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Design of a Solar Home System for rural Cambodia

Graduation Report

Master Thesis by Tom van Diessen


August 2008

Design of a Solar Home System


for rural Cambodia
Graduation Report

Master thesis by Tom van Diessen


August 2008

This is the report of a graduation project at the Delft University of Technology, within the master programme of Integrated Product design at the faculty of Industrial Design Engeneering

In cooperation with Kamworks & Picosol:



Arjen Luxwolda

Jeroen Verschelling

Henry de Gooijer

Supervisory team:
Dr.ir. Sacha Silvester (chair TU Delft)
Ir. Annemiek van Boeijen (mentor TU Delft)
Ir. Henry de Gooijer (mentor Kamworks)

For more information contact Tom van Diessen at Tvdiessen@hotmail.com.

II

PREFACE
This report is a reflection of the master graduation project conducted for the master Integrated Product Design
at the faculty of Industrial Design at the University of Technology in Delft, The Netherlands.
The project was conducted with the support of Foundation Pico sol in cooperation with Kamworks, in Sre Ampil,
Cambodia
From various design assignments I have learned that my specific interests are with social cultural Ecodesign.
The primary design for the needed, from a strong cultural objective matching with the local circumstances. Not
forcing up our western products but using the strengths of a country, its culture and environment to create a
product that fits within the users living atmosphere and perspective. I like to design from functionality, making
Spartan, robust products, that fulfill their primal goal. I think a product developer has a responsibility to always
go to extremities in searching for solutions, rather from a desire to do good than with a economic motive.
This is what also attracted me in this assignment, providing something basic as electricity by designing a responsible product that fits within the living patterns and desires of people on the Cambodian countryside. Kamworks would offer the ideal circumstances for a project where being submerged in the Cambodian countryside
is almost crucial in creating a succesful product. I regarded this project as the big finale of my study! The last
moment to demonstrate to myself what I have learned, to test what Im capable of and where my weaknesses
and strengths lay.
I look back at an interesting last study project, where I not only learned a lot on a practical and academic level
but certainly as much about me in person. It was a bumpy roller coaster ride, where local circumstance were far
from ideal and often limiting in obtaining the desired project progress. Luckily the project could be concluded
with a very satisfying end result where I feel that I can be proud off.
Wonderful people, the beautiful Cambodian countryside, the close contact with the Kamworks employees, test
families and playing football with the children of the orphanage have made it an experience to treasure forever.
I would like to thank family and friends for their support and the welcome distraction. Special thanks to Cristina
in being the most incredible and supportive girlfriend, even from far away, Jaap en Thijs for being wonderful
friends and great project coaches and mostly to my parents, for always being there, understandable, patient
and very parent like.

Tom van Diessen


Rotterdam, August 2008

III

ABSTRACT
Cambodia is still struggling with its violent past and has one of the lowest electrification rates in Asia, while the
costs of the available electricity even rank as one of the highest in the world. Extension of grid electricity lines
is expensive and time consuming, especially in a predominately rural Cambodia. Therefore many households do
make good use of rechargeable car batteries for lighting and television. This is however a far from ideal situation
as the heavy batteries have to be charged several times a week, in a small shop where a throbbing generator is
present. Due to this charging abuse and its poor use, the batteries are entitled to a short life, bringing unnecessary high costs and a low energy efficiency. Now, with oil prizes rising and the economy improving people are
in need of better power solutions, a Solar Home System (SHS) could fulfill this need.
Kamworks Ltd is a small Cambodian solar energy that is specialised in installing large professional solar systems and are now expanding to the consumer market, to contribute to their mission: affordable energy for
sustainable development. Coming years, the Cambodian government stimulates the application of solar home
systems through a grant boost. This and the lack of SHS currently in Cambodia creates a market opportunity for
Kamworks and forms the motive for this graduation project, to design an innovative user-friendly Solar Home
System for rural Cambodia.
The Solar Home System was created by an elaborate analysis of the local context, where many Cambodian
families were visited to map their energy needs, desires and living situation. Then a number of pilot SHSs were
created on basis of a preliminary design, to evaluate the technical functioning of the system and practically
test the system in operation. The experiences of installation and production of a SHS could thereby already be
taken into consideration early in the design process. Three systems were evaluated in the field by test families,
whereby the product use, performance and appreciation was monitored technically by datalogging and practically by a series of surveys. Based on this extensive design research the pilot SHS was further elaborated to a
final SHS product design, ready for production. Thereby creating a unity in the systems appearance and use
The result of this project is the design of three types of Solar Home Systems as one product family and one
complete product. The SHS has become a true modern powerhouse for rural Cambodia. A distinctive desirable
product of superb quality that matches with the Khmers culture, styling, way of living, energy consumption
and house situation. The system is easy to install, durable, strong and can be produced local at Kamworks.
The solar panel can be mounted securely to the house with the use of a new composite support. The technical
components are enclosed in the Dragonbox, a user friendly connection station with a high aesthetic value in creating a product desire, a commercial value in being distinctive and a functional value by protecting the system
components. A charge regulator furthermore guarantees a safe use, an extended battery life and provides the
users with the so desired energy feedback. Making the Kamworks solar home systems a secure energy source
available for all, for an affordable prize.
Kamworks had the desire to bring the SHS on the market soon, the outcome of this project enabled them to
do so. Currently four systems have already been sold and installed according to the final designs. Kamworks is
determined to continue with the production of the systems in the framework set by this project and expects to
start full production in november. Many customers are already eagerly waiting for what could be seen as the
new generation of Solar Home Systems in Cambodia.

VI

Terms of Abbreviations
A

Ampere, the unit of electric current

Ah

Ampere hour, unit of the electric charge of batteries

EdC

Electricit du Cambodge, the national electricity company in Cambodia

GDP

Gross domestic product

Gelcoat

A protective polyester outside polyester layer of a composite product.

GFRP

Glass Fibre Reinforced Plastic/ Polyester

Homebox

The SHS composite connection station

Kamworks

A small solar company with which the SHS development is collaborated with

Khmer

a\ The language spoken in Cambodia


b\ A native or group of inhabitants in Cambodia
c\ The ancient culture of Cambodia

LDC

Least developed country

MIME

Ministry of Industry, Mines and Energy

NGO

Non-Governmental Organization

Wp

Power output of a solar panel, at 25C and in full sun, with irradiation of 100W/m2

PV

PhotoVoltaic, a material with the ability to convert daylight into electricity

REE

Rural Electricity Enterprise, a small power supplier with a mini pwer grid

REF

ural Electricifaction Fund, the grant provider and stimulant of the SHS implementation

SHS

Solar Home System

Support

The composite solar panel support, univerally mountable on every indicated house.

Watt, unit of electrical power

Wh

Watt hour, the unit of energy

VII

CONTENTS

Orientation

1. PROJECT DEFINITION
1.1
1.2
1.3
1.4
1.5

INTRODUCTION
PROJECT STAKEHOLDERS
PROBLEM DEFINITION
PROJECT APPROACH
REPORT STRUCTURE

2. PROJECT CONTEXT
2.1
2.2
2.3
2.4
2.5

CAMBODIA
SOLAR ENERGY
SHS DESCRIPTION
SIMILAR PRODUCTS
CONCLUSION

Analysis

3. PRODUCT - USER CONTEXT


3.1 INTENDED USERS
3.2 CURRENT ELECTRICITY SOURCES
3.3 ELECTRICITY USE AND DESIRES
3.4 KHMER HOUSE
3.5 DAILY RITUALS, USE OF HOUSE
3.6 KHMER ART & ARCHITECTURE
3.7 CONCLUSION

4. TECHNICAL CONTEXT

Design research

4.1
4.2
4.3
4.4

VIII

SHS COMPONENTS & CONNECTIONS


COMPOSITE PRODUCTION
INSTALLATION
CONCLUSION

5. PILOT PRODUCT DESIGNS


5.1
5.2
5.3
5.4
5.5

INTRODUCTION
PRELIMINARY REQUIREMENTS 
THE SHS
SHS BOX 
SUPPORT STRUCTURE

2
3
3
5
5
7

8
9
11
13
16
17

18
19
20
21
22
23
25
25

26
27
29
31
33

34
35
35
36
37
40

Design research

6. PILOT PRODUCT EVALUATION SET-UP


6.1
6.2
6.3
6.4

RESEARCH APPROACH
FIELD TESTS (test families)
PRODUCTION & TECHNICAL TESTS
CONCLUSION

7. PILOT PRODUCT EVALUATION


7.1
7.2
7.3
7.4
7.5

THE SHS
SHS BOX
SUPPORT STRUCTURE
SHS TECHNIQUE
SHS FINAL REQUIREMENTS 

Final Product

Synthesis

8. PRODUCT SYNTHESIS
8.1 IDEAS
8.3 CONCEPTS, BOX APPEARANCE DESIGN
8.4 CONCEPT CHOICE

43
44
47
49

50
51
52
53
54
59

60
61
63
64

9. FINAL DESIGNS

66

9.1
9.2
9.3
9.4
9.5

67
68
72
75
77

THE SHS
SHS BOX
SUPPORT STRUCTURE
PRODUCT FAMILY
PROTOTYPE BUILDING

10. PROJECT EVALUATION


Evaluation

42

10.1 PRODUCT - USER INTERACTION


10.2 DESIGN OPTIMIZATION
10.3 RECOMMENDATIONS
10.4 PROJECT REFLECTION
10.5 FINAL CONCLUSION
REFERENCES
REFERENCES

80
81
83
84
85
86
88

IX

1. PROJECT DEFINITION

In this chapter the project guidelines and constraints are defined by describing the initial project objectives, the
parties involved and the problem to be solved. This was translated into a certain project approach and design
vision that can be recognized in the report structure.

1.1 INTRODUCTION
Electricity is one of the ingredients for development and can revert the spiral of poverty and economic recess.
Cambodia is still struggling with its violent past and has one of the lowest electrification rates in Asia, with only
12 percent of its population of 13 million connected to a power supply [ASTA, 2008]. In addition, the costs of
the available electricity rank as one of the highest in the world due to corruption and lack of alternatives.
Extension of grid electricity lines is expensive and time consuming. Cambodia has a largely rural population,
distances are long, population density small and the average power consumption low. Therefore about 90%
of the rural population in Cambodia has found an alternative in using wet-lead car batteries for their electricity
supply. This however has major drawbacks on a social, economical and environmental level. Now, with oil prizes
rising and the economy improving people are in need of better power solutions, a Solar home system could
fulfill this need.
SHSs have proven their ability to supply modern sustainable energy to rural areas of the developing world.
Apart from its ecological advantages, it is also in many cases the most economic way to electrify rural areas
and thereby improve the quality of life. There are however still many improvements to be make in the general
design of the SHS, as there is a large failure of systems over time, many installation and maintenance problems,
a high prize and unreliable load conditions. The specific situation in Cambodia, with the often used car batteries
will also be of influence in how a SHS will be perceived.
In short the main objective of this project is to design an innovative user-friendly Solar Home System for rural
Cambodia. Therefore develop a SHS that focuses on; high quality for a low prize with an appealing durable
design. That matches the desires and needs of the users and creates a understanding, and social cultural acceptance of solar energy. The installation and maintenance should be well organized and careful handling of the
system stimulated by a high product appreciation.
The SHS will be developed as a complete product; outside, a universal support structure for two types of standardized Solar Panels is to be designed and inside, a user-friendly connection station is to be created.
Meaning that the project will follow three principal directions:
Usability and aesthetics, have the main focus and services the end-user of the SHS
Produce ability and installment, are tools to reach the main objective of a high quality durable product
Technical operation of the system, is the basis of the entire system and should therefor performe optimal.

1.2 PROJECT STAKEHOLDERS


Delft Design Institute

The Faculty of Industrial Design Engineering holds a wealth of knowledge and experience in design-related subjects. These facilities and know-how to create have been brought together in the Delft Design Institute (DDI).
The DDI is an academic institute in which staff and students perform highly innovative projects to stimulate and
inspire own designers and companies. The products have a high scientific and societal relevance.[Tudelft; DDI,
2008] The projects are derived from and in line with the research program of the Faculty and play a demonstrative or evaluative role. Projects should meet six criteria; Leading to actual products, High scientific quality,
Societal relevant, Significantly innovative, of commercial interest and have a Publicity value.

Picosol

Pico Sol is a Dutch Foundation that supports solar energy projects in developing countries with know-how and
financial support. They are active in Cambodia since 2000 with installing solar electricity systems at orphanages and schools. A Cambodian affiliate NGO entity has just been licensed, its main goal will be to increase the
awareness of local communities in Cambodia on the advantages of Solar energy.
The company Kamworks came to life as a Pico Sol spin-off a few years before and will among others function as
a vehicle for project realization. A connection of Pico Sol projects for communities and implementation of solar
home systems for Cambodian households under the REF program is currently in discussion [Luxwolda, 2007].

Rural Electrification Fund

The Rural Electrification Fund (REF) is set up in 2004 by the Worldbank to accelerate development of electricity
in rural area in Cambodia. The aim is to promote the necessity of rural electrification at affordable prices for
economic, social and household uses, thus improving the standard of living, develop the areas and contributing
to its poverty reduction. The private sector is encouraged in providing sustainable rural electrification services.
The goal is that by the year 2020, all the villages of the Kingdom of Cambodia will have access to electricity.
Among other programs the REF provides a 100$ grant assistance to Solar Firms for supplying 12,000 Solar Home
Systems (SHS of at least 40w) for households in rural areas. To entitle to this subsidy the technical demands set
by the REF-grand will form the basic principle for the SHSs design in this project. [Recambodia; REF, 2008]

Kamworks

Kamworks Ltd was established as a Cambodian solar energy company in 2006 and is located in the countryside
on the grounds of an orphanage. Selected young adults from the orphanage are trained and offered a job opportunity to contribute to Kamworks mission: affordable energy for sustainable development, by providing
modern and high-quality electricity and lighting for rural households at an affordable price (Fig 1.1).
Kamworks now mainly installs solar electricity systems for the professional market but is about to start producing their own consumer goods. Knowing that lighting is a basic demand, the Angkor light was developed in 2005
as a low end-end consumer product and is now being prepared for production. On the high-end the SHS for
rural households will now be developed. With a solar panel of 40 to 80Wp a rural family can power a few lights,
radio and television. At present, relatively high investment costs and a scare market hamper the large scale
introduction of these systems. Kamworks expects that within the framework of the REF program, good quality
systems will come into the reach of families with a higher and presumably model income.
In 2006 Kamworks won a World Bank Development Marketplace Prize with its innovative business plan. This is
being implemented at present and entitles the full product life-circle; setting up local production, training their
employees and entrepreneurs to increase their technical self-sufficiency in selling, installing and servicing solar
energy systems. A series of small shops with a trustable brand name is set-up to optimize sales, service and
user-contact. In this way end user satisfaction is best assured. [Luxwolda, 2007].

Fig 1.1 The Kamworks building,


solar array and mission

1.3 PROBLEM DEFINITION


About 85% of the Cambodian population does not have electricity. Some of these households do make good use
of rechargeable car batteries for lighting and television. This is however a far from ideal situation as the heavy
batteries have to be charged several times a week, in a small shop where a throbbing generator is present. Due
to this charging abuse and its poor use, the batteries are entitled to a short life, bringing unnecessary high costs
and a low energy efficiency.
For these people, a small solar panel can be a useful and a lasting solution. These systems are also known as
solar home systems (SHS), which consists of a solar panel, a battery and a charge controller in between. A
SHS normally provides enough energy for a small television and a few lamps. Coming years, the Cambodian
government stimulates the application of solar home systems through a grant boost. This and the lack of SHS
currently in Cambodia creates a market opportunity for Kamworks and forms the motive for this graduation
project.
The goal is to design an innovative user-friendly Solar Home System for the rural Cambodian market, taking
social cultural aspects into account. The technical demands set by the REF grant providers form the basic foundation for the SHSs design. The SHS will be developed as a complete product; outside, a universal support
structure for two types of standardized Solar Panels is to be designed and inside, a user-friendly connection
station is to be created. The system has to be locally producible by Kamworks, and easy to install.

1.4 PROJECT APPROACH


Kamworks desires to bring the SHS to the market as soon as possible. The project set up is therefore very
practical and enables Kamworks to already build up experiences with the SHS, its production and installation
during the product development. Which should lead directly to a first series of the Solar Home Systems, ready
to put on the market.

Project Set-up

Initially the local context and technical operation of the SHS will be investigated. This, together with the steps
that Kamworks has already made in the SHS development will lead to a first SHS pilot product that will be tested
with a number of families in the field. Thereby the system functionality, product context and the user desires will
get known and the experiences in the production and installation of a working prototype of a SHS can already
be implemented early in the design process. For Kamworks this is also an opportunity to already get to know its
new product, customers and market. During the project, the SHS is designed thru production in close contact
with the end-users, by a number of irritative steps of trail and error.
The results and experiences of the pilot SHS product field research will be the direct input for the synthesis of
the SHS final design and the project should conclude with the production of the 1 series of SHSs.

