Energieonderzoek

SYN-Energy: The application of photovoltaic (PV) cell – energy storage combinations as power sources in consumer and professional products at both outdoor and indoor utilizations

(2003-2008)

Aanvragers:
Prof.dr.ir. J.C. Brezet, TUD
Prof.dr. W.C. Turkenburg, UU
Prof.dr. W.C. Sinke, ECN
Prof.dr.ir. R.E.H.M. Smits, UU
Dr. J. Jelsma, UT

Uitvoerder:
Dr. S.Y. Kan, TUD
Student Assistant (TUD)
Research Assistant (TUD + ECN)
Dr. S. Silvester, TUD
Ir. M. Veefkind, TUD
Drs. N.H. Reich, UU
Drs. E. Alsema, UU
Dr. W. van Sark, UU
Dr. B. Elzen, UT

Overall aim

The goals of the SYN-ergy project have been achieved to a large extent. An outstanding integration of the complementary knowledge of the four involved institutes has taken place, the required multidisciplinary cooperation has been good, the scientific findings have been published internationally on a broad basis, several demo-products have been designed, prototyped and tested, and a dissertation has been completed. The second planned dissertation is well on its way, but the completion time will be in 2010. Moreover, a patent has been endorsed for the PV-battery integration and 9 master theses completed.
The societal impact of the program has been high, particularly within the framework of the Energy Valley transition program, leading to regional PV-based networks and programs, such as Fryseps, the Northern Solar Alliance and the PV-embedded program of the universities of Delft and Twente with the NHL University for professional education. Likewise, the results of the program have been integrated in several courses in the curricula of TUD, UU and UT. In addition, based and building upon the findings from the SYN-ergy project, new research is being executed and planned in the area, both within individual universities and with the involved partners together.

The Solar Mio computer mouse has been the integrating end product of the SYN-Energy program. The first half year of 2007 the emphasis was on the design and making and of the prototype of the Solar Mio (Delft + Utrecht). Than the test samples for the user tests were assembled (Delft + Utrecht). In 2007 September till December user tests were conducted with the Solar Mio.  In total 14 participants at 3 locations: Delft. Utrecht and Twente have tested the Solar Mio in their daily computer use. The tests varied from 4-6 weeks to 10-12 weeks. One test still continues: The Dutch Minister of Environment, Dr. Jacqueline Cramer, has the Solo Mio at her office for further exploration, but no definite results are known yet (the Minister used to be university researcher).

Dissemination of results

At Delft University of Technology several Lectures and Design Exercises were using the knowledge gathered during the SYN-Energy program, such as the LCED course, the 3TU SET Curriculum and the ECO Design Minor. Over the years ca. 800 masters students have been confronted at all Delft faculties with the SYN-Energy knowledge output, in different phases. In addition, it is estimated that TU Delft staff alone gave ca. 100 national and international lectures on the program and it’s results. About 20 Master Graduation projects have been conducted using the knowledge gathered during the SYN-Energy program.
Applied universities, such as the NHL in Leeuwarden, are including SYN-ergy outcomes in their curricula. A popular PV-design book is on it’s way with SYN-ergy as point of departure (Dr. C. Bakker, TU Delft). The relevance of this project is on two main dimensions, notably (1) the application of PV to help achieving sustainability and (2) incorporating user aspects in the design of products so that they actually serve user needs while at the same time contributing to sustainability goals.

Other indicators of societal relevance, co-created by the SYN-ergy project:

  • The creation of the PV-embedded program (NHL, TU Delft, UTwente)
  • The Fryseps PV-product design research program, under Energy Valley
  • The rapid increase in PV-based master graduation projects with companies and for developing countries
  • The possibility of PV-integrated products for the Afsluitdijk, considered by the Dutch government
  • The Frisian program on integration of PV in the design of small boats
  • In general: far more attention of governmental climate programs at the regional, national and EU-level for PV-integration into products, services and installations.

