it is not possible to create a satisfactory prototype with this technology.

Fig. 12. Piezoelectric element with an LED indicated by the arrow

C. Induction To test the feasibility of the use of induction, a number of experiments were done with various sizes of coils, magnets and LEDâ&#x20AC;&#x2122;s. This failed to produce any significant results.

More in-depth experiments and high precision parts might provide better results but at this point it is not feasible to use the induction principle to power the lighting units.

IV. EVALUATION A. MEMS Contact was made with researchers of University of Twente Fig. 13. Different experiments for induction (Guus Rijnders) and Holst Centre (Rob van Schaijk) through phone and email. Both initially responded enthusiastically, but V. CONCLUSIONS AND RECOMMENDATIONS after a review of the requirements for this project indicated It is not feasible to power this project with an energy that the technology is indeed too immature for this application. harvesting technology. While six distinct potential energyThis means that the MEMS energy harvesters are not a harvesting technologies have been identified, none of them suitable technology for this project. proved to be suitable for this project. While MEMS technology is not yet to the right level of maturity, it does hold B. Piezoelectric To test the effective energy yield from bending a a lot of promise for the future. Experiments with piezoelectric piezoelectric element, analogous to how it would bend on and induction were unsuccessful in the short time available. A water waves, two experiments were executed. The first more thorough search for the potential of these technologies experiment was a hands-on approach of connecting a LED for this is recommended, but not feasible for the scope of this directly to the element and noting the light output, the second research.

To ensure a satisfactory result of the project, it is consisted of measuring the produced energy with an recommended that the use of energy harvesters is disregarded oscilloscope. and an alternative solution will need to be found.

The first experiment, as show in Fig. 12, was simply a low energy SMD LED soldered directly to a piezoelectric element.

REFERENCES [1]

K. Ashton, "That 'Internet of Things' Thing, in the real world things matter more than ideas," RFID Journal, 22 June 2009.

[2]

OPENLIGHT, "fLUMENS," [Online].

Available: http://www.openlight.nl/flumens. [Accessed 10 January 2014].

[3]

E. Callaway, "TO CATCH A WAVE," NATURE, pp. 156-159, 8 November 2007.

[4]

S. J. Raymond , "Wave Energy Conversion Systems Designed for Sensor Buoys," Electro Standards Laboratories, [Online].

Available: http://www.electrostandards.com/ProductDetail/?productid=2291.

[Accessed 10 1 2014].

[5]

Photonis, "Electro-Optics Handbook," [Online]. Available: http://www.photonis.com/attachment.php?id_attachment=95.

[Accessed 9 10 2013].

[6]

Light-Emitting-Diodes-dot-org, "Light-Emitting-Diodes-dotorg," [Online]. Available: http://www.ecse.rpi.edu/~schubert/LightEmitting-Diodes-dot-org/Sample-Chapter.pdf. [Accessed 9 10 2013].

[7]

Farnell, "Listing of commerically available LEDs.," [Online].

Available: http://nl.farnell.com/jsp/search/browse.jsp?N=204192&Ns=P_ATT_ BASE_VALUE_1000024_EN_GB%7C0&locale=nl_NL&appliedp arametrics=true&getResults=true&suppressRedirect=true&isRedirec t=&originalQueryURL=/jsp/search/browse.jsp%3FN%3D204192%2 6No%3D0%26getResults%3D. [Accessed 9 10 2013].

[8]

Analog Devices, "UNDERSTANDING HOW VOLTAGE REGULATORS WORK," [Online].

Available: http://www.analog.com/en/content/ta_fundamentals_of_voltage_reg ulators/fca.html. [Accessed 9 10 2013].

[9]

S. H. Salter, "Wave power," Nature, pp. 720-724, 21 June 1974.

[10]

P. D. Mitcheson, E. M. Yeatman, K. Rao, A. S. Holmes and T. C. Green, "Energy Harvesting From Human and Machine Motion for Wireless Electronic Devices," in Proceedings of the IEEE, 2008.