Production

Kamworks wishes to have the production of the SHS entirely in their own hands, mostly due to the local attitude
and production restrictions in Cambodia. In a previous project experience in the use of Glass fibre reinforced
plastic (GFRP) was gained by Kamworks and is now considered also as the most suitable process for the production of the SHS. Due to the local limitations at the start of the project and the desire to create a product to test
fast, the use of GFRP was taken as a given fact. The production with the composite material was also dictating
in the appearance design of the product.

Solar home Systems

There are a number of SHS variations, which all entitle multiple parts. The SHS will be part of product family of
three types of SHS of variable prize and size. Although the project focus will be on the design of the small SHS,
all should be taken into account and be designed in the end. Each design consists of a connection station inside,
a universal support structure for the solar panel outside and a additional load of lamps and switches.

Design process

Besides a practical set up of the project, two complete consecutive


design processes will be handled in this graduation assignment. During the 1st, quicker process the focus will be on the SHS technology
and functionality and lead to a principal design of a pilot SHS product
for testing. This design will be evaluated in a extensive design research, which will function as the analysis of the 2nd design process.
The 2nd process can be regarded as a redesign of the initial pilot
SHS product, where the design is elaborated and optimized, now
mostly focussing on the design aesthetics and user interaction. The
production and installation will be a red thread during the entire
project and should guarantee a producible final design of the SHS.

Design method

The standard cyclic design method at IDE, as described by Rozenburg and Eeckels [1998] is not entirely applicable to this project.
The context of the design process in a development country doesnt
loan itself for predefined rounded off steps as one has to react to
practical situations that present themselves. Further more, being in
Cambodia, cultural aspects have to be considered and the design
process as described earlier has been defined so.
To reach the main objective, during the project high involvement of
the Kamworks employees by production and installation and of the
end-users by a great amount of field surveys was desired. That way
the SHS is designed in context, user centered, by a number of iterative steps of trail and error, according to a fuzzy process where in
practise parallel design phases were handled simultaneously.
The design method is visualized in the schedule of Figure 1.2
Fig 1.2 Design method

Product vision

The SHS should be designed as a complete product, producible in and suitable for the Cambodian market. By
field research of the installers and end-users at which the opportunities that rural Cambodian housing offers for
installing a SHS, and the way in which people are dealing with the technique will be examined.
In addition, attention must be given to the level at which the installation and operation of the designed product
can be communicated. The support structure for the solar panel, should not rust, resists considerable winds, is
theft preventive and can be packaged folded or dismantled. An understandable central indoors connection station for the SHS should be created. A central Homebox that provides some energy feedback and encloses the
SHSs technical components (the battery, controller and optionally a small
DC-AC converter) is considered. The product should contain a number of
outlets where devices can be connected to. Important points of attention
are simplicity in installation and use, social- cultural acceptance, reliability
and locally available materials and production facilities.
However the SHS will be designed for the rural affluent few, its design
should later also be useful to the many rural poor and therefore be made
plug and play with a distinctive appearance.

1.5 REPORT STRUCTURE


The report is written almost chronological and is very practical in nature, it
is rather more complete than incomplete, as it mostly serves as a reference
document for Kamworks for future development, recommendation and design description. Since the initial goal of the project was to end with a final
product, ready for production and sales. Therefore the report doesnt always
follow the standard academic report structure but rather a logical set-up in
relation to the project.
The report is structured according to the global set up of the design process
as visualized in Figure 1.2 and is displayed in Figure 1.3 What follows is a
short chapter description and their logical sequence of information.
Chapter 2: forms the projects theoretical foundation, mainly based on literature, as the project context is explored.
Chapter 3 and 4 form together the project analysis phase. First the environment for the SHS and the user interaction with the product in context is
described in chapter 3. Second all issues concerning the technique and functionality of the SHS are described, for the set up of preliminary requirements
of the pilot product later.
Chapter 5,6,7 together form the design research. First the designs of the
pilot product are described in chapter 5, immediately presenting the result of
the first design process, as the synthesis is woven into both the analysis and
the description of the pilot product. These designs were solely created for
the purpose of a design evaluation. In chapter 6 this set-up of a pilot product
evaluation is described and should be read as a set-up of a practical series of
qualitative tests, rather than an academic conducted test series. In chapter 7
the experiences and results of the Pilot product tests are evaluated according
to the research set-up in Chapter 6 and with the pilot product as described in
chapter 5. The results can be regarded as an analysis for the 2nd design process since recommendations for a product redesign are opted and translated
into the final list of requirements.

Fig 1.3 Report structure

Chapter 8 describes the final product synthesis with a strong focus on the final appearance design of
the Homebox since the internal parts are already defined in the pilot product design and the design of the support structure for the panel follows directly from the previous design research. Ideas were created based on
the previous research, then evolved to structural variants by taking the placement of components into account.
Finally the ideas were elaborated to concepts of which a final design is selected based on concept surveys with
the test families
Chapter 9 is a full description of the final designs of the Solar Home Systems and the consequential prototyping of these designs, which lead to the
first serie SHSs, almost ready for production.
Chapter 10 is an evaluation of the final design and the entire graduation
project
Figures, tables and Graphs are numbered per chapter and referred to in the
text by the abbreviation: Fig , followed by the figure number.

2. PROJECT CONTEXT

In this chapter the project context is explored, mostly on a theoretical level and based on literature. This forms
the foundation of the project, as it outlines the principal ingredient of the project like Cambodia, solar energy,
the Solar Home System and similar products are described.

2.1 CAMBODIA
Country

After decades of civil strife, Cambodia is on the road to recovery. The almost total destruction of social and
economic institutions and loss of life as a result of Cambodias dark history left the country to begin from ground
zero in 1979. Now about 30 years later infrastructure is being rebuild, education has improved and mortality
rates have dropped, but the progress is slow, the country is suffering highly from corruption and is still struggling to ban poverty, obtain economic growth and ensuring environmental sustainability [SCW, 2006].

Economy

Cambodia is a developing country with a large proportion of the population (84% in 2005) living in rural areas.
The countrys official Gross Domestic Product is low with 1800$US per person per year [CIA, 2008] and incomes
are largely unequally distributed to the wealthy few (UN GINI index 41,7 in 2004). The rural population being
mostly self-sufficient, agriculture does accounts for 31% of the GDP in 2007, with another 15% from the garment sector, 14% from foreign aid and the remaining part mainly of tourism. Poverty rates have declined but
still remain relatively high with 36,1% of the total population living below the poverty line [SCW, 2006], 90%
of which live in rural areas. Cambodia is classified as a Least Developed Country (LDC) which ranks it amongst
some of the poorest in the world. Another significant factor of social and economic development is the prevalent
corruption of government and official bodies, Cambodia is ranked as 162 in 2007 on the corruption perceptions
index (CPI), a worldwide survey among 180 countries [CPI, 2008] .

People

More than 90% of its 14,2mln population is of Khmer origin and even 95% is Theravada Buddhist [CIA, 2008].
Both tradition and religion still have a large influence in the daily life in Cambodia and social organization. More
than 50% of the population is less than 21 years old. The population lacks education and productive skills, particularly in the poverty-ridden countryside, which suffers from an almost total lack of basic infrastructure.

Culture

The majority of the predominantly rural society in Cambodia, still follows traditional social patterns and lives according to the rules of Theravada Buddism of tolerance and solidarity. This patterns are however slowly changing in the rural-urban areas due to western influences, increasing wealth and the young age of the population.
Khmer culture is superstitious, full of symbolism and very hierarchical. The greater a persons age and position,
the greater the level of respect that must be granted to them. Legally, the husband is the head of the Khmer
family, but the wife has considerable authority, especially in family economics. The family and community life
is very important, there is still great distrust against outside influences, partly due to the recent war-trauma. A
strong feeling of pride for the village, for the district, and province usually characterizes Cambodian community
life [Russell R. Ross, ed. ,1987].
Like in many Asian Countries that are ranking high on Uncertainty Avoidance and Collectivism, based on Hofstedes dimensions, Cambodians are hesitant and distrustful in trying new things, they very much take each
others position and opinion into account when making decisions [Hofstede, 2008].

Energy

Cambodia has made considerable progress in reforming the power sector, but, in addition to some of the highest electricity costs in the world, Cambodia also has one of the lowest electrification rates in Asia, with only 15
percent of its population of 14 million connected to a power supply and most of this group is even located in or
around the Capital ,Phnom Penh. [Worldbank, 2008].

EdC-grid

Villages

Households

Number

REE-grid

370
864

Household batteries

10,488

Household gen-set

3%
7%
85%
-

None of these*

617

5%

Total

12,339

100%

Number

42,000
84,000
1,155,000

2%
4%
55%

63,000

3%

756,000

36%

2,100,000

100%

Table 2.1 Electricity


status in rural Cambodia
[Recambodia,
2008] * Either have
no electricity or only
use dry cell batteries

As can be seen in table 2.1, the national Energy company (EdC) only provides 3% of the villages and 2% of all
households with electricity. An additional 7% ,of mainly larger provincial towns, is provided by electricity thru
small low-tech, often inefficient Rural Electricity Enterprises (REE) [Worldbank,2008]. Besides villages next to
the sparse roads, grid electricity is virtually nonexistent in rural areas. Therefore many villagers in rural areas
(55% of the households) found an alternative in the use of automobile batteries for their basic electricity need,
however 36% of the population doesnt have electricity at all [Recambodia, 2008] and about 80% still uses
kerosene for lighting [NIS, 2008]. For many villagers these sources of electricity and lighting are their only option, but they are far from ideal. The batteries have a short lifespan and their capacity deteriorates rapidly due
to their inefficient and bad circumstance of use, therefore battery electricity is expensive and costs about 2 to
3,5$US /kWh [Boom, 2005]. Besides for use of lighting 32% of the rural households uses the batteries to power
a black & white television. Kerosene lighting gives very poor light and is health hazardous. The lack of sophisticated lighting puts a break on development and restricts working activities to daylight hours only.
Since grid electricity will not be available to the majority of Cambodia for many years to come, alternatives for
sustainable electricity supply should be found, Solar Photovoltaics (PV) is a mature technology with a range of
possible applications in Cambodia. [ASTAE, 2008]
In a rural household the use of energy source depends on their economic position, they desire to climb higher on the energy ladder by
their capacity to pay [Ramani, 2003]. The most sustainable comfortable energy source are on top and are only affordable for an decreasingly amount of people according to the income pyramid, figure 2.1 .
Solar energy is a high-end energy source and for market prizes only
affordable for the happy few. (MIME, 2006)
Fig 2.1 Income and energy pyramid

10

2.2 SOLAR ENERGY


Solar energy is converted by solar cells to electrical energy. The main advantages of solar PV systems in Cambodia is their independence from the electricity grid and their long lifetime. Though the investments costs are
high, no later costs and maintenance efforts have to be made. In this chapter is described how solar cells work,
electricity is generated and what are the depend factors of efficiency.

Solar Basics

Solar cells take the energy from sunlight and convert that
energy into electricity by a chemical process in semiconducting materials. Most solar cells are made from silicon which
has both the conductive properties of a metal and an insulator. Meaning that electrons in the atom are principally tightly
bound but can be manipulated to have conductive properties.
Solar cells are made by joining two types of semiconducting
material: P-type, with positive ions and the N-type with negative ions, this way an electric current can move in a solar cell.

Sunlight to Electricity

Sunlight contains photon particles, these strike and can penetrate a silicon atom, then the atom ionizes and all the energy
of the photon is converted to an outer electron that can now
move and create an electric current (Fig 2.2).
A typical mono crystalline solar cell has a n efficiency of 1215% and consists of a glass cover to seal the cell, an anti-reflective layer to maximize incoming sunlight, a front and back
contact or electrode, and the semiconductor layers. [Girasolar,
2008]

PV Systems

Fig 2.2 Sunlight to Electricity

Solar cells can only produce an electrical current when they are connected to other system components with
an electricity demand, or load. PV systems can either be stand-alone, or grid-connected and are basically used
in 3 situations.
Grid-connected PV systems; When the electricity grid is available but electricity from a clean source (solar)
is desired, solar panels can be connected to the grid.
Stand-alone PV systems; or solar home systems (SHS) are used when no electricity grid is available. A
battery is needed to ensure the availability of electricity and cover the needs of a household.
Back-up systems; are used when electricity from the grid is available but unreliable. The solar system can
be used to provide electric power during periods when there is no electricity from the grid (blackouts).
This project will limit itself to the design of a off-grid, stand-alone Solar Home System.

SOLAR ENERGY IN CAMBODIA

The efficiency of the PV system depends on the quality and orientation of solar panel. The amount of energy
that it generates then depends on the local irradiation.

Irradiation

The intensity of the suns irradiation varies per hour of the day, time of the year and weather conditions. Therefore a standard expression of solar energy is set to hours of full sun per square meter, which is 1000 watt.
Meaning that 1 hour of full sunlight would deliver 1kWh/m2 of peak power by a solar panel.

11

Cambodias Climate has a good potential for photovoltaic power generation. Table 2.2, [NASA, 2008] displays
the hours of full sun during the year in Phnom Penh. With an average of 5,3 hours of full sun every day it is
one of the sunniest countries in the world. The maximum fluctuation in solar radiation volume throughout the
year is relatively low, and has been estimated at 17%. Which is important for the use of PV-systems as a stable
energy source. [Recambodia,2008]
Dailysolarradiation kWh/m2/d
7

Cambodia: 12N /105E


6

Yearsaverage:5,3hour

FullsunHours

0
January

February

March

April

May

June

July

August

September

October

November

December

Table 2.2 , Daily solar Irradiation

Figure 2.3, Solar radiation Map Cambodia

Figure 2.3 shows that the solar irradiation in Cambodia increases gradually from the northwest of the country
with an average low of 4.1 kWh/m2 to the southwest of the country with an average high of 5.3 kWh/m2[NIDO,
2006].

Orientation & Tilt Angle Solar Panel

The Solar Panel of the Kamworks SHS will be mounted under a fixed angle. To get the most from fixed solar
panels, you need to point them in the direction that captures the most sun over the course of a full year. Since
the sun and earth rotate opposite of each other this ideal angle and orientation depends on the position on the
earth. The preferred orientation is facing south in the northern hemisphere, and facing north in the southern
hemisphere [Perez, 1993] The ideal tilt angle depends on many variables like the latitude, limitations of the
topography, surrounding and climate and can be determined by complex calculation methods like Perez/Page
Method and the more extensive RETScreen method at Nasas Atmospheric science Data center. As shown in
Table 2.2 the optimal tilt angle for Cambodia (12N / 105E ) according to RETScreen is 17,5, the hours of full
sun then increase with 6% to 5,51 hours a day, compared to a flat surface. [NASA, 2008].
Monthly Averaged Radiation Incident On An Equator-Pointed Tilted Surface /
RETScreen Method (kWh/m2/day)
Latitude 12
Longitude 105
10-year Average
Tilt 0
Tilt 26
Tilt 90
OPTimal Tilt
OPT ANG

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

5.19
5.14
5.95
4.09
6.01
36.0

5.70
5.64
6.12
3.55
6.12
26.0

5.89
5.82
5.82
2.59
5.93
13.0

5.95
5.86
5.39
1.71
5.86
0.00

5.54
5.44
5.34
2.28
5.49
10.0

5.14
5.03
5.03
2.38
5.12
13.0

5.20
5.10
5.05
2.30
5.17
11.0

5.09
5.01
4.80
1.89
5.03
5.00

5.08
5.01
4.85
2.00
5.04
7.00

4.79
4.74
4.93
2.69
4.95
20.0

4.92
4.88
5.49
3.60
5.51
32.0

4.98
4.94
5.81
4.16
5.91
38.0

Table 2.3, Optimal Tilt angles for Cambodia

Annual
Average
5.28
5.21
5.38
2.77
5.51
17.5

The solar panel should be installed as accurate as possible to reach the most optimal efficiency. Installation mistakes as orientating the panel in the wrong direction, eg. South-west instead of fully south can reduce the panels
efficiency by 10%, a 20 degrees larger tilt angle can decrease the efficiency by another 10%. A solar panel
should not be installed horizontally, due to the desired cleansing function of rain. Since the panel is installed one
time for many years, its extremely important for the entire SHS efficiency to do this accurate.

12

2.3 SHS DESCRIPTION


What is a SHS?