Knowledge from the program has been extensively transferred via publications, various other media, the Klankbordgroep, workshops, national and international symposia, meetings with government, new networks like Fryseps and Energy Valley etc. By presenting the fysical end-result of the project, the Sole Mio design,  to the Minister of Environment, Dr. J. Cramer, extra attention from the top-level could be gained. The role of the Klankbordgroep has been important, not only in commenting the research but also in dissemenation of the results to industry.  A first meeting with the advisory board (klankbordgroep) was organized in the fall of 2004. Representatives from a PV-industry (AKZO-Nobel), a Consumer Goods Producer (Philips), a Design Consultancy (Kemna & Holsteijn) and three (PV-) product developers (Epyon, Dream Control & True Solar Autonomy) are a member of this board. It was a stimulating exchange of information that provided us with various ideas that are relevant in developing a product useful for ‘the real world’ (rather than just a scientifically interesting prototype).  The members of the board have been involved further during the later stages of the program in 2006 with more concrete research results and the evaluation prototypes of the Solar Mio.

Results

Introduction
Worldwide there is a growing need for electrical energy to be used in mobile consumer and professional electronic products in a combined indoor and outdoor user context. Solar or photovoltaic (PV) cells could play an important role in fulfilling this need sustainably.
Although consumer products powered by PV cells are already on the market, the integration of the technology in a product is still problematic for product designers.
The requirements for PV application in consumer products are different from existing (large) PV systems. Designers lack information about the possibilities and constraints of the use of PV energy in products.
In order to improve the practice of PV powered product design the SYN-energy research program was set up. The electro-technical design of products, as well as usability was addressed in a number of design projects. In this summary we will present the lessons learned during the 5 years of projects in the framework of SYN-Energy and its spin-off.

Approach
Since we aim to improve the entire product development process with respect to the integration of PV technology in product design practice, all lessons learned are related to the Delft Step-by-Step Innovation Model (figure 1)  [Buijs, 2003].
This model is the standard model for teaching about product development at the faculty of Industrial Design Engineering. The model describes the activities that take place in a product innovation process. It discerns four stages in a product innovation process: strategy formulation, design brief formulation, product development, product launch and use. The end of each stage can be seen as a decision point in which the results of the activities in that stage are evaluated and decisions are made for the next stage. The outcomes of the final stage will again provide input for a new stage of strategy formulation.
For the analysis presented in this paper, the lessons learned are collected for each project and related to the stages in the Delft Step-by-Step Innovation Model.

Analysed projects
About fifteen projects will be analysed with respect to the integration of PV technology in product design. These projects are mainly design projects, such as a wireless PV powered computer mouse, outdoor products and lamps for rural households in Madagascar.
In addition PhD research programmes and educational programmes, such as a minor sustainable design, are addressed.

Results
In this summary we highlight several of the findings, but have to stress that this list is not complete. The findings are structured in accordance to the design stages in the Delft Step-by-Step Innovation Model.

Stage 1 - Strategy formulation
In this stage strategic ideas for innovation or potential new business opportunities are formulated, based on the strategic strengths of a company and opportunities in its competitive environment.

  • Basic knowledge about possibilities and limitations of PV technology is necessary to identify opportunities for PV application.  [Van Onselen, 2007].

Stage 2 - Design brief formulation

  • In this stage the new business opportunities are detailed into a design brief, which serves as a starting point for the actual design of a product. 
  • The use context greatly influences the feasibility of a product. 
  • Calculation of energy balance to determine feasibility and practical use is a must.
  • At least the ‘target group use pattern’ of products should be estimated before a proper energy balance can be calculated.
  • When defining user scenarios, both product use as incident light scenarios related to the product use have to be identified in order to match the energy consumption with energy conversion by the PV cells.

Stage 3 – Product development
In the product development stage the rather vague design brief is worked out to a concrete product that is ready to be produced and launched in the market.

  • Basic practical knowledge about all components in the energy chain is necessary, in order to make a sound conceptual design. 
  • The Energy Matching Model [Kan, 2006], which describes the elements of the energy chain of a PV powered product, can be used to structure the design process and could contribute to a more transparent process [Geelen, Kan, Brezet, 2008].
  • Energy balance and matching calculations are recurring steps during the development of product concepts. They are used for evaluation and generation of ideas. 
  • A benchmark evaluation of similar (PV powered) products can contribute to the understanding of the essential parameters involved in the design of a product. 
  • Trade off between an appealing visual design and functional design is often a challenge, considering the specific characteristics of PV cell shape and performance.
  • The influence of the energy consumption of Balance of System components has to be taken into account with respect to the total energy consumption of the product. 
  • Actual building and testing of a functional model will be needed to confirm all the assumptions taken in the design process. 
  • The use context of a product is an important factor for the energy payback time of the PV cell. For the product design an aim should be to make this time as short as possible.