[11]

S. Priya and D. Inman, Energy Harvesting Technologies, New York: Springer, 2009.

[12]

W. J. Wu and B. Bor Shiun Lee, "Piezoelectric MEMS Power Generators for Vibration Energy Harvesting," intech, 2012.

[13]

S. Boisseau, G. Despesse and B. Ahmed Seddik, "Electrostatic Conversion for Vibration Energy Harvesting," Small-Scale Energy Harvesting, 31 October 2012.

[14]

I. L. Baginsky and E. G. Kostsov, "High Energy Density Capacitance Microgenerators," Small-Scale Energy Harvesting, 31 October 2012.

[15]

S. Meninger, J. O. Mur-Miranda, R. Amirtharajah, A. P. Chandrakasan and J. H. Lang, "Vibration-to-electric energy," IEEE Trans.Very Large Scale (VLSI) Syst., p. 64â&#x20AC;&#x201C;76, February 2001.

[16]

P. Wang, K. Tanaka, S. Sugiyama, X. Dai and X. Z. Jingquan Liu, "A micro electromagnetic low level vibration energy harvester based on MEMS technology," Microsystem Technologies, 16 April 2009.

APPENDIX B Feasibility inquiry

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

Wave ≈ Energy Project proposal for a light installation powered by micropower energy harvesters Arvid Jense OPENLIGHT, Intelligent Lighting Institute http://www.openlight.nl/ ; http://bit.ly/19jyx1h Technical University Eindhoven a.jense@student.tue.nl +31 6 4980 4158

Abstract—A light installation using micropower energy harvesters is proposed. The energy harvesters would need to generate at least 40µW/cm2 to create a clearly visible light installation in an urban environment. State of the art energy harvesters manage to produce 100µW/cm2, but these are not commonly available. This means key for the feasibility of this project is a partnership with a developer of energy harvesters.

I. INTRODUCTION OPENLIGHT, the creative lab of the Intelligent Lighting Institute at the TU/e proposes an interactive light installation based on energy harvesting. This installation is to be placed at the Luminale lighting biennale at the Messe Frankfurt, the biggest lighting fair in Europe, with the option of being exhibited at other international events.

Joining this project as a partner would be an interesting opportunity to demonstrate the achievements of recent research endeavors. The project could functional as a demonstrator for future applications of energy harvesters in a more conceptual environment. As such it could interest potential investors and costumers in the technology.

To give an overview of the feasibility of this project and to inform potential partners of the essential constraints in joining this project, firstly the concept of the installation will be explained after which the feasibility is examined.

Fig. 1. A visitor throws an object into a still body of water

II. CONCEPT We propose an installation powerful in its effect, state of the art in its technology and clear in its concept. A net of light devices is laid down in a body of water, when a person disturbs the water, the wave pattern will be translated in to light by the light devices by converting the energy of motion of the wave directly into electrical energy to power LEDs. This is shown in Fig. 1 and Fig. 2. To keep this coupling a direct as possible, it is desirable not to use any type of energy storage.

Fig. 2. Waves of light appear.

To realize this concept a big number of individuallyoperating light devices will have to be created as shown in Fig. 3. These will individually be connected through a net. The amount of devices will be dependent on the amount of light generated by each device, but a number of 100 devices per square meter is to be expected. A total surface of at least 4m2 is desired.

A micropower energy harvester is used to convert the energy of water motion into electrical energy. Which type of energy harvester is to be used will be considered in the feasibility part of this document.

Power conditioning is most probably needed as the electricity generated might not have the right properties to effectively power the light source.

The most likely candidate for a light source this is a high efficiency LED.

9-10-2013

Working generators have been reported to generate up to 100µW/cm2 [6].

While this type of micropower energy harvester seems to be sufficient for powering this light installation, there are no commercially available energy harvesters with this kind of performance. The only way to acquire these would be through a partnership with a developer of energy harvesting technology.

A side note to these numbers is that these values are calculated in perfect laboratory conditions, it is up for testing whether these levels could be reached through human created waves in water.

A

B C

Fig. 3. Basic structure of the installation, with the green part (C) being the energy harvester, the orange part (B) containing the power conditioning and the white part (A) being the light source.

