P08456-LED Lighting for an

Underwater ROV
Jeremy Schiele-Project Manager
Jonathan Lent-Mechanical Engineer
Ryan Seeber-Computer Engineer
Justin VanSlyke-Mechanical Engineer
Benoit Hennekinne-Electrical Engineer

Sponsored by:

P08456-Project Description
End Users: Underwater ROVs and RITs
robotic platforms (RP-1, 10, 100)
Waterproof light for underwater exploration
Top Level Requirements (eng. Specs):

Waterproof design (min. 400 ft depth)

High light output (min 250 lm @ 5 Watts)
Low power consumption (max. 10 Watts)
Controllable from remote surface unit
Modular housing design must be able to house
thrusters motor unit as well

P08456-Light Unit Concept

Watertight bulkhead
electrical connector
Corrosion resistant
aluminum housing
Two LED colors available
Light unit controllable
from surface
Two mounting systems
available

P08456-Thruster Housing Concept

Utilizes the same rear portion as LED light

unit, bulkhead connector, and PCB assembly

P08456-Mounting System Concept

Two mounting systems to meet
specific requirements for each
housing application

Light = Adjustability
Thruster = Rigidity

P08456-Functional Flowchart
Battery
Power

Convert battery
power into
required voltage

Provide LEDs
w/ correct amt.
of power

Light

Heat
User
Input

Process
Input

Send PWM
to LED
driver

Receive data
from Temp.
sensor

Temp.
Data

P08456-Summary of Design
Review
Continue to meet
with customer to
fine tune housing
design
Breadboard of
electrical
components is next
step for verification

P08456-High Risk Areas

Risk: Pressure & Sealing
Requirements

Operation pressure: 216

psi (500 ft)
All leak-points need to
be verified and secured

Mitigation:

FEA analysis of housing

design
Pressure chamber
testing of prototype at
Hydroacoustics Inc.

Risk: Heat Dissipation

LED board produces up

to 10 watts of heat
Can cause premature
failure for LEDs and
damage other
electronics

Mitigation:

Thermal resistance
analysis of LED board
Separate LEDs from
other electrical
components
LED board will have
extra thick copper
traces to evacuate heat

P08456-Product Development Phase

Phase 0: Planning
Phase 1: Concept Development
Phase 2: System Level Design
Phase 3: Detailed Design
Phase 4: Testing & Refinement
MSD I
0

MSD II
3

Current Phase of Development

Final
Production
Units

P08456-Current State of Design

Spec. Customer
Design Specification
Number Need No.
1
3
Low wattage LED system
2
3
Low heat generation from LEDs
3
1, 2
Luminous flux
4
2
Multi-spectrum light
5
5, 6
Enclosure size
6
6, 7
Assembly/Disassembly mount
7
8
MicroController voltage
8
8
Board Voltage
9
8
LED Voltage Power
10
1
LED Current
11
10
Submergable (water tight seals)
12
10
Pressure resistant
13
4
Preservation of open architecture
14
9
Preservation of open source system
Lights & thrusters contolled by 1
15
8
software package

Importance
Unit of Measure Marginal Value
Ideal Value
Final Design Value
(1 < 5)
5
watts/ fixture
10
5
3.30 @ 350 mA (12 max)
5
watts/ fixture
2.8
1
2.41 @ 350mA (7.65 max)
5
lumen/ fixture
250
350
300 @ 350 mA (675 max)
3
NA
White + 1 color White + 2 colors
White + 1 color
4
in x in x in
3x3x6
2x2x4
2.75 dia x 4.5
3
sec
90
60
TBD
4
volts
5
3.3
5
4
volts
5
3.3
5
4
volts
24
7.6
24 (driver) 3.15 (LED)
5
amp
1
0.7
1
5
ft
400
500
500 est.
5
psi
170
216
216 est.
4
y/n
y
y
y
4
y/n
y
y
y
5

y/n

TBD

Current design meets all specs possible at this point in development

P08456-Current Budget

Cost / LED light unit: $380.87

Cost / thruster housing unit: $323.69
Development & bread board: $200.00
Prototype Unit: $150.00

Total Light Unit Budget: $1873.48

Product provided to P08454: $1295.00

P08456-MSDII Schedule Milestones

12/7 Machine Drawings finalized for CNC
12/12 All off-the-shelf parts ordered by
12/14 Housing prototypes made
1/13 Pressure, light, and PCB testing
complete
2/18 Documentation complete (EDGE, tech
paper, poster)
2/20 Production of 8 units completed
2/22 Final Project Review