Stage 4 - Product launch and use
In this stage the product is actually put in the market and used.

  • End users in general, have little knowledge about using PV technology. It is therefore important to provide information that is tailored to those users, both for marketing as instructions for use.
  • Users have to be able to assess their / the environmental gain by buying and using a product. 
  • Sunbathing – placing a product in light to charge – could be acceptable for users when it is clear why, how and when sunbathing has to take place [Reich, Elzen, Netten et al, 2008].
  • There is often a contradiction between the technical lifetime versus the economic lifetime of a product.

Conclusions and recommendations
Most of the lessons learned concern the product development stage. This is the stage we have most information about, since most of the activities in the analysed projects took place in this stage of the process. To improve the entire product development process, more research that covers the other stages should be done. Issues that need attention are, amongst others:

  • Preconceived ideas of product designers about PV technology application,
  • Experiences and perceptions of users
  • Marketing of PV powered products
  • Environmental impact of PV powered products,
  • Knowledge transfer to design practice and education. 

Output

Proefschriften

  • Dissertation S.Y. Kan, Energy Matching, Key towards the design of sustainable photovoltaic powered products, Delft, 19-12-2006.
  • Dissertation N. Reich, On the design of product integrated photovoltaic systems, University of Utrecht, September 2010
    Nederlandse samenvatting kort 

Publicaties in internationale tijdschriften

  • Kan, SY, & Silvester, S. Synergy in a smart photo voltaic (PV) battery: SYN-ENERGY. Journal of sustainable product design 3 (1-2),  29-43., 2004 (project 1)
  • Kan, SY, Verwaal M. and Broekhuizen H.;  The use of Battery – Capacitor combinations in photovoltaic powered products, Journal of Power Sources, 162, p.971-974, 2006 (project 1)
  • Kan, SY and R. Strijk,; Towards a more efficient energy use in mature designed photovoltaic powered products, Journal of Power Sources, 162, p. 954-958, 2006 (project 1)