III. FEASIBILITY A. Light source To keep the requirements within reasonable limits, the installation should be placed in a dark urban environment. As such surrounding area will have an ambient luminance of approximately 0.1 lux [1] in this scenario. For the installation to be plenty visible, it should produce about 1 lux at peak level to the visitors. This is around the luminance at which the human eye’s photopic vision regime starts, meaning the installation will be seen clearly and without adaptation issues [2].

A typical low energy LED produces about 5 cd/W [3]. To get the desired amount of light with such LEDs, about 20µW/cm2 at peak is needed.

The number of LEDs used in the installation is dependent on type used. If the led with the lowest power consumption of 1mW and a light output of 5mcd is used, 2000 lights per square meter are needed. While a more intense light using 20mW and generating 100mcd would need 100 lights per square meter.

White LEDs function at 3.6V DC, meaning either the energy harvester will need to generate this voltage, or power conditioning has to be used to get this voltage..

B. Power conditioning Different power conditioning methods are available to drive the LED, but all of these have energy loss. We’ll estimate the efficiency of power conditioning at 50% [4], bringing the energy requirement up to 40µW/cm2.

C. Energy harvester The most likely energy harvesting methods to use in this project are piezoelectric generators and MEMS generators, where the first has been estimated to achieve up to 350mW/cm2, and the second of up to 400mW/cm2 [5]. These generators are still in an early stage of development and current devices only generate several orders of magnitude less energy.

IV. CONCLUSION A general analysis shows that the light installation would be possible using state of the art micropower energy harvesters.

Though considering that the technology is still in its developmental phase, the feasibility of this project is highly dependent on a potential partnership. The installation could be a demonstrator and educational project for the current state of research and could function as a showcase for attracting new investors.

[1]

V. REFERENCES Photonis, "Electro-Optics Handbook," [Online]. Available: http://www.photonis.com/attachment.php?id_attachment=95.

[Accessed 9 10 2013].

[2]

Light-Emitting-Diodes-dot-org, "Light-Emitting-Diodes-dot-org," [Online]. Available: http://www.ecse.rpi.edu/~schubert/LightEmitting-Diodes-dot-org/Sample-Chapter.pdf. [Accessed 9 10 2013].

[3]

Farnell, "Listing of commerically available LEDs.," [Online].

Available: http://nl.farnell.com/jsp/search/browse.jsp?N=204192&Ns=P_ATT_B ASE_VALUE_1000024_EN_GB%7C0&locale=nl_NL&appliedparam etrics=true&getResults=true&suppressRedirect=true&isRedirect=&ori ginalQueryURL=/jsp/search/browse.jsp%3FN%3D204192%26No%3 D0%26getResults%3D. [Accessed 9 10 2013].

[4]

A. Devices, "UNDERSTANDING HOW VOLTAGE REGULATORS WORK," [Online]. Available: http://www.analog.com/en/content/ta_fundamentals_of_voltage_regula tors/fca.html. [Accessed 9 10 2013].

[5]

W. J. Wu and B. Bor Shiun Lee, "Piezoelectric MEMS Power Generators for Vibration Energy Harvesting," intech, 2012.

[6]

HOLST centre, "HOLST executive report," [Online]. Available: http://www.holstcentre.com/~/media/Files/Holst_ER2012_DEF_lowre s.ashx. [Accessed 9 10 2013].

[7]

http://sbp.so/, "What distance is a firefly visible from?," [Online].

Available: http://sbp.so/firefly. [Accessed 9 10 2013].

9-10-2013

APPENDIX C Schematics

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

17-1-2014 4:45:32 f=5.00 D:\Documents\eagle\Openlight light net v1\Openlight light net v2_3.brd

17-1-2014 4:44:12 D:\Documents\eagle\Openlight light net v1\Openlight light net v2.sch (Sheet: 1/1)

APPENDIX D Code

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

#include <avr/io.h> #include <avr/interrupt.h> #include <TinyWireM.h>

// I2C Master lib for ATTinys which us

#define MMA8653FC_ADDR 0x1D// 7 bit I2C address for MMA8653FC //Define a few of the registers that we will be accessing #define WHO_AM_I 0x0D #define DEV_ID 0x5A #define OUT_X_MSB 0x01