A Solar Home System (SHS) is a small autonomous energy station, powered by a solar panel, that provides electricity for basic services such as lighting, radio, television, and operation of small appliances to rural households
often without access to electricity grids. A basic solar home system consists of a PV solar panel, a storage battery, a battery charge controller, and various end-use equipment like florescent lamps. Solar home systems can
eliminate or reduce the need for candles, kerosene and/or battery charging, and provide increased convenience
and safety, improved indoor air quality, a higher quality of light than kerosene lamps for reading, and reduced
CO2 emissions [Foley 1995; Cabraal et al. 1996 and 1998; Kammen 1999; Loois and Hemert 1999].
Since the early 1990s, solar-home-system technology was maturing, costs were declining, and commercial
markets were developing. At the same time, population growth was outpacing the ability of electric utilities to
extend rural electricity grids and developing countries were increasingly recognizing the economic difficulties of
achieving full grid-based rural electrification. Governments and many NGOs began to perceive that solar home
systems could provide least-cost rural electrification and could supplement grid-based electrification policies.
[Martinot, 1996]
Since then Solar Home systems projects have been abundant in many developing countries. These projects
were not always successful however, often problems occurred with the lifespan, maintenance and even the plain
use of the systems. In some projects 2/3 of all installed systems broke down within the 1st year or simply never
functioned properly at all [Krauter, 2003]. This was often due to the harsh conditions in which the systems were
placed, the low service-after-installment and the lack of context orientated placement of the systems. Traditional
SHSs consist of separate components which makes the system more vulnerable to abuse and failure.
A basic Solar Home System (Fig 2.4)
1. PV module/ panel: A number of photovoltaic cells electrically interconnected and
mounted together, in a sealed unit of convenient size.
2. Support structure: Used to mount the PV
modules in place. Depending on the application, the PV modules can be mounted on
rooftops, in building structures and in the
open fields.
3. Charge controller: limits the rate at which
electric current is added to or drawn from
electric batteries. It prevents overcharging and may prevent against over voltage,
which can reduce battery performance or Figure 2.4, Configuration of a Solar Home System
lifespan, and may pose a safety risk. To protect battery life it also prevents complete
draining (deep discharging), and performs controlled discharges, depending on the battery technology.
Many charge controller systems display operation data. Simple charge controllers stop charging a battery
when they exceed a set high voltage level, and re-enable charging when battery voltage drops back below
that level. Pulse width modulation (PWM) and maximum power point tracker (MPPT) technologies are more
electronically sophisticated, adjusting charging rates depending on the batterys level, to allow charging
closer to its maximum capacity. Charge controllers may also monitor battery temperature to prevent overheating and optimize use. [Eere, 2008]
4. Battery: two or more electrochemical cells connected in series which store chemical energy and make it
available as electrical energy. Batteries can be recharged when the chemical reactions are reversible; they
are recharged by running a charging current through the battery, but in the opposite direction of the discharge current. There are many types of electrochemical cells; the traditional wet lead-acid, the modern
sealed lead-acid and the dry-cell like lithium-ion(Li-ion) are the most common. Further characteristics vary

13

due to many factors including internal chemistry, current drain, and temperature. The battery choice depends strongly on its application, environment and prize [Wikipedia, 2008].
5. Electric appliances/ Load ; like lighting, television and radio form the load for the system and demand
the amount of electricity used at any given time (power).

The Kamworks SHS

Kamworks wants to deliver a high quality and appealing product, an integrated SHS specifically developed for
the rural countryside of Cambodia and with high service. Besides a functional energy provider, it should be a
desirable product. So instead of installing the technical components separately, they are enclosed in a indoor
connection station (Homebox). This way the system will becomes more a product , that is distinguishable,
user-friendly and with an appealing design to stimulate the proper care of the system. By concealing the technical components, Kamworks can furthermore guarantee the functionality of the product and optimize the total
systems efficiency. Therefore a 1 year warranty can be given on the entire system.
At principal the system will be installed by trained experts, to guarantee proper installment, mainly the orientation of the panel and connections of the system parts are fundamental for a supreme functioning system.
The size of the SHS should match the energy consumption of the household according the capacity to pay.

SHS sections

A solar Home System consist of 3 principal parts (Fig 2.5); Energy generator >
energy storage and distribution > Energy
load. These parts all have a specific function and are installed in various areas of
the house, together they form a Solar
Home System.
1. Energy generator; consists of a PV
solar panel and support structure.
The PV panel generates electricity
during the day and has to be firmly
installed with a mounting system that
is and resistant to harsh climate conditions for many years on/next to the
house
2. Energy storage and distribution;
The energy, generated by the PV
panel is stored in a battery, a charge
Fig 2.5, SHS sections
controller operates sort of as the energy gatekeeper and protects the battery and connected appliances. By concealing these components in
the Homebox, the customer cannot access the battery directly to connect devises, but does this thru the
charge controller. In consequence the battery life can, with the right type selected, be prolonged up to 3-4
years.
The homebox design (appearance) should take away the desire to open it. It will also have a warranty seal,
which prevents opening by the customer and limits opening only for maintenance by an technician The
Homebox should communicate the functioning of the system by a display that communicates intuitive; If it
works (solar panel), how much energy is available (battery) and in case of malfunctions an error message
(load). The charge controller can communicate such information and thus should be integrated with the
homebox.
Principally the SHS operates at 12V, DC-power, if normal grid power of AC, 220V is desired, an inverter can
be used to convert the power. This does effect the systems efficiency and is only sensible for larger SHSs.
3. Energy load; Lighting and small electrical appliances can be connected to the Homebox. Kamworks installs
4 fixed light spots and switches with the solar home system to guarantee efficient and secure lighting in
the house. The customer should be able to connect other electrical appliances, like television, VCD-player,
radio and mobile phone chargers fool-proof by himself.

14

SHS product Family

For now three SHS versions will be developed by Kamworks, according to an increasing energy demand and
budget. The market opportunities for a small 20w system for lighting only, have yet to be investigated. Therefore a medium sized SHS will be the smallest available system now and is meant for the basic energy needs
like lighting the house, radio and a b/w Tv. The 2nd, large, system is double the size of the medium system and
is meant for lighting a large house and the use of a color Tv. The 3rd, Large+, system is the same as the 2nd,
but has a 220V AC socket. This is perceived as more luxurious as it resembles grid electricity and any electrical
appliance (if not consuming to much energy) can be connected to it. It can also directly replace the noisy inefficient generators of many affluent families.
Minimal energy scenarios SHSs (Table 2.4)
Assumptions; 3 days autonomy, total system efficiency 60%, daily 5 full sun hours
Lamps
7w

Medium*
Large**
Large+Ac***

Directional light

Radio

1w

5w

TV
h

Total

25/40w

(W *h)

10

b/w

120 Wh/ d

10

color

230 Wh/ d

10

color AC

210 Wh/ d

Table
2.4, minimal energy scenarios of SHSs


* A medium sized 12v, 40W panel, 48Ah battery, DC solar system with polytop and Homebox
** A large size 12v, 78W panel, 96Ah battery, DC solar system with polytop and Homebox
*** A luxurious 12v DC ~ 220v AC solar system, 78W panel, 96Ah battery with inverter, polytop and Homebox

KAMUNASAL

A separate brand name was set up for the activities of Kamworks on the consumer market, to indicate the difference with
the core business of Kamworks, in mainly being a knowledge
and technology provider.
The SHSs will be sold under this brand name, in still to be
developed Solar shops and mobile stores (Fig 2.6, 2.7). This is
also where the customers will be able to get information, replacement parts and technical support for the systems. The store concept
is a way for Kamworks
Fig 2.6, opening solar shop

to enlarge its reach and


potentials in providing
knowledge about and
sustainable energy for
everyone. A wide variety of services and products will be available in the store, where the SHS will be the most high end
product in the Kamworks sales range. Therefor additional promotion material will be developed. The SHS will further more
be used for educational purposes and powering the electrical
appliances in the store

Fig 2.7, Kamunasal mobile stores

The Kamunasal brand identity and strategy is under development at time of this project and thus can not be taken into
account in the development of the SHSs.

15

Fig 2.8, Various SHS; by Khmer Solar, a SHS in Koh Duch, in Sre Ampil and a SHS by SunLaBop in Laos

2.4 SIMILAR PRODUCTS


Competitors

The market of solar energy in Cambodia is still in its children shoes, there are just a few market players providing
solar systems to households. Besides Kamworks there is, Khmer solar, Kc solar and Advantec Sources.
The solar market has great potential though and is large enough for all companies. So far the emphasis for these
companies has been on installing large professional solar systems for GOs, NGOs and e.g. schools. The consumer market is now being explored, also due to the REF-grant, so far Khmer Solar is taking the lead in installing
SHSs . It is to be expected though that kamworks can easily become market leader with their innovative, high
service approach and distinctive design of the SHS, which will be unique in Cambodia.
Examples of traditional SHSs
So far, just a very limited amount of SHSs have been installed in Cambodia. Estimations reach up to just 2000,
mostly very bare bone systems where the components are exposed, connections made by messy wires and appliances can be connected directly to the battery (Fig 2.8).
As can be seen in Figure 2.9 Solar panels can be installed in many ways. In Laos (a neighboring country) the
houses are fairly low, therefor the panels are often mounted on separate poles. In Cambodia however the
houses are much higher and parcels often surrounded by trees, making mounting on the house more desirable,
due to shade. A mount on the roof ridge would therefor be better, if the panel still can be properly orientated
towards and sun and strongly mounted, so not like in the upper right photo.
Examples of integrated SHSs
Various international companies are experimenting with the idea of an integrated SHS. The Powerbox and
powerhouse are specific designs for developing countries in Africa, the Solarbox is for harsh outdoor conditions
and the Sundaya boxes for the western market. They all have the box sealed for the users, have standardized
connections and a sort of display to give energy feedback. The extent to which the design is modified for the
user context varies. Only the Sundaya boxes are made for installing on the wall

Fig 2.9, Various solutions for installing small solar panels; in Laos, at a temple and on a roof ridge

16

Various SHS for developing countries are displayed in figure 2.10, they are placed on the market under the
principal of dislocated ownership; rent, paying per Kwh or by credit system.
In figure 2.11 several integrated SHS for the western market are shown, they are sold directly to customers

Fig 2.10, Powerbox, GiraMundo, Netherlands - Xining New Energy; China - Powerbox, Wise energy, Ghana

Fig 2.11, the S3 & S4 by Sundaya, Netherlands

Solar Box, Switserland

Powerhouse, shell Solar

2.5 CONCLUSION
Cambodia is a Least developed Country with 85% not having direct access to electricity. Electricity is expensive
and its availability far underdeveloped. Both tradition and religion still have a large influence in the daily life and
social organization. Khmer culture is superstitious, full of symbolism and very hierarchical.
The main advantages of solar PV systems in Cambodia is their independence from the electricity grid and their
long lifetime. The efficiency of the PV system depends on the quality and orientation of solar panel and for
Cambodia should be fully south at an tilt angle of 17,5 degrees. The amount of energy that it generates then
depends on the local irradiation, which for Cambodia is an yearly average of 5,3 full sun hours a day
A Solar Home System (SHS) is a small autonomous energy station, powered by a solar panel, that provides electricity for basic services to rural households. Kamworks wants to deliver a high quality and appealing product,
an integrated SHS specifically developed for the rural countryside of Cambodia and with high service. Besides
a functional energy provider, it should be a desirable product. So instead of installing the technical components
separately, they are enclosed in a indoor connection station (Homebox). Three SHS versions will be developed
by Kamworks, according to an increasing energy demand and budget.
A separate brand name was set up for the activities of Kamworks on the consumer market. The market of solar
energy in Cambodia is still in its children shoes. It is to be expected though that kamworks can easily become
market leader with its unique SHS design.

17

3. PRODUCT - USER CONTEXT

In this chapter the environment for the SHS and the user interaction with the product in context is described.
A image is formed of the users where the SHS will initially be designed for, their living situation, daily rituals,
construction of their houses, use of electricity and electricity desires. Finally Khmer art and architecture is noted
as possible input for the SHS appearance design.

3.1 INTENDED USERS


Kamworks is a small starting company that still needs to generate income by immediate sales. Therefore the
Solar Home System is intended at principal as a cash product for the more wealthy rural affluent. In the often
remote countryside, an increasing group of people are acquiring considerable wealth and desire higher living
standards. The wealth in cities is furthermore growing of which the family still living in the countryside also
benefits. This creates a large new group of possible customers for the relatively expensive SHSs.
There is still a great variety in the income and status of rural families. A average poor family in rural Cambodia
can earn between $200-$500 per year and spends about $20 on (kerosene) lighting [MIT, 2007] and up to 50$
in battery charging a year [Boom, 2005]. Based on field research and observations by Reitenbach and MIME
[2007], the rural population can be divided into four target groups, dependant on income and living standards
Very poor ~1,5$ / day
They live often in small, slightly elevated huts, made from palm leaves, bamboo slats, wood and a thatched
roof. They are just partly self-sufficient in their food supply, cultivating rice, catching rats and frogs, but largely
depend on community help. They mainly use kerosene for lighting, sometimes own a radio but just rarely own
a discarded car battery for additional lighting. They live from day to day and are not able to make larger expenditures. Often just one or two old bikes serve as family transport.
Rural Poor 1,5-3$ / day
This group forms the largest part of the rural countryside. They live in small wooden houses on poles, with
thatch, iron or asbestos roofs. They are mostly farmers and sometimes own a very small shop. Although only
2-4% has electricity, about 60% owns a reasonable/old small car battery for lighting, a radio and often a black &
white TV, additionally kerosene is also used. They can manage to save small amounts of money to make larger
expenditures. Sometimes the family has a shared motorbike. [MIME, 2007] ,
Rural affluent >3$ / day
When a family climbs higher on the social ladder and acquires more wealth they often remain living at the same
location in the countryside, but then upgrade their house and desire better living conditions. These families are
often farmers with larger lands and are able to purchase machines to cultivate it. Only up to 15% has electricity,
about 85% has a good quality large car battery to power their electrical appliances like a dvd-player, stereo and
b/w or color TV. These families often own several small motorbikes. [MIME,2007]
Rural rich >10$ / day
These families form a very small group on the rural countryside. They live in modern brick or half brick/wood
houses with tile roofs. They often have a business, have a long family history, own large areas of land, or are
government related. About 40-50% has a own generator to fulfill in their electricity need, often they also provide
electricity for a small fee to some neighbors for lighting and thus operate as a REE. The majority also has one or
more car batteries for their principal energy supply or as a backup. They have many electrical appliances mostly
operating at 220V AC power. These families often own several motorbikes and sometimes even a car.
SHS focus
Currently Kamworks should focus the SHS on the rural affluent, who can be considered as early adopters.
These wealthy families are progressive, not afraid to take risks and are usually interested in new technology
and products. Their energy need usually still fits within the abilities of a SHS. It can be expected that there will
be a trickledown effect to the rural poor, as word of mouth advertising is a common thing in Khmer culture,

19

though, to make the SHS affordable for this group some credit system should be set-up. One of the strongest
motivation for the Khmer to buy things is the desire to posses what the neighbors have, sometimes even when
its not financial viable.
The rural rich usually have an electricity consumption (by 220v, AC), many times larger than a SHS can provide
and often have a generator, therefore they dont form the focus for the SHS. From the user research it consequently seemed they perceived a SHS a step down, since they already had a generator providing all the electricity they needed and are not familiar with solar energy. There is an opportunity for the SHS though within this
group, promoting it not so much as a principal energy supplier, but mostly as innovative, renewable energy that
is flexibly available for small electrical appliances, also during the day, without starting the noisy generator.

3.2 CURRENT ELECTRICITY SOURCES


Since grid electricity, with only 10% availability, in the countryside is virtually nonexistent, rechargeable lead-acid
car batteries are used by the majority of the rural population. Kerosene is often still used additionally for lighting.
Other energy sources, like wood/charcoal/gas, for cooking etc. are left out of this project consideration.

Grid electricity

Normal grid electricity is usually only available next to the few main roads in the rural areas. In some locations
small REEs (rural electricity entrepreneurs) operate a primitive unreliable grid, calculate high prizes and provide
electricity only in the evening, usually between 18-22h.

Generator

The few affluent families that own a generator, only run it in the evening and thus still dont have regular electricity during the day. The generator can usually only be operated by 1 or 2 family members, is perceived as
very noisy, stinky and unsustainable. But it provides a high status in the society and lacks alternatives to fulfill
their high energy demand..

Car batteries

The batteries can be charged at small battery charging stations, usually set-up by
a smart local villagers with a generator. These battery charging stations are usually
very primitive, very unsafe, insufficient and always use a noisy generator to often
bombard the batteries at high voltage for fast charging. The local operator is often
inexperienced and has little knowledge of electricity.
The stations are well spread, in 10% of the cases, often in more remote areas they
have a pick up en delivery station. Meaning that in the majority, the family has to
bring the heavy battery to the store their selves (Fig 3.1).
The way of charging is very damaging, the battery capacity decreases rapidly and
usually a battery breaks down within a year of use. The batteries are charged without
a charge controller, directly by the generator. They are often just tight together by
some uncovered copper wires, independent on their state of charge, type or age.
Therefore unsafe situations easily occur and is overcharging impossible to prevent.
For example, during the field research an operator just determined the moment to
stop charging, when a battery in the line started to boil.
The prize of battery charging is even with the current increase of fuel prizes very low,
depending of the location about 1500-2000R for a 50Ah battery and 2000-2500R for
a 70Ah battery. This low prize puts a high pressure on the stations to charge the
batteries with minimum time and effort. Often resulting in a low quality service, at
which the state of charge, thus the amount of energy that the customer gets is uncertain and the battery gets certainly damaged. The Khmer are aware of this problem
and do try to choose the best charging station available, But due to large distances
and a limited budget there is usually no choice.
Fig3.1, Charging, transporting and connecting car batteries

20

Kerosene

Due to the restrictions and costs of car batteries many people additionally
still use kerosene lights. Compared to the heavy car batteries, kerosene
lights are mobile and can be used for domestic tasks in the evening. The
Khmer are very superstitious and therefore usually leave a night light on,
especially when they have young children. Furthermore they use the kerosene light together with the television and as an orientation light, as a
normal lamp is then perceived at too much light.