Patents

  • Kan SY , Smart PV  battery;  octrooi no. 1015956

Conference papers/other professional products

  • Kan S.Y.2003; PV Powered Mobility and Mobile/Wireless Product Design, the Proceedings of the ISES Solar International Congress 2003, Goteborg, Sweden, presented June 22-28 2003, ISES Sweden, Stockholm
  • Veefkind, M. (2003) Industrial Design and PV-power, Challenges and Barriers . In: Proceedings of the ISES Solar World Congress, Götenborg (Sweden), June 14-19
  • Veefkind, MJ, Flipsen, SFJ, & Broekhuizen, HF, Gathering data on the energy to be harvested with portable consumer products, methods and equipment.. In  DGS e.V. &  PSE GmbH (Eds.), Eurosun 2004: the 5th ISES Europe solar conference  (pp. 3-379-3-385). Freiburg: PSE GmbH. (project 1)
  • Veefkind, MJ, & Bremer, AP, Cross-functional education of engineering sciences in industrial design engineering.. In P Lloyd, N Roozenburg, C McMahon & L Brodhurst (Eds.), The changing face of design education  (pp. 611-616). Delft: Delft University of Technology Faculty of Industrial Design. (project 1)
  • Kan, SY, Beers, S. van, & Brezet, JC, Towards mature design of PV powered products.. In  s.n. (Ed.) , EuroSun 2004. Vol. 3  (pp. 3-206-3-215). Freiburg: PSE. (project 1)
  • Website with overview of various solar consumer products giving various product specifications (internal use) (project 2)
  • Website for polling of favorite solar product (internal) (project 2)
  • Performance measurements of 120 commercial solar cells under weak light, measuring conversion efficiency and spectral response (internal) (project 1,2)
  • Website displaying measuring results on performance of solar cell devices under low-light conditions (internal) (project 2)
  • Spreadsheet evaluation tool for energy balance and LCA of solar products (internal) (project 2)
  • Memo on LCA aspects of solar products (internal) (project 2)
  • Sioe Yao Kan,  Martin Verwaal and Herman Broekhuizen)  Battery – Capacitor combinations in photovoltaic powered products, the 24th International Power Source Symposium, Brighton, UK April 2005, (project 1)
  • Kan S.Y. and R. Strijk, 2005; Towards a more efficient energy use in mature designed photovoltaic powered products, the 24th International Power Source Symposium, Brighton, UK, April 2005, (project 1)
  • E.A. Alsema, B. Elzen, N.H. Reich, W.G.J.H.M. van Sark, S.Y. Kan, S. Silvester, M. Veefkind, J. Jelsma, Towards an Optimized Design Method for PV-Powered Consumer and Professional Applications – the SYN-Energy Project, 20th European Photovoltaic Solar Energy Conference, Barcelona, 6-10 Juni 2005 (project 1,2,3).
  • N.H. Reich S.Y. Kan, W.G.J.H.M. van Sark, E.A. Alsema, , S. Silvester, A.S.H. van der Heide, R.W. Lof, R.E.I. Schropp, Weak Light Performance and Spectral Response of Different Solar Cell Types, 20th European Photovoltaic Solar Energy Conference, Barcelona, 6-10 Juni 2005 (project 1, 2)
  • E.A. Alsema and M.J. de Wild-Scholten, The Real Environmental Impacts of Crystalline Silicon PV Modules: an Analysis Based on Up-To-Date Manufacturers Data, 20th European Photovoltaic Solar Energy Conference, Barcelona, 6-10 Juni 2005 (project 2)
  • Reich N.H., Veefkind M., Alsema E. and Kan S.Y., 2006; Industrial Design of a PV powered consumer application – case study of a solar powered wireless computer mouse, Proceedings of the 21st European Photovoltaic Solar Energy Conference and Exhibition, Dresden, Germany, (Eds. W. Palz, H. Ossenbrink, P. Helm), WIP-Renewable Energies, Munich, Germany (project 1,2)
  • Veefkind M., Kan S.Y., Silvester. S., Verwaal M., Elzen B., Alsema E.A. and Reich N.H., 2006 ; The design of a solar powered consumer product : a case study ; proceeding of the 2006 Going Green – Case INNOVATION conference, Vienna, Austria.
  • Sioe Yao Kan and Martin Verwaal; Figure of Matching algorithm for analysing and quantifying the matching of battery – capacitor combinations in photovoltaic powered products, 25th International Power Source Symposium; 23rd – 25th April 2007, Bath, UK
  • Sioe Yao Kan , Martin Verwaal , Menno Veefkind , Sacha Silvester , Nils Reich, Wifried van Sark  and Erik Alsema, Boelie Elzen and Jaap Jelsma, Lessons learned: Power supply and battery choosing process for the photovoltaic powered wireless mouse, 25th International Power Source Symposium; 23rd – 25th April 2007, Bath, UK
  • N.H. Reich, M.P. Netten, M. Veefkind, W.G.J.H.M. van Sark, E.A. Alsema, S. Silvester, B. Elzen, M. Verwaal, A solar powered wireless computer mouse: design, assembly and preliminary testing of 15 prototypes, in: Proceedings of the 21st European Photovoltaic Solar Energy Conference, (Eds. G. Willeke, H. Ossenbrink, P. Helm), WIP-Renewable Energies, Munich, Germany, 2007, pp. 2842-2845.
  • N.H. Reich, E.A. Alsema, W.G.J.H.M. van Sark, E. Nieuwlaar, CO2 emissions of PV in the perspective of a renewable energy economy, in: Proceedings of the 21st European Photovoltaic Solar Energy Conference, (Eds. G. Willeke, H. Ossenbrink, P. Helm), WIP-Renewable Energies, Munich, Germany, 2007, pp. 3538-3542.
  • Lenny van Onselen, Kristina Lauche, Sacha Silvester, Menno Veefkind, Technology Window: A new Method to determine valuable product-market combinations, International conference on Engineering Design, ICED 2007, 28-31 August 2007, Cité des Science et de l’industrie, Paris, France
  • N.H. Reich, B. Elzen, M.P Netten, W.G.J.H.M. van Sark, E.A. Alsema, M. Veefkind, S. Silvester, Practical Experiences with the PV powered computer mouse “Sole Mio”, 23rd European Photovoltaic Solar Energy Conference, 1-5 September 2008, Valencia, Spain.
  • N.H. Reich, W.G.J.H.M. van Sark, E.A. Alsema, H. de Wit, A.H.M.E. Reinders, A CAD based simulation tool to estimate energy balances of device integrated PV systems under indoor irradiation conditions, 23rd European Photovoltaic Solar Energy Conference, 1-5 September 2008, Valencia, Spain.
  • N.H. Reich , M. Veefkind, W.G.J.H.M. van Sark, E.A. Alsema, W.C. Turkenburg, S. Silvester, A solar powered wireless computer mouse: Industrial design concepts, Solar Energy, Elsevier, article in pres
  • D.V. Geelen, S.Y. Kan, M. Verwaal, J.C. Brezet, M.P. Netten and S. Silvester; 5 years PV powered product development at the Delft University of Technology, Lessons learned from the SYN-Energy program and spin-offs, 34th IEEE PV Specialist Conference, Philadelphia, 7-12 june 2009, Abstract submitted.