#define XYZ_DATA_CFG 0x0E #define CTRL_REG1 0x2A

#define GSCALE 2// Sets full-scale range to +/-2, 4, or 8g. Used to calc real #define #define #define

LED_B LED_G LED_R

4// ATtiny Pin 3 1// ATtiny Pin 6 3// ATtiny Pin 2

B G R

#define RESOLUTION 8

int

accelCount[3];// Stores the 12-bit signed value

const int numReadings = 4; int readingsX[numReadings];// the readings from the analog input int indexX = 0;// the index of the current reading int totalX = 0;// the running total int averageX = 0; int readingsY[numReadings];// the readings from the analog input int indexY = 0;// the index of the current reading int totalY = 0;// the running total int averageY = 0; int int int int

readingsZ[numReadings];// the readings from the analog input indexZ = 0;// the index of the current reading totalZ = 0;// the running total averageZ = 0;

int analogR = 0; /*

int readingsXY[numReadings]; // the readings from the analog input int indexXY = 0; // the index of the current reading int totalXY = 0; // the running total int averageXY = 0; */ void setupTimer1(void (*isrPointer)(void)); void setup(){ pinMode(LED_B,OUTPUT); pinMode(LED_G,OUTPUT); pinMode(LED_R,OUTPUT); digitalWrite(LED_B,HIGH); digitalWrite(LED_G,HIGH); digitalWrite(LED_R,HIGH); //Blink(LED_B,2); TinyWireM.begin();

// show it's alive // initialize I2C lib Init_MMA8653FC();// Setup MMA8653FC

// initialize all the readings to 0: for (int thisReading = 0; thisReading < numReadings; thisReading++) readingsZ[thisReading] = 0; setupTimer1(myISR);//set timer1 up to call myISR every 10ms }

void loop(){ //updateSoftPWM(); readAccelData(accelCount);// Read the x/y/z adc values /* averagingZ(); averagingXY(); analogWrite(LED_B,averageZ); analogWrite(LED_G,averageXY); */ averagingX(); averagingY(); averagingZ(); //analogR=RESOLUTION/2; analogR=map(averageZ,0,255,0,RESOLUTION); //analogWrite(LED_G,averageY); //analogWrite(LED_B,averageZ);

//softPWM(((2*average)/8));

//analogWrite(LED_B,(abs(accelCount[2])-127)*2); //analogWrite(LED_G,((abs(accelCount[2])-127)*2)-(255-(abs(accelCount[0])+

/* softPWM(16-(accelCount[0]/32)); analogWrite(LED_G,255-(abs(accelCount[1])/2)); analogWrite(LED_B,255-(abs(accelCount[2])/2)); */ delay(10); }

void Blink(byte led,byte times){// poor man's GUI for (byte i=0; i< times; i++){ digitalWrite(led,LOW); delay (400); digitalWrite(led,HIGH); delay (175); } } void readAccelData(int *destination) { byte rawData[6];// x/y/z accel register data stored here

readRegisters(OUT_X_MSB, 6, rawData);// Read the six raw data registers in

// Loop to calculate 12-bit ADC and g value for each axis for(int i = 0; i < 3 ; i++) { signed long gCount = (rawData[i*2] << 8) | rawData[(i*2)+1];//Combine th gCount >>= 6;//The registers are left align, here we right align the 12-b

// If the number is negative, we have to make it so manually (no 12-bit da if (rawData[i*2] > 0x7F) { //gCount -= 127;//not sure if +1 is needed gCount = ~gCount + 1; gCount *= -1;// Transform into negative 2's complement # } destination[i] = gCount;//Record this gCount into the 3 int array } } // Read a single byte from addressToRead and return it as a byte byte readRegister(byte addressToRead) {

TinyWireM.beginTransmission(MMA8653FC_ADDR); TinyWireM.send(addressToRead); TinyWireM.endTransmission(false); //endTransmission but keep the connection