3.3 ELECTRICITY USE AND DESIRES


During various field researches 40 Cambodian families have been visited
and a general image of rural life in Cambodia could be formed. Electricity
stands at the cradle of development as it provides lighting and communication; fundamentals for daily life, to exploit a business, study, prepare food
and for social gatherings.
There are many factors that define the ideal source of electricity. Grid
electricity is desired most and has the highest status as it is the most flexible and the rich peoples thing, but its hardly available and the costs are
relatively high. From the field research in Pursat [HOPE, 2008] it appeared
that the Khmer find it most important to have an secure energy source,
one that is reliable and available when they want and where they want.
Although they are not too much aware of the differences between DC 12V
and AC 220V power, they do want to be able to connect all possible appliances, sometimes 12v appliances are more difficult to find also.
Electricity of a generator does provide all the electricity they want, but is
only available when the generator is working, usually in the evening when
electricity is needed for lighting. A generator however is noisy, stinks, demands maintenance, cant be turned on for short intervals, has to operated
and consumes fuel, that still has to be bought from somewhere else.
A battery is easy to use, although sometimes mistakes are made in reversing the positive and negative poles when connecting appliances, which is
dangerous for the battery and can damage the electrical devise (Fig 3.2).
The commonly used wet car battery needs maintenance and is in principal
dangerous and bad for the environment as it contains acid. Many Khmer
indicate that they want to keep it away from their children. The largest disadvantages of using battery electricity is that it is uncertain when its empty
and takes a lot of effort in recharging it, as the 15-20kg battery has to be Fig3.2, electricity context
brought to a charging station. Obviously the household is without electricity when the battery is being charged,
which sometimes takes more time because of problems at the primitive charging stations. Some indicate that
its important to always have electricity when having a small business.
Solar energy is not a commonly known energy source, but does have many advantages above the currently
used sources.
Cambodians are very creative in connecting appliances to a battery, the 12v DC power is not dangerous, still it
is desirable to improve the situation. Switches are never used and a devise is turned on/off by simply applying/
removing the positive clamp on the battery. Threads are just knotted together and lamps hang freely on hooks
or are taped to a pole. Light bulbs are not common, instead CFLs are mostly used, but their quality and lumen/
watt varies widely due to the often inefficient cheap balances used. They dont use wall sockets, thus electricity
is only available at the battery source. AC color TVs are often altered in small repair shops to be able to operate
them at 12V DC power. This however is done very ineffective by simply connecting 2 cables behind the transformer, causing an very high power consumption, up to 120-180W have been measured in the field research.

21

3.4 KHMER HOUSE


It is important to define what a Khmer house of the rural affluent is like, since the SHS will be installed in and
on the house. The most suitable place and way of installing the solar panel, the location for the Homebox and
the fixed light points have to be determined. Khmer culture strongly expresses itself in the social living space
and should therefore also be taken into account in the appearance design of the homebox, the most visual part
of the system.

Khmer house types

Since there is quite a strict income division between various social groups on the rural countryside, its relatively
easy to determine the accompanying house types based on appearance and the material used. [MIME, 2007],
made a description of the various house types and division over the social classes (Fig 3.3) . The rural affluent
live in fairly big well maintained wooden houses with tile, iron or asbestos roofs.
Thatch with Iron or
thatch roof

Wood with iron, or


asbestos roof

Very poor
Rural Poor
Table 3.3 A division of house types based on social classes

Wood with tile roof

Brick or
Half brick-wood

Rural Affluent

Rural Rich

The rural affluent house

A Khmer house is build very traditional, especially the better quality houses of the rural affluent are build according to the same decades old construction plans. Fig 3.4. A Khmer house is single leveled and build on poles,
due to the climate, risk of floods, practicalities and tradition. It is not so much that the house is elevated, as the
most important living space is actually the one bellow the house.
A Khmer house doesnt need a foundation and is build directly on the soil by wooden/concrete poles, on which
the 1st level wooden poles are mounted, then a wooden skeleton is build, which will supports the roof and the
walls of the house (Fig 3.5). The wall doesnt have supportive strength and is build up by hammering wooden
planks, usually vertically, to the outside of the house construction (Fig 3.6). The roof is about half a meter suspended on all sides, creating more shade on the walls and protecting the wood. At some point water is channeled
and captured into large water jars behind the house. Often the principal source of water for a household.

Fig 3.4 A traditional Khmer House

22

Fig 3.5 The house supportive skeleton

Fig 3.6 The Roof point and overhang

Windows dont have glass but do have bars for security, windows have shutters to close during the day against
the hot sun. A Khmer house is with an average height of 6 to 8m fairly high. The ground floor is about 3m, with
an additional 3m to the roof beams and then 1 meter to the roof ridge. The 1st level doesnt have a ceiling and is
open until the roof to let warm air rise. The 1st level consist usually just of 1 large living space, with 1 additional
small bedroom, the kitchen is always downstairs and a bathroom is just outside behind the water jars.
Architecturally the houses are very similar, an overview of several types is given in Figure 3.9 on the next page

3.5 DAILY RITUALS, USE OF HOUSE


The most important living space in a rural house, is actually the open space under the house (Fig 3,7). Life here
revolves around a large bamboo sitting area from dawn to dusk. This is where a family spends its free time,
receives guests, prepares food and do the domestic tasks. The Cambodian climate is year round tropical warm,
the space under the house is shaded ,ventilated and cool. Only during the rainy season they spend more time
in the house. The kitchen and water source for washing and drinking are generally also downstairs under the
house or in a small hut beside it. The Khmer love to be outside so during the day rural life solely takes place
outdoors. In the evening when the night falls, the families moves back inside, to the large central space upstairs
(fig 3.8).
The house is usually not divided in rooms as they dont find privacy to important and the families are fairly big.
From the field research it appeared that the richer families do sometimes divide the house in separate rooms by
curtains or wooden walls and become more western in their daily rituals.
In general the Khmer dont have to many possessions or furniture , they prefer to sit on the floor or on a bamboo
bed, so they never have chairs or a table. Shoes are not worn in the house, as the floor actually functions as
their chair and table, that is where they sit, sleep and eat on. A house always has a central cupboard where the
valuables are stored and the electric devises are placed on. The family usually gathers around the tv at night.
The children sleep on the bamboo mats on the floor, the parents usually sleep on a elevated bamboo bed, and
when present in the separate room. As the Khmer are quite religious there is always a small altar somewhere
connected to a support pole, to make sacrifices.
The interior is dark and sober, with only natural colors. The walls are hardly never painted and the floor is from
bamboo or wood, colorful mats are just placed to sit or sleep on. The only decorations are random colorful
posters, usually from landscapes, married couples and hair models. There are always some photos prominently
display of a wedding or deceased family member, as marriage and funerals are the most important events in
Khmer culture.
The families all indicate, that the SHS should be installed in a fixed place, upstairs where it will be safe, easier
to keep clean and close to the their tv and radio. The solar panel should primary be installed where it will work
most effectively and secondary where its most visible. The lights should be placed central in the large living
space upstairs and at the bamboo bed downstairs and in the kitchen or if present the shop [HOPE, 2008].

Fig 3.7 Downstairs sitting Areas

Fig 3.8 Upstairs central living space

23

24

3.6 KHMER ART & ARCHITECTURE


Cambodia has an rich history and a distinct Khmer culture that also reflects into the countries art and architecture. Due to the appearance design of the Solar Home System, some attention is given to the modern symbols
of the Khmer culture.
The Khmer are proud of their rich inheritance, the most outstanding Temple Angkor Wat (Fig 3.10), became a
national symbol and is displayed on the national flag (Fig 3.11). The supreme art work can now a day be found
mostly in the many temples of Cambodia (fig 3.12). The elaborate carvings and the symmetrical, layered roof
structure being the most distinct features. Similar symbols can be found in the Khmer houses, as can be seen
on the previous page.
Since there are not to many products made in Cambodia and the Khmers sparsely use of furniture, there are
hardly any modern products with the distinct Khmer features. From field research a image of preferred product
features could be formed [HOPE, 2008] , [Concept choice, 2008] .
The Khmer like straight lines and shapes, the curvatures should be small and the transitions between planes
strict. Round shapes are by some even perceived as ugly. They like pointy shapes, with distinct layers for various
functions. Things that point upward, towards the sky, high as the religious mountain symbol of mount Meru.
Symmetry and repetition are important themes Elaborate decorated furniture and textiles are valued higher and
bright colors seen as a welcome change in their sober interior. The color blue and yellow are valued as the most
pleasant color, as they are bright and radiant like a clear summer day.
It should be noted that this is the classical view of the Khmer to products. The younger more urban orientated
youth ogles to western products and seeks a mixture to the traditional values and the wealth of the west. Meaning that for example they do like round shapes, but still desire a certain repetition in the shape.

Fig 3.10 Angkor Wat

Fig 3.11 The Cambodian Flag

Fig 3.12 A temple roof

3.7 CONCLUSION
Kamworks needs to generate income by immediate sales. Therefore the Solar Home System is intended at principal as a cash product for the more wealthy rural affluent of which only up to 15% has electricity and about
85% a good quality large car battery to power their electrical appliances. Kerosene is often still used additionally
for lighting. Grid electricity is desired most and has the highest status but has many set-backs. The largest disadvantages of using battery electricity is that it is uncertain when its empty and takes a lot of effort in recharging
it. The Khmer find it most important to have an secure energy source, one that is reliable and available when
they want and where they want. They are very creative in connecting appliances to a battery,
The rural affluent live in fairly big well maintained wooden houses with tile, iron or asbestos roofs. A Khmer
house is single leveled and build on poles, the most important living space is actually the open space under the
house. Walls are not supportive and the roof always overlaps everywhere. In general the Khmer dont have to
many possessions or furniture.
Cambodia has an rich history and a distinct Khmer culture that also reflects into the countries art and architecture which should be given attention to in the appearance design of the Solar Home System.

25

4. TECHNICAL CONTEXT

In this chapter all issues concerning the technique and functionality of the SHS are described, for the set up of
preliminary requirements of the pilot product later. The abilities of the SHS, and the knowledge of the components and connections are elaborated. The composite production process is defined and many of the current
production problems solved. The installation for the 1st time is analyzed by giving a installation training and
observing a solar installation. As input served the installation surveys, composite tests, electronic notes and
component datasheets.

4.1 SHS COMPONENTS & CONNECTIONS


Besides a SHS that fits within the user context, it also has to be technically outstanding. Therefore the system
components (Fig 4.1) and connections have to be properly selected to match each other. At the start of the project Kamworks had selected the principal components for the three types of SHSs, based on the requirements
set by the REF-rant guidelines [REF, 2007]. Within this project the assembly, connections and functionality of
these components will be defined and tested. The Datasheets can be found in Appendix A

Fig 4.1 The main SHS components

The following components are used in the SHSs and will be assembled in the box, mounted on the support
structure and installed in the house. In table 4.1 the initial quantities and type per SHS are indicated.
Component

Details

Battery

IBT BT48-12HC deep cycle battery; C20 = 48 Ah

Medium

Large

Large+

1x

2x

2x

Charge controller

Phocos

12v Socket

CML-05

CML-10

CML-15

12v cigar Lighter socket, female

2x

2x

2x

12v plug

12v Cigar Lighter plug, male

2x

2x

2x

Inverter

Victron Phoenix 12/180 Pnom = 180VA

Fuse holder

Ripca FHA16

1x

1x

1x

Fuse

Standard Blade fuse

10A

15A

20A

Lamp holder

Fixed lamp holder, black

4x

6x

6x

Directional light

1w LED light unit

1x

1x

1x

10

Solar Panel

Kyocera KC40T; Pnom = 40 Wp

1x

11

Solar Panel

Sharp NE-78T1; Pnom = 78 Wp

Additional items that are not displayed:


-

1x

1x
1x
Table 4.1 , List of components SHS

EL-DC-2U-7W-12V, Fluorescent lamps, 3x (medium) or 5x (large & large+)


Single/double switches and connection boxes, amount depends on the situation at location
Cabling, 2x5m Solar LAPP solar cable 2.5 / 4mm2, for connecting the solar Panel to the Homebox
20m VAF 2 x2.5 / 4 mm2 incl. 50 cable clips 7mm, for installing all fixed light points

27

Component assembly
The charge regulator is the so called spider in the web that controls the electricity flows within the system. The
electric schemes of the SHSs are displayed in figure 4.2, the three areas of use and the inverter for the large+
system are marked in different colors. The yellow zone marks the panel and support structure, the Homebox
red, the load blue and the inverter green. The panel and load is connected to the Homebox where the colored
areas overlap, at principal the inverter will be installed outside the Homebox due to safety and complicity of
integrating this part. For maximum system efficiency components should be properly connected with cables
of the appropriate diameter. Cables have an inner resistance, that increases by high currents and cause heat,
that inconsequence results in considerable energy loses. The necessary cable diameters are defined in the REF
requirements and the Charge controller manual.

Fig 4.2 , The electric schemes of the 3 solar Home systems


System Protection
The SHS will be fully secured in use by the utilization of three different type of fuses. The charge regulator controls the power currents of the entire system and is protected against reverse polarity by an onboard electronic
fuse, in case an appliances is wrongly connected. The same fuse stops the load if to high a current is demanded
according the controllers type (5-10-15A), the system is then reset after 2 minutes.
Furthermore, the 12v car plugs have a so called single use fast fuse of 10A that breaks immediately when to
high a current is demanded by the electrical devise. This is to protect the more expensive and delicate charge
controller. The battery is double protected by an additional blade fuse, this is a single use slower reacting fuse
to prevent any chance to dangerous situations with the battery in case of overload or reverse polarity that bypasses the controller.
Connections to the Homebox
With the SHS several fixed lamp posts will be installed in the house. They will be connected directly to the homebox and can be switched on/off by satellite switches in the house. High efficient 7W lamps will be installed to
guarantee efficient and secure lighting in the house. A 1w directional LED lamp is placed as an orientation light
to replace the use of the kerosene lamp as a night lamp for comfort and superstition.
Other electrical appliances like television, VCD-player, radio and mobile phone chargers can be connected to the
homebox thru a 12v car-plug by the users themselves. It is assumed that the Khmer will turn the devises on/off
by simply inserting/removing the plug, like they do now with the clamps on the battery and because there are
multiple devises to connect. A male car-plug should be connected to the appliances by the Kamworks installer
to guarantee proper connection of + and - for starters. The users should however have the freedom to connect
plugs to new appliances themselves later and often desire to still be able to connect the devises to a regular
battery.

28

4.2 COMPOSITE PRODUCTION


The production of the SHS by the use of Glass Fibre Reinforced Polyester (GFRP) was predefined at the project
start. This entitled Kamworks to gain expertise in the production process of hand lay-up and design the product
according to the material properties already in an early stage of the process. Though still a great number of
production problems had to be solved to secure a sufficient product quality.

Glass Fibre Reinforced Plastic

Composites are engineered materials made from two or more constituent materials, which are chemically
bonded to obtain a better combination of material properties. GFRP consists of a thermoset polymer matrix
(resin) that surrounds a woven glass matt, which functions as a reinforcement. Design goals of fibre-reinforced
composites often include high strength and/or stiffness on a low weight basis. [adapted from Callister 2000 by
Hensen, 2008]. The actual material properties of the composite largely depend on the handling of the materials
during the production process, since material and the final product shape are created at the same time. Hand
lay-up is an accurate craftsmanship and is important to master in producing high quality products.
Composites have certain characteristics, advantages and disadvantages in comparison with other materials. Because of these, composites are often preferable above conventional materials, such as wood and steel [adapted
from in t Groen, 2004 by Hensen, 2008].
The most important advantages:
By varying combinations of fibre and matrix, different material properties can be reached, creating a material which can be customized for each application. Material properties can even differ per product part.
Very good strength to weight ratio
High chemical resistance (chemicals, moisture, UV, corrosion resistant)
High form freedom
Possibility for inserts
Low initial costs which enables the production of small series
The most important disadvantages:
More expensive than other materials, because of high labour costs
No possibility to recycle the material
[adapted from Bttger and Lepelaar, 2006 by Hensen 2008]
Synthetic resins and fibres are the most commonly used and the easiest to handle in the hand lay up process.
However the development of a 100% natural resin is under way and the use of natural fibres becoming more
customary with the use of the closed mould, RTM (resin transfer moulding) production process.
The use of natural fibres is more sustainable and thus preferable, but the production process far more complex
since the RTM or intermediate VA-RTM (Vacuum assisted resin transfer moulding) process have to used to obtain
quality products. For this reason Kamworks focusses first on the hand lay production with synthetic materials.
Although epoxy has slightly better material properties, Kamworks chose to use a polyester resin instead of epoxy
since its easier to process, cheaper, wider available and safer to use.