Internationale boek bijdragen

  • Kan, SY, Silvester, S, & Brezet, JC. Design applications of combined photovoltaic and energy storage units as energy supplies in mobile/wireless products. In I Horváth & P Xirouchakis (Eds.), Tools and methods of competitive engineering. Vol. I (pp. 309-318). Rotterdam: Millpress 2004(project 1)
  • Flipsen, SFJ, Bremer, AP, Jansen, AJ, & Veefkind, MJ, Towards a selection method for designing alternative energy systems in consumer products. In I Horváth & P Xirouchakis (Eds.), Tools and methods of competitive engineering. Vol. I (pp. 523-530). Rotterdam: Millpress 2004 (project 1)
  • Brezet J.C. and Silvester S., 2004; Responsible Industrial Design Engineering – RIDE, In I Horváth & P Xirouchakis (Eds.), Tools and methods of competitive engineering. Vol. I (pp. 523-530). Rotterdam: Millpress. 2004 (project 1)
  • Jaap Jelsma, ‘Bridging the Gaps between Technology and Behaviour: A Heuristic Exercise in the Field of Energy Efficiency in Households’, in Harald Rohracher (ed.), User Involvement in Innovation Processes, München/Wien: Profil (2005), pp. 73-106. (project 3)
  • Gennip P van, Kan S.Y. and Silvester S., 2006; Power Quest an on-line software tool to find novel power system applications, In I Horváth (Eds.), Tools and methods of competitive engineering. Vol. I Rotterdam: Millpress  (project 1) TMCE 2006, Lubiana, Slovenia.

Publicaties in Nederlandse tijdschriften, boeken, vaktijdschriften en overige

  • S.Y. Kan; Efficient gebruik van zonnencellen en opslagmedia, in Op Onderzoek, Wetenschap in Nederland, Uitgeverij Boom, p.176, 2007 (project 1)
  • N.H. Reich; iPV-SIM – computer model for simulation of power supply of devices with solar cells (v.0.93) (project 2)
  • Prototypes of PV powered wireless computer mice (Solar Mio) (project 1,2 and 3)
  • Mathijs Netten, Gebruiksonderzoek Sole Mio >> Summary of user experiences with Sole MIO PV mouse User tests Report of Solar Mio (project 1,2 and 3)
  • M.Verwaal: Brief PV guide as aid for the ‘product analyses’  by the participants of the ECO Design Minor

Master theses

  • M. Verkuijl, PV streetlight
  • S. van Beers, Solar Charging Stations for Electrical Vehicles
  • B. Weitjens, Backpack Solar Charger
  • L.G. van der Kamp: Educational Solar Play object
  • B. Keukens, Pupil locator
  • L. van Onselen, Photovoltaic Opportunity fuzzy frontend method
  • P. van Gennip, PowerQuest,
  • D. Geelen, Solar Mobile Companion
  • S. Boom; Ankor, PV powered Lamp