TinyWireM.requestFrom(MMA8653FC_ADDR, 1); //Ask for 1 byte, once done, bus while(!TinyWireM.available()) ; //Wait for the data to come back return TinyWireM.receive(); //Return this one byte } void readRegisters(byte addressToRead,int bytesToRead,byte * dest) { TinyWireM.beginTransmission(MMA8653FC_ADDR); TinyWireM.send(addressToRead); TinyWireM.endTransmission(false); //endTransmission but keep the connection TinyWireM.requestFrom(MMA8653FC_ADDR, bytesToRead); //Ask for bytes, once

while(TinyWireM.available() < bytesToRead);//Hang out until we get the # of for(int x = 0 ; x < bytesToRead ; x++) dest[x] =TinyWireM.receive(); }

// Writes a single byte (dataToWrite) into addressToWrite void writeRegister(byte addressToWrite,byte dataToWrite) { TinyWireM.beginTransmission(MMA8653FC_ADDR); TinyWireM.send(addressToWrite); TinyWireM.send(dataToWrite); TinyWireM.endTransmission(true); //Stop transmitting } void Init_MMA8653FC(){ int c = readRegister(WHO_AM_I); if (c== DEV_ID) Blink(LED_G,1); else Blink(LED_R,1); MMA8452Standby();// Must be in standby to change registers // Set up the full scale range to 2, 4, or 8g. /* byte fsr = GSCALE; if(fsr > 8) fsr = 8; //Easy error check fsr >>= 2; // Neat trick, see page 22. 00 = 2G, 01 = 4A, 10 = 8G writeRegister(XYZ_DATA_CFG, fsr); */ writeRegister(XYZ_DATA_CFG, 00);

//The default data rate is 800Hz and we don't modify it in this example code MMA8452Active();// Set to active to start reading }

// Sets the MMA8452 to standby mode. It must be in standby to change most regi void MMA8452Standby() { byte c = readRegister(CTRL_REG1); writeRegister(CTRL_REG1, c & ~(0x01));//Clear the active bit to go into sta } // Sets the MMA8452 to active mode. Needs to be in this mode to output data void MMA8452Active() { byte c = readRegister(CTRL_REG1); writeRegister(CTRL_REG1, c | 0x01);//Set the active bit to begin detection } void averagingX(){ // subtract the last reading: totalZ= totalZ readingsZ[indexZ]; // read from the sensor: readingsZ[indexZ] = (abs(accelCount[2])-127)*2; // add the reading to the total: totalZ= totalZ + readingsZ[indexZ]; // advance to the next position in the array: indexZ = indexZ + 1; // if we're at the end of the array... if (indexZ >= numReadings) // ...wrap around to the beginning: indexZ = 0; // calculate the average: averageZ = totalZ / numReadings; // send it to the computer as ASCII digits } void averagingY(){ // subtract the last reading: totalZ= totalZ readingsZ[indexZ]; // read from the sensor: readingsZ[indexZ] = (abs(accelCount[2])-127)*2; // add the reading to the total: totalZ= totalZ + readingsZ[indexZ]; // advance to the next position in the array: indexZ = indexZ + 1;

// if we're at the end of the array... if (indexZ >= numReadings) // ...wrap around to the beginning: indexZ = 0; // calculate the average: averageZ = totalZ / numReadings; // send it to the computer as ASCII digits } void averagingZ(){ // subtract the last reading: totalZ= totalZ readingsZ[indexZ]; // read from the sensor: readingsZ[indexZ] = (abs(accelCount[2])-127)*2; // add the reading to the total: totalZ= totalZ + readingsZ[indexZ]; // advance to the next position in the array: indexZ = indexZ + 1; // if we're at the end of the array... if (indexZ >= numReadings) // ...wrap around to the beginning: indexZ = 0; // calculate the average: averageZ = totalZ / numReadings; // send it to the computer as ASCII digits } /* void averagingXY(){ // subtract the last reading: totalXY= totalXY readingsXY[indexXY]; // read from the sensor: readingsXY[indexXY] = abs(accelCount[0])+abs(accelCount[1]); // add the reading to the total: totalXY= totalXY + readingsXY[indexXY]; // advance to the next position in the array: indexXY = indexXY + 1; // if we're at the end of the array... if (indexXY >= numReadings) // ...wrap around to the beginning: indexXY = 0; // calculate the average: averageXY = totalXY / numReadings; // send it to the computer as ASCII digits averageXY = map(averageXY,64,0,255,averageZ);