Chemical Reaction

Fig 4.3 Composites test to define its process

During the process a liquid polyester resin solidifies by


an exothermic reaction that is initiated by a catalyst
(hardener). The amount of premixed accelerator (cobalt) defines the speed of the process and the amount of
catalyst the processing time to hardening. An additional
restrainer (inhibitor) can prolong the processing time of
a premixed resin (polyester). The mixing relations come
very strict and the processing time is highly dependant
of the working temperature (Fig 4.3). An increase of 10
decrease, doubles the speed of the process.

29

Step 1, The positive mould

Production process

At Kamworks the SHS will be created by so called hand lay-up, where the
final product is created by applying several layers of material by hand. Several tests [Composite tests, 2008] have been conducted to tackle Kamworks
composite problems and to gain experience in working with composites in
the Cambodian climate. They have resulted in the following process description (Fig 4.4), a full description can be found in Appendix B.
Step 2, The negative mould

A.

B.

Step 3, The Final products

C.

1. The positive form; should be an accurate representation of the final


product, usually made from foam or wood and carefully finished. It is important that the wood/foam is sealed of by a layer of varnish or polyester putty
to prevent the resin to react later. When the mould is properly sanded and
polished, up to 5 layers of mould release wax should be applied. If the mould
remains undamaged, it can be used to make multiple negative moulds.
2. The negative mould; is made by the same process as the final product
later. When the negative mould is fully cured, it can be released from the
positive plug and be prepared for the final product by applying again several
layers of mould release wax. The amount of wax can be reduced over time,
when multiple products are made.

C.

A.

Step 1: Create a positive mould equal to the desired final product


Step 2: This mould is then used to make a negative mould.
Step 3 : With the negative mould then multiple products can be made.

B.

3. The final product; the negative mould can be used multiple times to
make final products, but should always be waxed.
A. First a layer of colored polyester gelcoat is applied to the mould.
Gelcoat is harder and more resistant to external influences and forms a
aesthetic protective layer around the later product. A contrasting color
pigment is mixed with the gelcoat as it assist properly applying future
layers. The process is initiated by adding a small amount of hardener,
as the climate in Cambodia is very hot a small amount of inhibitor might
be added to increase the processing time. The gelcoat should be applied
in two layers for a smooth finish. When the last layer gelcoat is almost
cured the resin and glass matt can be applied.
B. The polyester resin can be initiated with the same hardener and then
be applied to a surface in a thin layer, the glass matt should then be
pressed with additional resin into this fresh layer of resin. The matt will
adsorb the resin and the glue that keeps the glass fibres together will
dissolve, making the mat flexible and easier to shape into the mould. A
minimum amount of resin should be used and air bubbles avoided to
obtain a stronger composite material. Multiple glass fibre layers of can
be added to strengthen the shape, also specific areas can be reinforced
this way.
C. The product can be released from the mould, then cut in the right
shape and cleaned

The current working conditions at Kamworks are very primitive, making it


hard to produce high quality products. The additional lack of proper protective wear, ventilation and cleaning agents furthermore posses a health risk
for the employees and dangerous situations are impossible to avoid. There
Figure 4.4, Hand-lay up produc- are not sufficient mixing cups, cleaning cloths and detergents (acetone e.g.)
tion process GFRP, with the SHS
to clean brushes and the workspace, causing unnecessary loss of material,
0-serie
higher costs and most important a very undesirable production situation.

30

4.3 INSTALLATION
The installation is a crucial moment in the life cycle of the SHS, since it has great influence to the correct functioning of the Solar Home System for the decades, the customers satisfaction and indirect to Kamworks profit.
Since most installation missions will be far from Kamworks in remote areas it makes it even more weighty. The
installation of the SHS should be straightforward, adaptable to any situation and limit the chances of errors. It
therefore also forms an integral part of this project and is taken into account already in the early stages of the
design process.

Fig 4.5 , Solar Systems installed by Kamworks; rotatable panel on a floating church, angle of solar panel, roof
mount, solar system on a school, adjusting the mounting holes of a solar panel

Besides being properly prepared for any situation on an installation mission, have all the necessary tools and
materials and have well trained personal. The design of the SHS also has influence to the success of installment.
The SHS consists of 3 parts, the panel & support, the Homebox and the Load. Considering the installation special attention should be given to the following elements of the SHS.
The mounting of the Support structure
The orientation of the Solar Panel
The location and orientation of the HomeBox
The connections of the Solar panel and Load to the Homebox
For complete comprehension of the critical elements of installment, several field researches have been conducted. All with a different emphasis of the Installation.
Analyses of large Solar Systems installed by Kamworks (fig4.5); their capacities and installation approach.
SHSs installed by competition(fig4.6); things that go wrong, communication to the end-user[Appendix C]
Installation observation of a Solar system by Khmer Solar (fig 4.7); overall installation process, communication, orientation and mounting of the panel, placement and connection system components. [Appendix D]
A SHS installation training for future installers COMPED (fig 4.8) ; Critical attention points, communication
of the design to the installers, indistinctness [appendix E]

Fig 4.6 , SHS installed by competition; SHS, system board with controller, superette battery, CFL light point,
solar panel on the roof

31

Most important observations are displayed bellow, with the additional photos:



Upon arrival, check the contract, payment and what system will be installed, while the other unloads all
materials
At start of the installation, communicate properly with the customer where he wants the SHS and how to
access all areas. Leave a Professional impression from the start.
Take even the most unexpected tools and make sure there is sufficient power to use them, by for example
a generator
Install a system with 2 persons, let both be responsible for a part of the installation, and let them check

Fig 4.7 , Installation observation of a Solar system by Khmer Solar; tools, lifting up the support structure,
installing the system components, Solar system, end-user explanation

each others work. There should be one supervisor.


Minimize cable lengths and use cables with the proper diameter
Standardize all connections between the system components, to enable a mechanic to easily fix problems
in the future. Mark all wires and use a standard color coding for both the cables and connectors
Secure all connections with cable clips or if possible with a cable gutter
Be careful in taking materials up the roof, prevent moving up/down to much.
The mounting of the support structure and panel should be tested before installment
Make sure that the support structure can be universally mounted to every thinkable roof construction
The solar panel should be adjustable to the orientation and roof angle of the house to guarantee the proper
placement of the solar panel. A compass and level are crucial here.
Connect the battery before the SHS, to avoid high voltage to the load or damage of the controller
Check carefully if the roof did not get damaged during installment
Choose the location for the ground carefully and think if will be effective
clean all materials and close of all holes that are created
Explain the system carefully to the end-user, leave behind a reference user manual.

Fig 4.8 , SHS installation training for future installers COMPED; explaining the system functions, homebox connections, connecting the load, putting up the solar panel

32

4.4 CONCLUSION
System components and connections

Within this project the assembly, connections and functionality of the SHS
components will be defined and tested to make it technically outstanding.
The charge regulator is the so called spider in the web that controls the
electricity flows within the system. The SHS will be fully secured in use by
the utilization of three different type of fuses.
There are three areas of use; Power in, the panel and support structure.
Power store, the Homebox. Power out, the electric appliances as a load .
With the SHS several fixed lamps will be installed in the house and controlled by remote switches. Other electrical appliances can be connected to
the homebox thru a 12v car-plug by the users themselves.

Production

The production of the SHS by the GFRP was predefined at the project start.
Therefore experience in working with the material and process is build up,
initially still a great number of production problems had to be solved to
secure a sufficient product quality.
With GFRP can by varying combinations of fibre and matrix, different material properties be reached, creating a material which can be customized for
each application. It has good strength to weight ratio and high form freedom and the low initial costs enable the production of small series.
During the process a liquid polyester resin solidifies by an exothermic reaction that is initiated by a catalyst (hardener). At Kamworks the SHS will be
created by so called hand lay-up, where the final product is created by applying several layers of material by hand. A product is made in 3 steps, 1st
a positive mould, then 2nd with this negative mould, which will 3rd finally
be used to create the final product

Installation

The installation is a crucial moment in the life cycle of the SHS, since it has
great influence to the correct functioning of the Solar Home System for the
decades. The installation of the SHS should be straightforward, adaptable
to any situation and limit the chances of errors.
Besides being properly prepared for any situation on an installation mission,
all the necessary tools and materials have to be present and the personal
well trained. The design of the SHS can also contribute to the succes of the
installation
During installation, attention should be given to the following elements of
the SHS: The mounting of the Support structure, orientation of the Solar
Panel, location and orientation of the HomeBox, connections of the Solar
panel and Load to the Homebox.

33

5. PILOT PRODUCT DESIGNS

Based on the previous analyses and orientation preliminary requirements for the design of a pilot SHS product
were set up. These requirements are related to the issues that will be tested in the design research and vary
from the requirements of the final product later. The pilot SHS product designs are described and form a basis
for the final product design, especially the technical part is detailed as it will not be elaborately discussed again
in the final product design description later. The complete SHS, the Homebox and support structure will be described separately. The Support structure design was created by design upgrades after each installation, these
will be described in order to explain the eventual design.

5.1 INTRODUCTION
At the start of the project the main goal was to rapidly develop a pilot SHS to test in the field. This way the SHS
could be designed in context, with the user central and also with a strong emphasis on production and installation. Thereby reducing the time-to-market, since experience with the product and the new market is already
build up during the development of the product.
The emphasis in the pilot SHS product was mostly on the technical operation, production, installation and user
interaction and not so much on the product aesthetics yet. Kamworks had already been working on a design of
the Homebox. This design was maintained and elaborated, for time already invested in these moulds and the
desire to test the Pilot SHS fast. The focus within the pilot designs is on the Homebox, as the support structure
is not as detailed yet and should 1st be more defined in location and mounting.
Since the batteries for the SHS were delayed months, 4 replacement batteries were bought to conduct the SHS
tests. This means however that the development of the SHS will concentrate itself around the Medium, 40W
system, since only a limited amount of batteries were available.

5.2 PRELIMINARY REQUIREMENTS


To create a medium (40wp) pilot SHS product design for the design research a number of criteria were set up.
These are specific for the issues that will be tested and will be elaborated for the final product. The principal
ones are noted bellow.
The SHS
1. Functions and performs technically perfect
2. Is safe to use and protected against abuse
3. Provides the desired amount of energy
4. can be produced in series without any restrictions
5. The system should be user friendly and its use and operation understandable for all
The Homebox
6. Has an distinctive appearance and is regarded as an appealing product.
7. Is closed off for the users but can be serviced for maintenance
8. Should have a clear and understandable display to give energy feedback to the end-users
9. The system components should be located properly, optimizing the system operation and interaction
10. Electric devises are easy to connect.
11. Design is strong, durable and matches its function
The solar panel support structure
12. Is easy and secure to mount to a standard Khmer house
13. Is straightforward to install and limits the risk in errors
14. Is corrosion resistant
15. Is strong and can resist high winds
16. The solar panel can be properly orientated and installed in the right tilt angle
The load
17. Lights and switches are properly connected to a house and the box
18. The user can easily connect additional electric appliances to the Homebox
19. Matches with the customers energy need

35

5.3 THE SHS


The SHS is developed as a complete product, that functions as a small domestic power plant. Meaning that the
main components are integrated into one so called Homebox and the system should express one identity. It
should be perceived by the end-users rather as a new product, than for example an adapted battery box. The
appearance of the system is therefor also very important in creating an extra product desire. There are three
types of SHS, these should notably form one product family but have distinctive differences (Fig 5.1, 5.2).

Enclosed box

The Kamworks SHS will be the 1st SHS in cambodia where the system components are integrated in a product.
To assure optimal functioning and use of the System, the product context and interaction should be carefully
analyzed.

Power supply

The medium, 40Wp Solar Home System should provide the household with
the desired amount of energy, within the capacity of the system. For the medium system, this is a bout 120Wh, per day, which equals a certain amount of
hours of using lamps, tv and a radio. The amount of energy that the system
generates should match the consumption of the users. Therefore the number
of lights, the type of tv and the hours, should made clear to users and feedback about the energy level been given.

End-user manual

As a reference document a short A4 is presented to the end-users, explaining solar basics, the functioning and operation of the SHS. In figure 5.3, the
manual for the pilot tests is display, the amount of information is kept very
condense and partly graphical, to make it more attractive for the users to
read. The manual is explained and handed to the end-user in Khmer after
installation of the SHS.

famBlx a tmFmsM r ab; e RbI k g p H


xatmFmKW 12v 4048 DC RbBnRBHGaTitCamYynigRbGb;dak;GaKuy
Your solar home system is a safe and secure energy
source that will full fill your daily electricity need. Your
system will work more smoothly if you know how to use
and maintain it.
Kamworks gives 1 year guarantee on the entire system
if you take good care, dont open the homebox and
break the seal.
If you do have problems with the system then contact a
Kamworks Technician:

Explanation of the system:


The solar panel provides electricity when the
sun shines. The panel works always with
daylight but gives more electricity when there is
more sun. The electricity is stored in the
homebox, which controls the electricity going
out for light and television, this way your solar
home system works more efficient.

You can get more energy from the system if you take good care of it.!!!!!!!!!!
1. Solar panel:
- dont put anything on the panel and make sure it is not in the shade.
-The solar panel should be cleaned form dust at least 1 time a month

2. The Homebox
shows how much energy the
system can provide.
When you check the energy
level on the display regular,
you know how much
electricity you can still use

Your system lasts longer


when you dont always empty
the battery

---------------------------- solar panel is working

------------------- Battery > 75%


---------------------------- Battery 75 < > 25%
-------------------------------------- Battery < 25%
Light flashing, battery < 10%
---------------------------- Battery empty
Light flashing, overload or short
circuit > disconnect appliances!

Fig 5.3 , SHS user manual


SHS use Instruction sheet

Life-time

6 May 2008

1/1

The complete SHS should have a lifetime of up to 20 years, which matches the lifetime of a solar panel. The
warranty service, with free maintenance of Kamworks however just entitles 1 year. Meaning that after 1 year
the end-user has full access to the system and is responsible for the maintenance. The battery for example
has a life expectancy of 3 to 4 years. How to tackle this contradiction, or how to communicate maintenance in
general should be well thought about in
the SHS
development and marketing plan.

Fig 5.1, The large pilot SHS

36

Fig 5.2, medium pilot SHS

5.4 SHS BOX


At principal Kamworks had made the bare designs for two sizes of Homeboxes, notably for the medium and
large SHS. The assembly of the boxes was not detailed and the assembly of the components not been taken into
account. In the kamworks design, the homebox appeared more as a Battery box, rather than an actual product
that serves as a powerplant. The shape is not sharply defined and is mostly based on the idea that the box
should be easy to carry. Which doesnt actually match with its use, since the box is installed in a fixed location.
The integrated handles largely describe the appearance of the box. The box is like most Kamworks products
mono color yellow, without any distinct features. Although it is already clear that the design of the box should
be improved, it does serve the initial goal, of testing the principle of an integrated SHS.
During the development of the pilot Homebox, the problems in the composite production have been solved and
in addition the possibilities with the production technique were explored.

Medium &w Large box

Although both the large and the medium box where developed at the same time, the main focus was on the
medium system. Therefore the SHS box will be described
according to the first design of the medium box, the functions and principal solutions are equal for the Large box.
The Large+ system is left out of consideration in the pilot
product design (Fig 5.4).
Fig 5.4 , the large and medium Homeboxes

Closing the HomeBox

The Homebox consist of two parts, a lower part that holds the battery and a top part that functions as a lit,
where the charge controller and 12v plugpoints are installed. In order to give a 1 year guarantee on the system,
the end-user cannot open the box during this period. Therefore the box should be sealed for the end-users but
still accessible by Kamworks employees for servicing the system. Since the box has to be opened easily for the
pilot tests, a flexible hinge is used to connect the parts and a simple combination lock to seal the box (fig 5.5)

Fig 5.5 , opening the box, the flexible hinge, the combination lock, the sealed box

The display

Since the Systems components are hidden, it is extremely important that the customer finds all the user information that
he desires. The display is furthermore an opportunity to give a
clear added value to the SHS, since the energy feedback can
give more certainty about the availability of electricity and create the feeling of the so much desired secure energy source.
The energy feedback also transforms the Homebox from just
a battery box to an actual product. (Fig 5.6)

Fig 5.6 , the energy feedback display on top of the box

37

It is important also how and what information should be provided on the display. Since the charge controller interface can not be modified, only the graphical layout of the display can be adapted. Thus for the Pilot Homebox
a sticker is created based on the graphics on the charge controller and previous observations from field research
A graphical representation and explanation is given in Figure 5.7.

Solar panel in operation

Battery > 75% full


Battery 75 < > 25% full
Battery < 25%
When flashing < 10% battery

Fig 5.7

Battery empty = 0%
When flashing, overload or short
circuit > disconnect appliances!