} */ void myISR() static uint8_t timerLocation;

{//this function will be called every 10ms

if(analogR>timerLocation)digitalWrite(LED_R, LOW); else digitalWrite(LED_R, HIGH); /* if(analogG>timerLocation)digitalWrite(LED_G, LOW); else digitalWrite(LED_G, HIGH); if(analogB>timerLocation)digitalWrite(LED_B, LOW); else digitalWrite(LED_B, HIGH); */ timerLocation++; if(timerLocation>RESOLUTION)timerLocation=0; } //Copy code from here down, AND uncomment the following line and move it near //void setupTimer1(void (*isrPointer)(void)); //function prototype for void (*userISR)(void); //pointer to the user's ISR

void setupTimer1(void (*isrPointer)(void)) { userISR = isrPointer;//save the pointer to the user's ISR //set timer1 up to generate an interrupt every millisecond TCCR1 |= _BV(CTC1);//clear timer1 when it matches the value in TIMSK |= _BV(OCIE1A);//enable interrupt when OCR1A matches the ti sei();//enable global interrupts OCR1A = 62;//set the match value for interrupt OCR1C = 62;//and the same match value to clear the timer #if F_CPU == 1000000//1MHz system clock TCCR1 |= _BV(CS12);//set prescaler to divide by 8 (this starts #elif F_CPU == 8000000//8MHz system clock TCCR1 |= _BV(CS12) | _BV(CS11) | _BV(CS10);//set prescaler to divide by #else Clock must be 1MHz or 8MHz!//Error, only 1MHz or 8MHz clock (F_CPU) sup #endif } ISR(TIMER1_COMPA_vect) {

//handles the Timer1 Compare Match A inter

userISR();//and call the user's ISR }

APPENDIX E SMD instructable

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

Food

Living

Outside

Play

Technology

Workshop

Soldering tiny SMD components the easy and fast way (with a hotplate)

by ArvidJense on January 16, 2014

Table of Contents Soldering tiny SMD components the easy and fast way (with a hotplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Intro: Soldering tiny SMD components the easy and fast way (with a hotplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Step 1: Gather parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Step 2: Dispense some solder paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Step 3: Apply paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Step 4: Add the first component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Step 5: Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Step 6: For the really tiny parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Step 7: Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Step 8: Test and cheer! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Author:ArvidJense

My portfolio I'm a Dutch guy doing things with music and technology. At the moment I'm finishing my BSc in Industrial Design Engineering as well as my BAMus with Honours in MediaMusic. Not limiting myself to any genre or discipline, I like to work on anything related to music, design, technology, research... You can contact my by sending an email to: arvid@arvidjense.com

Intro: Soldering tiny SMD components the easy and fast way (with a hotplate) I've being doing electronics for a little while and while SMD components seemed to provide a lot of advantages, I was intimidated by their small size; "how the hell do I solder that?" But as I wanted to use a specific tiny accelerometer for my project, which only came in the minuscule 2x2mm (about 150 of these fit into an M&M!) I was forced to learn it. And to my surprise, it was even more easy an foolproof than normal soldering! This Instructable shows you step by step the process of soldering a small SMD PCB. Total time of doing it is under 5 minutes, even less when you get some practice.

For this Instructable I skip the part of designing the PCB and sourcing the parts, just to focus on the soldering part. If you have any questions on design, manufacture or sourcing, don't fret to ask! And if this Instructable helped you, don't forget to vote ;)

Step 1: Gather parts Before you start, make sure you've got all stuff you need: A hotplate that can be set to a temperature of 250-350ยบC (I was very lucky to have access to a Weller station, but anything with an adjustable temperature range will work) Solder paste (Flux is not necessary as its already in the paste, but it can make fixing mistakes a lot easier) Precision tweezers An object to apply the solder paste with, this can be anything thin and rigid, I chose to use a jumper wire All of your components The PCB to put everything on

Image Notes 1. A tube of flux 2. My tube of solder paste 3. Precision tweezers

Image Notes 1. This stuff is small!

4. My PCB 5. The hotplate 6. My tiny SMD components 7. The jumper wire I used to apply the solder paste

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Step 2: Dispense some solder paste Now find a (discardable) piece of plastic and put a little blob of solder paste on it. A blob the size of a 3mm LED was enough for my board.

Step 3: Apply paste Use your 'applicator' of choice (the jumper wire in my case) to grab a tiny bit of solder any apply it to one of the solder pads on your PCB. To make things a bit easier, I chose to start from the centre of the board outwards and with the biggest parts before the smallest. The amount of solder paste needed is very little, but make sure there definitely is a little blob standing up on the pad.

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Step 4: Add the first component Now grab your tweezers, grab the component for you pad you just applied solder paste to and drop it into place. Gently push it into the paste to be sure it won't move. Be careful that you oriented the component right!

Step 5: Repeat Now simply repeat the previous steps for all the other components. Whether your apply all the solder paste first and then place all the components at the same time or apply and place for each component individually is up to you. To keep things interesting, I like to take a group of components of a similar size and place those at the same time. I work from the largest to the smallest components, which allows me to gradually increase precision and concentration; when I arrive at the really small components, I've already practiced on the large ones!

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Step 6: For the really tiny parts One of the components on my board is a 2x2mm accelerometer with 10 pins. The pins were so small that I was not able to individually dip the pads. After some trial and error of having to little or too much solder I figured out an (almost) fail-proof method. You take a tiny bit of solderpaste and apply it in between and on the sides of the pad.

The capillary action when soldering will make sure that all the solder is pulled onto the pads and you're sure that you didn't add too much solder. To help this action, I like to apply a little extra droplet of flux. This really makes the component float and pull towards the right pads.

When the solder and flux is in place, simply put the tiny part in place and you're ready to do the actual soldering!

Step 7: Soldering Everybody who has ever tediously soldered a complex strip-board design will love this step. Set your hot plate to the right temperature, I chose 270ยบC, but depending on you components and solder paste you might want to use a different temperature.

Carefully put your board on the hotplate with tweezers, making sure the components don't move. Now the magic happens! After a little while you can see the solder paste becoming fluid and really grabbing the parts into place. Check if all the components are in the right place while the solder is still fluid, and if they're not (like with the tiny parts being just one pin offset) push them into place with your tweezers.

Once you're sure everything is in place, carefully take your board with tweezers and put it on a heat resistant surface.

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Step 8: Test and cheer!

After the board has been cooled, test it! If everything went right and the board programs and/or the LEDs light up, you'll be very happy! If it does not work immediately, take a good look at all the solder pad and use a multimeter to figure out if any connections shorted or didn't connect at all. If this happened you can simply put the board on the hotplate again and add/remove some solder on the place an error occurred. Something you need to look out for is that the PCBs will slightly warp from the heat, this means that the second time you put a PCB on the hotplate, the edges might not touch the plate and it will take longer for the solder to heat up in those areas.

I was very happily please with how easy and error-free this process went and I hope this Instructable will help you as well!

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

Advertisements

http://www.instructables.com/id/Soldering-tiny-SMD-components-the-easy-and-fast-wa/

APPENDIX F Reflection

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

Reflection OPENLIGHT project Arvid Jense M1.1

Project reflection What was the event?

The OPENLIGHT project in M1.1. Starting at a broad brief, I designed and prototyped a lighting installation now ready for production. The project heavily focused on the technical realization phase.

More details can be found in the project report.

What was I expecting to learn (if appropriate)?

I’ve entered this project to both get immersed in the world of lighting (technology) as well as to have the budget and clear goal to be able to take my design into a functioning production series. I expected to get more experience in working solo on projects. I also expected to be able to make use of the universities recourses to further my expertise.

What have I learned?

The clearest achievement is that I indeed learned how to make my own PCBs. I got the basics of designing them, transferring them to Eagle software, prepare them for manufacturing, order them, order parts, assemble the whole and program it. It was very refreshing that the whole process went very smoothly.

Working by myself was harder than I expected. Where it allowed me to make design decisions very quickly, it also made keeping a clear schedule harder. I missed being able to discuss certain things with my peers. I could still do this with fellow students, but as they weren’t involved with the actual project, it wasn’t possible to go as in-depth as I would have liked.