The Homebox Display shows how much energy the system can provide. When the user checks the energy level
on the display regular, he will know how much electricity still can be used. An important element also is the
bottom warning Light, this indicates why the SHS possibly is not working, simply because the battery is empty
or when its flashing, because the system is used incorrectly by overload or reverse polarity. Additional to the display it is communicated to the users that the system will lasts longer when the battery is not always emptied.

Component assembly

All system components should be fixed inside the Homebox, the charge controller, 12v plug-points and fuse being the most important ones, since they connect to the exterior of the Homebox.
The charge controller,

Will be installed in the inside of the box lit, by making holes at the right location, the LED-lights are made visible. The charge controller is fixed by two long sinked bolts, that are secured in the box (fig 5.8).

Fig 5.8, holes and bolts for installation, display and charge controller, the charge controller inside the box

38

The fuse,

A fuse protects the battery against a sudden high current or reverse polarity and can break during normal use
of the system. Since it is somewhat a common thing that can break, it should be easily accessible for the user,
so they can repair this themselves. Its function should be communicated clearly though, as it is not good to take
out the fuse (fig 5.9) without any reason, as it resets the system (and charge controller).

Fig 5.9, Fixing of fuseholder inside the box, fuseholder, install fuse, fuseholder and fuse in the box
12v Plug points,

To secure proper connection of external devises and avoid reverse polarity, devises can be connected with so
called 12v car connectors. Two 12v plug-points are installed, to enable the users to connect multiple appliances
at once. From the field research it appeared they often use a Tv and vcd player or a fan and tv/radio at the same
time. For the success of the SHS, connecting devises should easy and not restrictive to just 1 devise at once,
since this might stimulate the users to find undesirable tinkered solutions (fig 5.10).

Fig 5.10, The two plug point connected inside the Homebox lit, inserting a 12v plug, a connected 12v plug
External connection for solar cable and lights

Due to the wet climate and the presence of many bugs it is desirable to have as few openings as possible.
Therefor the solar and light cable can be fed into the box thru a valve under one of the handles (fig 5.11).

Fig 5.12, internal component connections

Fig 5.11, valve for fixed internal connections

Internal component connections

All components should be securely connected by cables of the appropriate thickness, according to the electronic
schedule of chapter 4.1 (fig 5.12) . For the pilot tests an additional data logger will be installed to monitor the
system, which complicates the cabling.

39

5.5 SUPPORT STRUCTURE


The pilot product designs of the support structure concentrate itself more on the location and mounting of the
construction, rather than its appearance and material choice. The first designs of the support structure are just
made in galvanized steel and evolve with every pilot test according to a number of iterative steps, based on
findings of the previous installment. This due to a practical time pressure of wanting the install test systems
rapidly and because of the initial emphasis on the Homebox within the project.

Placement

The principal questions for the support structure, was


where to locate the Solar Panel on a Khmer parcel and
how to secure the solar panel and support structure.
From the analyses of Khmer houses and the installation
training at COMPED (Fig 5.13) it was concluded that a
separate Pole mount next to the house was not a good
option. Due to the height of a Khmer house, complexity
of installment, extra wiring and the necessity of an large
extra wooden pole and concrete for a base.

Fig 5.5, Separate pole

Fig 5.14 Satellite


support

The logical consequence is to mount the Solar Panel on the Khmer House. There
are however a number of restrictions because of the houses construction. The roof
overlaps about half a meter on all sides, the walls are not supportive and in the
rood ridge there is an additional distance between the foundation beam and the
outside wall. Although a house always has 2 or 3 roof points, they have a variable incline and are hardly ever oriented on a polar axis. Meaning that the support
structure has to be flexible and can be adjusted to the local situation at hand to
orientated the panel at the desirable incline of 17,5 degrees fully south. The idea
generation can be found in appendix F.

Due to leakage it seemed undesirable to make holes in the roof for mounting. Therefore a solution seemed to
install the panel on the side of the house, like a Satellite support (fig 5.14). After more carefully examining
this option there seemed to many variables in mounting that structure securely to a khmer house. Also the
production of such a support seemed way beyond Kamworks abilities So although the principle of a satellite
support is still promising, the choice was made to continue with a single pole mount, thru the roof, connected
to a construction beam of the house.
The principal of a single pole mount was elaborated in several pilot test installations and has evolved to a functional solution for the support structure.

40

Fig 5.15 Solar Panel top support structures, roof location

Three pilot support structure installations are display in Figure 5.15 and 5.16 and are numbered accordingly.
Image 1 and 2 show the same pilot support installation. Both figures are discussed bellow.
1. The support consist of 4 crossed metal square stave that are mounted behind the panel for additional rigidity of the panel and to divide the strengths on the panel, mostly applied by wind force. The pipe is mounted
single sided to a constructive pole of the house inside.
2. The tilt angle of the panel was predefined by a L-profile under the framework. The Pipe however was not
placed entirely straight, due to the bend beam it was mounted to. This was clearly noticeable when the
panel was placed and then adjusted. This panel was placed in the middle of the roof due to accessibility and
a split level attic, the customer however had preferred the panel to be more visible. To limit the freedom of
movement of the pole and additional metal plate was added on the corner to secure the pipe better.

Fig 5.17 Tightening the bolts of the support, connecting the panel, checking if the panel is orientated correctly. Three important actions to secure a durable installation. This should be intuitive in the supports design

3. This panel is installed near the roof ridge, where its easy to install and very visible, but also catches more
wind. For extra rigidity and to limit torsion a double profile was added at the top and an pipe inside secured
with an additional bolt. Since the panel has to be orientated in the right direction, the framwork is extended
with a wider tube that fits over the mounted pipe and functions as a cap. This was the support top is easier
to orient and mount.
4. A large SHS is installed also on a roof ridge. Due to the concrete on the roof ridge, a distance had to be
created between the house pole and the pipe. Additional profiles define the tilt angle and limit torsion by the
wind. A mounting pipe with a thicker wall thickness should be used to limit vibrations and torsion effects by
high winds. the pipe is double mounted by 4 L-profiles to the constructive beam of the house.
Fig 5.16 Solar Panel bottom support structures, pole mounting

41

6. PILOT PRODUCT EVALUATION


SET-UP

The first objective in the project goal was to finish a SHS design, based on the initial set-up by Kamworks and
install the SHS at several test families in order to elaborate and optimize the design thru a series of user-focused
design steps, whereby parallel to a technical analysis of the product, the usability and appreciation of the product would also be tested.
Since finishing a pilot design of a SHS and finding test families proved a lot more difficult than anticipated, the
initial set-up of designing thru a series of iterative steps faded. The local situation at hand, didnt allow a strict
separation of tests, their results and design consequence. This chapter should therefor read more as a set-up
of a practical series of qualitative tests, rather than an academic conducted test series.

6.1 RESEARCH APPROACH


Introduction

The pilot product evaluation was conducted with 3 test families, a working SHS was installed to find out the
technical operation, perception and use in daily life of the system. Besides the knowledge acquired by actually
producing and installing the system, a series of surveys were conducted with the families, to evaluate the SHS
use and their understanding of the system. Additional data-loggers were installed to monitor the functioning
of the system and the families energy use. With these experiences and test results a final design of the SHS is
created, ready for production, installation and use on short term.

Research questions

The pilot product tests were conducted with the goal to get an understanding of or answers to the following
general research questions and their alteration over time.
Product
How is the general appreciation of the SHS as their principal power supplier?
How is acceptance of the SHS as a sealed box system?
How is the SHS appearance perceived as a product?
What is their understanding of electricity and solar energy?
What is the perception of the display functions, is the energy feedback desired and understandable?
How is the general user product interaction evolving over time?
Is there a reaction in energy consumption or change of daily rituals after product implementation?
How to create a product desire (reason to buy) in the appearance of product, what do they like?
Technical
What is the technical performance of the system; does it function and provide the energy as expected?
How are the electrical appliances connected and controlled?
How is the installation, is the product adaptable to the local situation (attention points, tools to take)?
How are the material properties of the composite in practise and what are future production opportunities
of Kamworks with the material?
Although not an initial goal of the project, getting experience in selling the system and finding out what it takes
to deliver a system is important to Kamworks also.

Approach

A wide variety of issues are researched during the field tests, therefore the terms product, users and product
interaction are defined clearly in figure 6.1. Although 3 systems are developed, at principal the attention goes to
small system. During the tests the functionality of the design is more important than the actual design itself
Although all tests evolve around the same field research with the test families, they are described in separated
sections as if they are independent tests. The field test, describe the more practical part, the interaction with the
end-users, which follows from a number of predefined surveys . The production and technical part entitles more
the perspective of Kamworks to the SHS and to remain flexible in adapting quick to changes, is based more on
taking small iterative steps by trail and error.

43

Fig 6.1 Definition and relation of product, users and product interaction for the user tests.

6.2 FIELD TESTS (test families)


The field tests with pilot SHS were conducted with so called test families on the rural Cambodian countryside.
The families were selected based on a certain profile, their energy use and their willingness to cooperate. The
test entitled a full installation of a SHS in a Cambodian house and the family using the system as their principal
source of energy.
There would be several contact moments with the families, that would enable us to get to know the family and
the effect and appreciation of using the SHS. The installation itself appeared, beside a practise for the Kamworks
employees, also a valuable learning moment in the development of the system.

Objective

The main objective is to develop the SHS in close cooperation with the local people and to get an understanding
of the local living context and the way the SHS can be best fitted in there. Parallel to that the system performance and functionality is tested.

Carrying out

From the orientation research and according to earlier studies [Rotman, 2006] it became evident that people in
Cambodia find it very difficult to imagine things that they are not familiar with. They furthermore reason from
a very functional point of view rather than an appreciation of appearance and looks and also find it hard to indicate preferences if multiple choices are presented at once. Since Cambodian people are very polite and afraid
of losing face [Rotman, 2006], it might be difficult to obtain honest answers from the respondents, especially
as a Western person is present. As interpreters will be used, the information lost in translation should be limited
by the set-up of the field test.
Consequently, interviews and surveys should be supported by visual material. If choices are desired, they should
be presented in pairs and then be hierarchically ordered. A direct confrontation with the product is preferred
whereby consequential surveys and interviews are conducted with the same families to build up a bond of trust
and obtain more reliable and profound answers.

Method

A number of surveys were conducted:


1. Finding test families; suitable and willing families are selected and the test circumstances defined in a contract. This proved a lot more difficult than anticipated and is therefor described as a separate field test.
2. Baseline survey; to get acquainted with family, their daily rituals and current electricity use.
3. SHS installation; customer preferences in placement of the system, the product appreciation and how to
explain the system functioning and Kamworks service.
4. Follow up surveys; How is the system used and appreciated? Is it performing as anticipated and did it improve and/or change their use of electricity and daily rituals?
5. Concept choice; The test families are asked give their preferences of Homebox redesigns, using their
knowledge of the SHS.

44

Installation

The installation itself is not conducted by a predefined test plan, but rather as an orientation for the design
and training of the Kamworks employees in how to install small solar systems. Especially the support structure
is developed by an sequence of improvements that become apparent from the previous installations. Both the
requirements of the panel construction as the Homebox design can be elaborated by the lessons learned from
installation.

Finding test families

An overview of the search for suitable test families can be


found in appendix G. Over 20 families were visited, thus
it also contains valuable selling information for Kamworks,
as it demonstrates the customers behavior towards the
SHS. Initially the idea was that a family would buy the
SHS and receive a discount for participating in the test,
this way a realistic user situation would be created and the
test results be most reliable. The family should have an
energy consumption that matches the SHSs abilities and
live in the near surroundings of Kamworks, enabling easy
access to the system and respond quickly to situations. A
short visual explanation about solar energy and the various SHSs was developed to assist in finding test families
(Fig 6.2), this document is somewhat the 1st attempt in
communicating the SHS use and in creating sales material
for the SHS, see Appendix H.

Fig 6.2 Explaining the SHS at a potential test family

It appeared however extremely difficult to find families, with the right energy consumption (no AC appliances)
and be willing and able to pay for a SHS at once. People in Cambodia are very expectant and sometimes a bit
distrustful to unknown things, they rather have someone else take the 1st step in trying new things and then
follow them [HOPE 2008].
Since only 1 family, living in a more remote area, could be
found under the initial circumstances, a renting construction for a 3 month test period was set-up. To still enable
a reliable use situation, the family was asked to pay a security deposit according to their capabilities, to guarantee
them taking care of the system An additional small monthly fee for the use of electricity would be paid to make sure
they see the SHS as their principal power source.
Now, families were interested, but many times refrained
from participating in the tests knowing they would probably like the system and would be either be sad to see
it leave or would want to buy it when the test was over.
Just 1 family decided in participating in the test, eager
to have to opportunity to try such a nice new product.
During installation a neighbor appeared and indicated that
now, seeing the system looked so nice, she also wanted
a system; a large+ SHS and could pay for it directly. According to Sak, a Kamworks translator, this was a typical
Cambodian reaction; wanting what the neighbor has and
preferably even better.
Thus 3 test families were found finally, although under
various conditions and the third family with a large+ systems.

Fig 6.3 Test family locations

45

Test families

Three Solar Home Systems were installed in the end, their locations are marked in figure 6.3. What follows is
a short description of these families, an complete overview of the families and the installation can be found in
Appendix I. The families also received a single use camera to take photos of their daily life, these photos can be
found in appendix J. and give a interesting insight in their habits without actually being there.

Test Family 01

The family of Houng Chien consist


of 5 people. The children all go
to school and the parents work at
home. They have a small business
in selling ice, rice wine and separating rice and husk. Their house is not
traditionally build, since its and extension of an old house and is next
to a river that floods until the 1st
Fig 6.4 Family Houng Chiens house, electrical appliances and new SHS level of their house every year. They
have a generator for electricity, that also provides nearby construction workers of the bridge with electricity. He
wants to invest in a sustainable form of energy and stop using the generator, because of the noise, smell and
effort of running it. Since they have a generator most of their appliances is AC an consume way more than the
medium SHS can provide. He wants a SHS, to try this new energy source as one of the 1st and will initially just
use it for lighting and charging his cell phone (Fig 6.4).

Test Family 02

The family Chum Voung


consist of 3 people and
belongs to social class of
the rural poor. Miss Toch
Komh runs a small store
under the house and is
all day at home, her son
goes to school and her
husband is hardly ever
Fig 6.5 Family Chum Voungs house, electrical appliances and new SHS
home being a construction worker. The house is build traditionally, small but reasonably well maintained and is located on the corner
of a road next to a battery charging station. Making it an ideal location for Kamworks to test the SHS, since its
in a visible location next to the 1 thing it should substitute. The SHS will entirely replace their current use of a
car battery and kerosene and is initialy installed under a renting construction for 3 months (Fig 6.5).

Test Family 03

The family Wan


Na consist of 6
people.
They
have a close relationship with
the parents who
live in the adjacent
house,
where the solar
Fig 6.6 Left Family Wan Nas house, right of the parents, electrical appliances and new SHS panel and 2 of
the 5 lights that come with the system are installed. Miss Cheav Navy is home all day due to her sickness and
spends most of her time in the house of her mother, her children all study and her husband is home only once
a month being a policemen. Their house is small, not well maintained and doesnt match the social class of rural
affluent to which they belong and will be rebuild the upcoming year . They wanted a Large+ SHS, to be able
to connect AC appliances and to full fill in their future increase of energy need. An important consideration to
purchase a SHS is to always have sufficient light for her daughters to study (Fig 6.6)

46

6.3 PRODUCTION & TECHNICAL TESTS


By the need to produce several pilot SHSs for testing, the production of the system itself is also explored, more
by practise than predefined tests. The technical functioning of the system is monitored by datalogging, although
these tests were predefined, many problems occurred in getting the dataloggers operational, whereby they
could not be implemented at the desired moments.

DATALOGGING

Parallel to the user surveys, dataloggers are used to monitor the use of electricity
by the families and the technical performance of the system. The user product
interaction can thereby be mapped, their perception of the energy feedback and
the SHS. Over a longer period of time the variation in energy consumption and the
change of daily rituals also becomes apparent. At the same time the functionality
of the system can be investigated, which is valuable for maintenance, future sales
and development of SHSs by Kamworks.
The principal idea was to install the dataloggers directly when the SHS would be
installed, thereby also monitoring the learning process of the family in using the
system. A additional SHS-test system was installed at Kamworks, to experiment
with the SHS, learn what problems can occur during use and to simulate the use
of the system under controlled conditions. An extensive description of building,
operating and the results of the dataloggers can be found in appendix K.
At first an attempt was made to build dataloggers with a combination of a standard
buttterfly system board, shunts and a amplifier (fig 6.7). This sadly failed due of the
complexity of the electronics and the high currents on which the SHS operates, the
loggers appeared delicate and often demonstrated unexpected behavior.
In later phase old Squirll dataloggers were brought in from the Netherlands, which
after deciphering the old MSdos software and finding the right way to connect them
to the SHS with shunts could be installed at two test families and the kamworks test
system (fig 6.8). Since time had passed and the SHS were already installed, the
systems could only be monitored for a short period of time. This data still offers an
interesting insight in the SHS performance and the families use of it and still could
be partly used in the redesign of the Homebox.