Dealing with a client can be very tricky. There are so many design decisions to be made, yet so little time to discuss them. This project gave me a lot of experience of what to communicate and what not. It also made it clear that it is my job to keep the client updated on the status of the project, he/she is ultimately only interested in the end result, but if that is not what he/she had in mind, I am the one who has to fix it.

What is significant about this learning for me?

After this project I am able to independently develop and manufacture my own series electronic devices.

I have gained a lot of experience in the TU/e ID educational system.

How does this learning link to the competencies for my job?

Integrating Technology (IT): A huge part of the project was on learning how to make high-fidelity prototypes and products of electronics. These skills are are enormously important in the world of designing smart product as it removes the need of hiring an electrical engineer to do this part.

Ideas and Concepts (IC), Form and Senses (FS): While the concept phase has been kept short, it was an interesting experience to see what happens if not all alternatives are though through and choices are made on quick tests. For future projects, I would like to give this part a little more attention, as some details were still not 100% clear for myself at the end of the project.

Reflection OPENLIGHT project Arvid Jense M1.1 Design and Research Processes (DRP): As this project was designated as the masters research project, the research was a big part of the process. I formed it into a feasibility study. While the results were ultimately not useable for the project itself, it was a good experience; sometimes the result of research is that something is just not possible or true.

Descriptive and Mathematical Modelling (DMM): Both simulating the behavior of the design and programming the actual device involved a lot of programming in various languages. These include C++, Arduino and Processing. A major achievement was identifying an issue in the i2c library and repairing it directly.

How will this learning change my practice?

As been stated, I am nu able to quickly create professional quality prototypes for electronic devices.

I know myself a lot better in the face of longer term projects. I know I need to keep myself on the edge with both long and short term goals. I need to avoid hanging too long on decisions that donâ&#x20AC;&#x2122;t matter too much and spend more time on important but scary decisions.

What were my feelings about what happened?

While there were some frustrating moments during the process, I feel quite content about the end result. It is not completely finished, as the design is planned for production for the Amsterdam Light festival in the end of 2014. While I would have liked some more collaboration with peers, this did happened in the modules, where the project is meant to be solitary.

What went well?

I made good use of the resources of the university. I worked extensively in the /d.search-labs where I used the tools and talked to the experts. Their expertise was essential in getting the PCB right on the first try. Even though I did not make any mistakes, it is very pleasant to just be able to run some basic design decisions past someone.

The short concepting phase was enough to work on for the rest of the project. A lot of group project I have been in resulted in a lot of talk on different concepts, only to end up with a compromise. In the way performed in this project, a lot less time was wasted and the result didnâ&#x20AC;&#x2122;t suffer.

My initial time planning worked out pretty well. I set relatively large buffer periods, as I know I usually underestimate tasks. These were used, but I finished everything in time and without a huge amount of stress.

What didnâ&#x20AC;&#x2122;t go so well?

I underestimated the magnitude of a lot of single tasks. For instance, I expected to be able to transfer the PCB to Eagle in two days, while this took almost a week in reality. Also some issues with Arduino took a lot more time to be fixed than I would like. It stays important to put time in the planning for these sort of issues.

At some point motivation dropped, this was when there were hard-to-fix problems and no clear goals. While at some other points, when the goals were clear, I did not want to stop working at all.

What were the feelings of others involved?

Reflection OPENLIGHT project Arvid Jense M1.1 The client was pleased with the results, but didnâ&#x20AC;&#x2122;t give much reflection on the process. The coach was impressed with my work ethics and results, but presses me to be careful in presentation and communication. The people at /d.search-labs were impressed by the technical level of my project.

What evidence do you have?

The physical prototype, photographs thereof, the digital design files, feedback from the coach.

APPENDIX G Demo day poster

OPENLIGHT waveNETv0.1 Arvid Jense TU/e ID M1.1

waveNET v0.1

L i g ht. Ti m e. S p a ce. M ove

“Throw something into the water, and see the waves.”

concept Micro-energy harvesting

MEMS

Solar

Not feasible at the present

Piezoelectric

research

electronics Arvid Jense s135438

Coach: Cindy van den Bremen Assessor: Menno Stoffelsen