Fig 6.7 Butterfly dataloggers

Fig 6.8 Squirll datalogger


installed in the large SHS

System monitoring

In monitoring the SHS performance and use the following data should be registered; the amount of energy generated by the panel, the energy level of the battery and the energy consumed by the load connected. Additionally its important to
know, when the battery is full and when the panel is still able to generate power to
see if the family uses all the available solar energy.
To be able to interpret this data, the voltage and the current of the panel, the voltage of the battery and the current of the load should be logged. The voltage of the
battery dictates the entire system voltages. The state of charge of the battery can
be determined by the specifications of the battery. However since the test systems
are not operating with the right batteries yet, this information is not available.

Fig 6.9 Installing the calibrate solar cell for irradiation

To complete the picture the solar irradiation should be logged, to see if the family
adapts their energy consumption to the current weather and what the solar panels
efficiency is. Therefore a calibrate solar cell is installed at the Kamworks system,
to measure the solar irradiation per day (fig 6.9).
The Dataloggers can be connected to a properly configured laptop to download the
with an matching program (fig 6.10) . This is described in appendix L.

Fig 6.10 Downloading data


from an installed logger

47

PILOT PRODUCT SERIES PRODUCTION

The production of the SHS test systems entitles issues as making the composite box, assembling the components, the box finish, adding stickers and transporting they come to the attention by practise rather than predefined tests. The main topics will me described in short bellow.

Composite production

The remaining problems with composites have to be tackled and future opportunities discovered. Therefore several tests were conducted, besides producing the Homeboxes to optimize the production method. These tests
are described in appendix M. The principal points of optimization for serial production:
1. Putty, to prepare and repair the mold and damages in the product.
2. Sticky polyester, the polyester on the outside remains sticky. The most probable cause is the high surrounding temperature and humidity. Another cause could be the addition of too much hardener.
3. Mold making, experiences with mold making should be build up. Some knowledge is present at Kamworks
and described in literature from a previous graduation project but should be more elaborated (Fig 6.11).
4. De-coloring of gelcoat, yellow pigment doesnt seem to be UV-protected since it loses its bright color.
5. Finishing the product, the finish of GFR polyester material is difficult. Hazardous dust appears when drilling holes or cutting the material and should be limited in the product design, and inserts use investigated.
6. Damaging of the gelcoat, connection between layers should be improved and impact tests conducted
7. The strength of the product. How to laminate a product to make it most strong, concerning, flex, strain,
push and pull strengths. How to test durability, effect of water and sun.
8. Color transitions, it is desired to use multiple colors within 1 product (Fig 6.12).

Fig 6.11 mold separation


due to complex shape

Fig 6.12 tests with color transitions, de-coloring gelcoat and the use of inserts

The possibilities for Kamworks for a process upgrade to the so called vacuum-bag GFR (VA-RTM) process
should be investigated. The lowest threshold GFR process is hand laminating. The next step to a controllable
process with better quality products is vacuum-bag GFR. This has many advantages but also gives quiet a lot
of production waste. With a vacuum assisted process natural fibers can be used which are better for the environment and can give a nice appearance to your product. This processes are also more complex then hand
laminating and should not be thought of lightly. Some orientation test (fig 6.13) with the process are conducted
and are described in appendix N.

Fig 6.13 two test series with the VA-RTM


process were conducted, the 2nd with a more
complex form and a stronger pump to create
a better vacuum

48

Fig 6.14 fitting stickers

Fig 6.15 Assembling the components

Fig 6.16 transporting a SHS

Component assembly

The assembly of components in a composite box should be detailed and the connections standardized. The
guidelines for assembly follow from experiences with producing the pilot series systems, like in figure 6.15

Stickers

Several stickers are put on the SHS to communicate the energy feedback, connections, warranty and product
specifications. These should be of sufficient quality, matching colors and appropriate size (Fig 6.14) . Since this
is something Kamworks has to outsource, experience should be build up in preparing the right stickers.

Transport

All equipment including the SHS parts have to be easy to transport (Fig 6.16). The system components should
be properly fixed in the homebox and the support structure dismantlable, therefore a bit is experimented with
a foldable structure and fixing the battery in particular.

6.4 CONCLUSION
Although three systems are developed, at principal the attention goes to the medium system. During the tests
the functionality of the design is more important than the actual design itself. The main objective is to develop
the SHS in close cooperation with the local people and to get an understanding of the local living context and the
way the SHS can be best fitted in there. Parallel to that the system performance and functionality is tested.
Interviews and surveys should be supported by visual material. If choices are desired, they should be presented
in pairs and then be hierarchically ordered. A direct confrontation with the product is preferred whereby consequential surveys and interviews are conducted with the same families to build up a bond of trust and obtain
more reliable and profound answers.
Finding suitable test families was difficult according to the desired profile, often their energy consumption did
not match, they lived remote from Kamworks, were hard to convince and did not understand or trust solar energy. Therefore inconsequence a renting construction, for a 3 month test period was set-up for 1 family.
The technical functioning, use of electricity by the families and the performance of the system are monitored
with dataloggers. Which is valuable for maintenance, future sales and development of SHSs by Kamworks and
can be used to map the product interaction, perception of the energy feedback and SHS.
The loggers could not be implemented at the desired moments, due to their complexity. Thus the systems could
only be monitored for a short period of time. This data still offers an interesting insight in the SHS performance
and the families use of it and still could be partly used in the redesign of the Homebox.
The following data should be registered; the amount of energy generated by the panel, the energy level of the
battery and the energy consumed by the load connected. Ideally this will be completed with the solar Irradiation, which will be measured with a calibrate solar cell at Kamworks
The production of the SHS test systems entitles issues as making the composite box, assembling the components, the box finish, adding stickers and transporting.They come to the attention by practise rather than predefined tests. The remaining problems with composites have to be tackled and future opportunities discovered,
like a possible process upgrade to the so called vacuum-bag GFR (VA-RTM). Stickers are put on the SHS to communicate the energy feedback, connections, warranty and product specifications and will be the only production
part that Kamworks has to outsource.

49

7. PILOT PRODUCT EVALUATION

In this chapter the experiences and results of the Pilot product tests are evaluated according to the research
set-up in Chapter 6 and with the pilot product as described in chapter 5. The results can be regarded as recommendations for a product redesign and elaboration and are translated into the final list of requirements.
The main input for this chapter were the SHS pilot surveys with test families, they are described in Appendix O

7.1 THE SHS


Brand identity, trust, status and proud are very important consideration for a product purchase and appreciation
in Cambodia. Besides the Kamunasal brand name the SHS should therefor be presented as a western product
specifically designed for the Khmer. So technology by Kamworks (Europe) and the design modern, western with
clear Khmer aesthetic features, to appeal to their rich cultural heritage and chauvinism of both young and old.

One Product

The SHS should be regarded by the user as a small personal power station, a total system, where the Solar
panel functions as their electricity generator and the Homebox as a product that distributes the electricity. By
proper use and understanding of the system they can optimize their comfort and electricity supply. It is therefor
important that they see the link between the solar panel and the electrical appliances they can connect. The
Homebox should be regarded as a product, rather than a combination of technical components, to reach the
desired feeling of the SHS being a secure and reliable energy source.
Meaning that the panel support structure and the Homebox should be both visible and appear as one product.

A closed Homebox

The Homebox appears in the current design literally as a box, where the content is closed of for them with
a lock. The desire to open something that your not allowed to, combined with what some users stated as an
curiosity about the system components and brands, intensifies the urge to open the box. This almost natural
reaction should be avoided in the appearance design of the final Homebox, by presenting it more like a TV,
stereo or computer, products that you principally dont expect to open. Therefor the box should be closed of in
the back, with screws that are sealed by for example a warranty sticker, rather than a lock.

Energy consumption

An initial problem in finding test families was to find a matching energy consumption pattern with the system.
Often their television sets and stereos consumed far more energy that the system can deliver (up to 150Watts
for a Tv-set !). It is therefore important that in communicating the SHS specifications, there is an emphasis on
power supply, rather than power consumption. Since this issue reached beyond the scope of this project it is
recommended to Kamworks to investigate further in the actual power consumption and education of the people
in order to match the expectations of the SHS. In regard to the SHS design this fact should be taken into consideration for the SHS end-users manual and system connections.

Use understanding

The reactions to the end-users manual and the understatement of SHS use were positive. Most users made an
logical connection to the amount of energy they could use and the amount of sun that was available that day.
There should be however a better explanation in the SHS end-users manual about trouble shooting and the type
of electrical appliances to connect (AC-DC and load), this to prevent future problems when the users purchase
new devises. For the SHS design this means that the system connections should be clear and obvious and well
protected by accidental connection faults.

Lifetime

The lifetime of the entire SHS is up to 20 years, but some system components as well as lights have to be
replaced before. Therefore all connections should be standardized, since after the 1 year guarantee period the
customer has access the system components, however this is not desired, this should be taken into account in
the system design. Replacement parts should be easily available, to prevent use of inferior replacement parts.

51

7.2 SHS BOX


Besides the functional criteria of the Homebox a major attention point is the appearance. The SHS is a very expensive product, comparable with for example the highly valued Honda Dream motorbikes, to enable the SHS
to be successful and have a competitive advantage it should also be most of all a desirable product. This will
also stimulate taking proper care of the system and the desire to understand its use, thereby creating a stronger
product appreciation and content users. Its appearance should be striking in bright vivid colors like yellow and
blue, brightening up the rather sober interior of a Cambodian house. Its shape should be sharply defined, with
straight lines and transitions and decorated matching with Khmer architecture and culture.

Location

The SHS should be placed in fixed location as both the solar cable as the cable for the lights are fixed. The
people also didnt expect to be able to move the SHS, as it is heavy, expensive and it already gives light in the
locations where they want. The Homebox should however be temporarily disconnectable, for cleaning, water
damage or house reconstruction. A wall mount is preferable, but will complicate the design and installation due
to the weak walls of a Khmer house. Therefore placing the homebox on a cupboard or table next to the electrical
appliances is the most obvious, however it should be taken into account that the Homebox can also be placed
on the floor. Therefore the view angle of the display should be about 45 degrees, that way, it will both be visible
from a distance as close by if its placed either on the ground or a table (Fig 7.1).

Display

The energy feedback given by the display is clear to the users, however as people in rural Cambodia are not
familiar with a traffic light, the colors of the lights could have been selected more appropriate. The icons on the
interface are now very abstract and still represent a battery. Rather a more realistic representation and elaborate
information should be given. The Khmer easily interpret unknown data, but to guaranty the proper use, information should be made explicit, to an extent that Europeans might consider as an information overload, this should
however still not conflict with the aesthetic values of the product.

System components

The two 12v connection sockets are sufficient as the Khmer prefer to disconnect a devise by taking out the plug,
rather than tuning it off. Additional plugs should however be delivered with the system to enable the user to
later connect more devises. One of the test families had for example already modified the plug of a telephone
charger to a plug for a ventilator (Fig 7.2). He indicated that he really liked the way of connecting, as its easy
and eliminates the chance of reversing polarity but that it is also frustrating not to be able to connect whatever
he prefers because Kamworks didnt supply additional plugs.
The fuse should be placed on the back of the box as it only has a function in case of a malfunction. So the user
should be aware of its existence but it doesnt have to be clearly visible.

Fig 7.1 Mr Houng Chien now has to tilt the box to see the display lights Fig 7.2 A SHS customized ventilator

52

7.3 SUPPORT STRUCTURE


The principal attention points for the support structure are a straightforward installation, high strength and
weather resistance and an distinctive appearance.

Installation

During the installation of the support structure it became apparent that the support should only need to be
mounted and assembled on site, and that adjustments should be limited to the minimum. Considering that you
are not in a very comfortable position high on a roof in full sun to make accurate adjustments or customizations,
the installation should be rather plug and play. Since the solar panels efficiency and the structures strength is
highly depend of the correct installation, the chances to mistakes should expelled.

Roof mounting

As described in chapter 5.5 the optimal way of installing the solar panel universally to any Khmer house is to
mount it on the roof ridge by making a connecting thru the roof and bolting the galvanized pipe to a house pole.
The disadvantage however remains that a hole thru the roof has to be made, which is not to hard to make but
difficult to seal off against water damage. The advantage is that the pipe is on the top of the house and covered
by the panel, but for obvious reasons leakage should be prevented at any costs. However since the roofing material and roof angle of a Cambodian house is too diverse a standard cap is hard to make. The solution seems
to seal of the hole by a non transparent glue (to avoid light shinning thru), the benefit is that the glue is a bit
flexible to sustain the movements of the pole.

Strength

The connection of the pipe to the house, should be easily modified to the house situation by using various profiles. Ideally the pipe is connected to the corner of a house pole and at a point high at the roof ridge, that way
being better resistant to occurring torque forces. The connection between the pipe and the panel can be made
by a composite plug of sufficient strength and size accuracy. The benefit of a composite support would be that
its corrosion proof and that all connections can be predefined by inserts, it is however hard to obtain a sufficient
rigid part based on only the material properties.

Fig 7.3 A creative solar panel array of Khmer solar in Battambang

53

7.4 SHS TECHNIQUE


SHS COMPONENTS

Much experience has been build up with connecting and the


operating of the SHS components, it is advised however to
Kamworks to make a more extensive profile of possible malfunctions and their solutions. This can be based on the component manuals, datasheets and the project outcomes, but
should be elaborated with experience in the field with the final
SHS design, as the focus in the project was on the overall product design.
A number of principal observations :
The charge controller is well protected against reverse
polarity. It directly cuts the power and indicates on the
display that a wrong connection is made, after 2minutes
the system reactivates, so a adequate reaction is expected
Fig 7.4 Since there are no real alternatives,
from the user.
all trash is burned at Kamworks
Short circuit, the charge controller immediately shuts down
and displays and error message, a spark was even never notable, what could mean the electric devise might
not get damaged. It should be tested if the controller can also sustain high current connection mistakes
Overload, All charge controller have a electronic fuse that shuts down the power for 2 minutes if the current
exceeds its level and indicates an error message and then re-enables for about 30 seconds after which it
will shut down again if the situation is the same, it will however continue to do so indefinitely
The charge controller has a learning curve, it appears to take about 3 days, until the system indicates the
proper battery state and regulates the power in/out accordingly. This should be noted to the user, that will
especially take close attention to the system the first days, explaining the controller as a learning computer
works very well for them in avoiding initial disappointment.
The system is protected with 3 fuses; the charge controller seems to react the fastest, what prevents breaking of the other fuses, but there where situations that the 12v plug fuse broke first due to high current.
The charge controller has several jumper settings, they should be set to gel battery and sound off
When the battery is full and the sun shines, the power for a load is first extracted from the battery, that then
with a small delay is charged again by the solar panel due to the initial voltage drop.
When the battery is empty, it first has to be charged to a certain level before the charge controller reconnects the load, this level depends on the battery type and could now not be determined since the correct
batteries were not delivered until the end of the project.
The inverter consumes 3 to 4 watts in standby mode and should only be activated when in use.

Composite Production

The most important issue during the production of the composite products is to work accurate, understand the
process and be well prepared. Some points of attention:
All possible connections to the product should already be included in the design to limit finishing.
Mixing relations come close, the processing time is also highly dependant of temperature, meaning that in
the colder mornings it will be longer than at the hot midday. Always take account of the time.
The concentration of hardener and quality of polyester diminishes over time, whereby mixing variations
should be tested after a period of rest or with a new batch of material
A product can be laminated by just one person, as the products are small and the processing time can be
extended sufficiently.
White gelcoat generally has a longer processing time as it is meant for large surface products, so little to
no Inhibitor should be added. The composite support should be made from white gelcoat as it is more color
stable due to its high UV and weather resistance.
Several layers of mould release wax should always be applied to a mould to prepare it for production. Polish
sufficient between layers and let it harden before adding the next layer to guaranty a successful release
An additional layer of polyester with parafin oil can be added to prevent it from becoming sticky due to high
humidity. The strength of a glass fibre layer diminishes if its added directly there.

54

For a sustainable production process and sufficient working conditions the current production facility should be
evaluated. Cleaning detergents for brushes and protective materials ares now sparsely or not present. Creating
an unnecessary amount of trash (Fig 7.4) and putting the health of the worker into danger. In current conditions
its further more virtually impossible to create high quality products, which is important for example the desired
strength of the composite support.

Installation

The most important thing is to be well prepared for any situation on an installation mission. Have the entire
Solar system tested (put together) and packed, and have all the necessary tools and equipment for any situation
of installing. Although it is a small solar system, the installation does entitle the same procedure as a large solar
system. The profit margins are small and the customers mostly remote, far from Kamworks.
All has to be properly prepared, so installation and connection of the parts on site will not pose any surprises.
Returning to fix a part, get more tools or screws is not an option.

DATALOG RESULTS

Since the data became only available late in the design process, due to the many setbacks in setting up the
datalogging, it could not be used for its initial purpose. It does however form a very valuable data source for
social cultural aspects of energy consumption and daily life in rural Cambodia. Combined with baseline, installation and follow up surveys a clear image of their day patterns and living situation can be formed. This however
is far beyond the scope of this project, but forms a valuable input for the future product development and sales
strategies at Kamworks.
The performance of the system is hard to indicate since the the systems could not be monitored for a longer
period of time. Conclusions about the initial use of the system by the test families, their energy consumption
and daily rituals become very clear from the acquired data, also the principal functioning of the system becomes
apparent.
A complete overview of the data form the dataloggers can be found in appendix P.

Registered data

The following data has been monitored by the dataloggers and registered every minute;
The battery Voltage; to define the state of charge, indicate if the battery is charging or discharged
The Solar Panel Voltage; to define when the solar panel is able to generate electricity and when it is
actually charging the battery.
The Solar panel current; which will be translated into the actual power (watt) generated by the panel
The current of the load; which will be translated into the power (watt) consumed

Data interpretation

This data becomes visible in Graph 7.1, where the power use of SHS test family 1 is displayed for 1 day.
Panel (v), At night the panel voltage is 0, when the sun comes up and the panel is illuminated the voltage
rises to the battery voltage for the period that the battery is charged. When the battery is full but the panel
still Illuminated by sun, the panel voltages rises higher above the battery voltage. The voltage drops again
to 0 when the sun sets
Battery (v) the variation of the battery voltage is very small and balances between 12 and 14 volts. The
voltage drops when the battery is discharged by a load and increases when its being charged
Solar panel power (w), rises during the day, depending on the solar irradiation, in relation to the panel voltage it can be seen when the not the sun stops shinning but that the battery is full. Some power is still being
generated as the battery regularly checks and re enables the panel for short intervals when its empty.
Load power (w), clearly visualizes when the user consumes energy. Since every devise is turned on for a
period of time and has a specific power consumption level or pattern, the data appears in steps. Combined
with the knowledge from the surveys about their electrical devises, their specific use can then be defined
Test family 2 is quite old and have a very fixed day pattern and energy consumption, due to their shop and the
noisy generator of the battery charging station next door. Over a longer period of time, it will be interesting to
see if they modify their energy consumption and day pattern because more electricity is available. For example
in buying new appliances (ventilator) or shifting the opening hours of the shop.

55

Graph 7.1 displays the SHS power use for one day by family 02, registered with the data logger

A day description, based on the power use in Graph 7.1


The family has a shop bellow their house, that they open early, so they have an early start at 03.45 when 1
light is turned on in the living room for 15 minutes to get dressed. Then they open the shop and the lady of the
house prepares food in the kitchen so lights are turned on there. When the sun comes up they turn off 1 light
and turn on the radio. At 5.30 there is enough daylight so they turn off all lights. They play the radio until about
9.00 when the neighboring battery charging station starts their noisy generator. This is visible in the characteristic load pattern, due to the variation in volume, thus power use. At 11.30 her son comes back from school and
watches 30 minutes of TV, at 12.30 after lunch he again watches 30 minutes. At midday the battery was full so
is not being charged, when the son watches TV at 12.30 power from the panel, directly flows thru the battery to
the TV, this is visible in the equal voltage drop at that time. The rest of the afternoon no electricity is used until
17.45 the generator of the battery charging station is turned off and they turn on their radio. At 18.15 they turn
on the light in the store and the kitchen. At 19.00 they turn on the light in the living room to prepare the space
for dinner. At 19.30 the shop closes, they turn off the lights downstairs and the family has dinner upstairs with
the tv on. At 19.45h they get ready to sleep at about 20h they turn off all lights.
SHS sizing, based on the power use in Graph 7.2 and 7.3
In Graph 7.2 a three week overview is given of the SHS power use by test family 03, who have a large system,
with a 78wp panel and inverter. If looking at the general data overview, a few things can be noted. Their solar
panel is only charging the battery all day the 1st and 2nd of July, and that is probably even a cloudy day as
their load is then not extremely high. The rest of the days their system is clearly over dimensioned, as the solar
panel only charges the battery a part of the day. It is furthermore striking to see that the peak power of the
panel remains pretty low, however this is certainly due to the low energy consumption, there could also be a
problem in the connection.
The reasons for the low energy consumption is on one hand that they simply dont have appliances with a high
energy consumption, on the other hand it became apparent that the family is afraid to be without energy and
dont interpret the display energy feedback correctly. If the battery state light drops to the middle one, they
already reduce their energy consumption, however the battery is then still 25to75% full. This is explained at 27
of June, which let to a short increase in electricity use, but then even became less then the initial start.
The total power in and output on a day (Graph 7.3), follow each other with a small delay, because of energy
use during the night and generation during the day. The amount of energy consumed during 6 weeks is 2,5 KW,
where 2,9KW was generated. Thereby a preliminary system efficiency of 86% could be defined (without taking
a measurement variation into account).

56

Graph 7.2 gives the SHS power overview for three weeks by family 03, registered with the data logger

Graph 7.3 displays the total power consumed and generated by the SHS of family 3, over a period of 6 weeks

57

Irradiation

With the Kamworks system the Irradiation was measured to help and interpret the performance of the system
and the influence of weather to the energy consumption of the families. In Graph 7.4 the Irradiation during one
day is displayed, the increase and decrease of sunlight is clearly visible, it was probably a sunny morning, where
it became partly cloudy at midday, the clouds increased, whereby it started to rain a bit at 14.30 and continued
to do so until sunset.

Graph 7.4 The solar Irradiation on one day, measured with a single solar cell at the Kamworks system

Since the families both dont use all the available energy it is hard to state something about their change of
energy consumption due to the weather influences. The families both indicate that they do, but this can not be
validated with the datalog data. Striking though also is that people indicate a different, even lower use of energy
than is registered with the loggers.

Graph 7.5 The Irradiation at Kamworks over a 3 week period, registered during three measurements

In Graph 7.5, the irradiation is displayed during 3 measurements over a 3 week period. A full hour of sun is defined as 1000 w/m2 and can be maximum about 1350 W/m2 on the earth surface. The calibrate solar cell with
which the irradiation was measured is probably not properly calibrated as the logger has
registered values often higher than a full sun
hour and even reaching the maximum. It is not
probable that these values can be measured at
Kamworks and the full hours of sun calculated
in Graph 7.6 are pretty high for the cloudy and
rainy days that the irradiation was registered
When the irradiation data is compared with the
power in from the panel and the use of load,
not to much more can be concluded about the
performance of the system than the efficiency
mentioned before.
Graph 7.6, full hours of sun based on irradiation at Kamworks

58

7.5 SHS FINAL REQUIREMENTS


What follows is a set of final requirements based on the preliminary requirements of the pilot SHS and elaborated with the observations of the design research. The designs can be described on various levels, the SHS
family, the complete SHS and the SHS parts, therefore only the principal requirements for the SHS are noted,
to provide an overview.

Main Criteria

> Requirement

Appreciated
Functional
Reliable
Desirable
Producible
Placable
Usable
Attractive
Appropriate
Flexible
Effective
Understandable
Unique
Compatible
Sustainable
Secure
Sealed
Recognizable
Charismatic
Affordable

>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>

The SHS should fulfill the user expectations, as they were created during the purchase
Provide the electricity that is generated by the sun
Provide the energy that is promised, low maintenance, durable and strong
Create a desire towards the product, increase of status, express quality
Realisable in composites, in series, with component connections inserted
Especially the support should be easy to install and orientated, the design limit mistakes
Easy to connect devises and to control the light
High esthetical value, matching with Khmer style, decorations, bright colors
Fits with the general appreciation of all, not dependant of age, sex, income or house
The support mountable to any Khmer house, the devise connections adaptable
The system efficiency should be high and the devises applied economic in electricity use
The energy feedback is interpreted and the basics of solar energy understood
Clearly distinctive from similar products and the car batteries
Fits within the context, the panel should be resistant to high winds, water and corrosion
Making use of non-polluting materials and communicating solar energy
The system should be safe to use and be protected against abuse
The principal components are enclosed in the Homebox and not accessible for the user.
The complete SHS family and parts should be recognizable as one, with a mutual identity
Appear as a true powerhouse, firm and reliable, creating trust
High quality for a low prize, balance the cost prize according so

59

8. PRODUCT SYNTHESIS

The product synthesis is concentrated on the medium SHS, taking into account that the design has to be extrapolated to the large systems later. The strongest focus within the synthesis is on the final appearance design
of the Homebox since the internal parts are already defined and the design of the support structure for the panel
follows directly from the previous design research.
Ideas were created based on the previous research, then evolved to structural variants by taking the placement
of components into account. Finally the ideas were elaborated to concepts of which a final design is selected
based on concept surveys with the test families

8.1 IDEAS
The BOX

Ideas (fig 8.1) for the Homebox appearance design are based
on the previous field research and strongly inspired by designing in context. Inspiration was found by actually going to the
countryside for sketching (fig 8.2). Additional creative sessions
were held with a fellow design student, Stephanie Wirth.
Ornamentdecorationonthebox

DiscussionwithLeap
Besides
the appearance design some functional features were

taken into account like where and how to open the box, the visExplanation
ibility
of the display and the location of the plugs and lamps




Battery,largestatic
component.

Charge
controller

Definesboxsize,and
restrictstheshape

Dynamicinfo,
withviewangle

KAMUNASAL




Fig 8.1 Idea Sketches Homebox

connectors

Dragonornament

Fig 8.3 Khmer


ornament decoration to the Homebox
AccordingtoLeap,thisisatraditionalKhmerornament,thattheycallaDragon.Itis
aBuddhistsymbol,thoughnotnecessarilyreligiouslyrelated,moreculturalspecific
forCambodia.

In search for a way to decorate the box, to make


it Khmer styled, the appearance less a box shape
and more a complete product, the addition of
Khmer Ornament was considered (fig 8.3).
Fig 8.6 curver
boxen

The Support Structure

The most important criteria


for the support structure are
Thedragonisusuallyplacedontherooftopsoftemplesandhousesandpointsto
not the aesthetic values but
thesky.Thedragongivesprotection,ismagicandpowerful.
strength, corrosion resistance
LeapisveryenthusiasticabouttheideatoplacetheDragononthebox.Heseesno
and easy of installation. Since
reasonwhypeoplewouldbeoffendedbytheuseoftheornamentonaproduct.Hethinksthatshape
the experiences form the field
evenrelatestothefunctionoftheSHSandtowhattheKamunasalbrandwantstoexpress.
research gave already valuable

solutions. These functional
ities, combined with the metal

layout design (fig 8.4) of the
Fig 8.4 Installed metal supports
Fig 8.5 composite support
support structure in the field
research, was immediately translated to a composite final product (fig 8.5). Due to time pressure and the difficulty to predict the dynamic strength of composite materials, the shape of the support structure had to add
to the strength of the final product. Therefore additional ribs were added to the support arms of the complete
support, based on the well known Curver boxes (fig 8.6). The final design is described in chapter 9.3
ThisspecificornamentismodernizedversionofamoretraditionalDragon.

Fig 8.2 View from the Buddhist centre lake, where most of the Idea sketching was done to inspire.

61

8.2 COMPONENTS, STRUCTURAL VARIANTS



Due to the functionality of the Homebox components, their possible orientation is very restricted. This is further
more limited by the possible placement of the box on a table or floor
The light, should be placed on top, since it has to light the surroundings and if possible to box itself
The display should be placed freely in an angle of 45 degrees, to be viewable from various angles and
distances even when its placed on a floor, table or inside a cupboard
The battery, is a large, static and heavy component in the system and should be placed on the bottom of
the box. It also tends to predefine the box shape, which should be avoided.
The plug points should be placed together, to avoid the effect of eyes and a face of the box. They have to
accessible, since they will be actively used.
The opening of the box, should be hidden rather like with a television then with a lunch box, not making it obvious to try and open the system. Due to heat restrictions the charge controller should not be placed directly on
top of the battery.
Based on the placement and orientation of the system components in Figure 8.7, several 3D monoshapes were
created (figure 8.8) to form the basis for concept development.

Fig 8.7 several possible orientations of the system components

Fig 8.8 Based on the component configuration, some basic 3D mono shapes are developed.

62

8.3 CONCEPTS, BOX APPEARANCE DESIGN


Six concepts of the HomeBox appearance are displayed in Figure 8.9, all have taken the system components
and functionality into account. Concept 1 to 3 are actual different concepts, where concept 4-6 are variations
of each other.

Fig 8.9 Concepts of the HomeBox appearance designs

Concept descriptions

1. A playful compact SHS design. Where the blue line forms a strap around the central part, containing all
external components, giving it the feeling of a valuable object, a treasure chest. It is also marked as the
mega Angkor light, the light might take to much of the product focus.
2. The penguin or tuxedo is appreciated for its distinctive appearance but at the same time seems a bit a
undefined, the components are not displayed in the rendering, the light switch would be placed right.
3. A modern fresh SHS design, distinctive for its round shapes and component placement. It really looks like a
product, rather than a box. Interesting detail is that the box shape follows the Kamunasal brand logo
4. A SHS with charisma, a true powerhouse that matches Khmer culture, with a strict symmetrical shape and
with repetitive forms. The dragon ornaments emphasize the upward line in the product, making the product
a whole and ads the desired decoration and affliction.
5. The pyramid SHS, with a strong foundation, a blue battery base and yellow appearance jacket. According
to some the box has a bit a negative charisma, to others a repetition of consecutive layers like a Cambodian
temple roof. The dragon ornaments emphasis again the upward line, but have some competition of the blue
base. It does ad the desired decoration and affliction.
6. The power station, a combination of concept 4 and 5, the straight lines and strong foundation are combined, but maybe lacking some charisma due to a somewhat disordered shape. The dragons again come to
their right and accomplish the added value of affliction and decoration

63

8.4 CONCEPT CHOICE


CONCEPT SURVEY

The main goal of the survey is to distillate a concept choice. As a warm up, test subjects were asked first to
give their preferences in colors in shapes, as it is expected that this would assist them in reasoning and discussing their choices in the concept designs and create an more brought awareness of appearance preferences. It
also helps in putting their remarks into perspective later. The interactive survey (figure 8.10) is conducted with
Conceptchoice
Cambodians who are familiar with the SHS, since they already understand its purpose; the 3 test families and
Kamworks employees are consulted. At first it is made clear to them that this is a redesign of the pilot Solar
Evaluatingquantitativetheresultsoftheconceptsurveyresultsinthefollowingscores:
HomeBox that they all know, with similar features. A complete description of the entire concept survey is in
Appendix Q.

Families:2336

14
Kamworks:526

13

27

Families:3151

10
Kamworks:314

Families:6265

19
Kamworks:642

Families:1423

10
Kamworks:131

12

5

31

15

Families:4514

14
Kamworks:263

Families:5642

17
Kamworks:455

8

11

14

18

25

31

Fig 8.11 Concept preferences from test families and Kamworks employees

The quantitative results of the concept survey are displayed in figure 8.11. The considerations of all interviewed
persons seem to be different. Though they all agree on that concept 3 and 4 are the best ones. To put the
results better into perspective their remarks are noted bellow as qualitive results.

concept comments

64

Happy shape, Shape is not nice, looks like a toy, childish. Would look nicer without the holes in the
front and the light on top.

Too much color everywhere, looks like tuxedo. They dont know what to make of it

Looks like a cd or cassette player, with which some have cheap association. Looks a bit like is from
cheap khmer plastic. Some react with a Ohh when they see it, it looks very nice (okay!). They like
it a lot because of the round shapes. You can put it everywhere and it will look nice. The light in
front would be better, else the box would be in the shade.

Has style, really like it, looks strong, like it has a high status, proud, its classic and modern at the
same time. The dragon shape is very nice, that shows its a Khmer product.

Is like a seat high up, looks to negative, dont like the bottom part, the shape gets sad. the dragon
makes the shape nice still.

The shape is interesting, because has a foot. The form is not good, it looks like a thin guy, like it
has to balances on the bottom foot. Most prefer this shape above concept 5.

Shape preference

From the concept surveys and previous context research it becomes apparent that there is a large difference in the preference of shapes between the various generations of Cambodians.
The older generation of 50-60 strongly prefers straight lines, hard
transitions, symmetry and repetition in their products, very similar to what can be seen in traditional Khmer art and architecture.
The very strongly dislike round shapes, smooth transitions and
organic forms. Something that the younger generation of 20-30
prefers as it is perceived as more western and modern.

Fig 8.10 Concept survey with test family 3

Dragon Ornament

Fig 8.12 Concepts 1-3


with Dragon

All interviewed Khmer are very enthusiastic about using the Dragon ornament on the
SHS box, even adding the dragon to concept 1 and 3, increases their appreciation
considerably (figure 8.12) With the dragon the Homebox becomes a Khmer product,
which is good. The Dragon should be placed properly though, because there is a lower
quality expectation for Cambodian products and the traditional dragon shape should
be respected.
According to mr Houng Chien the dragon should be on top in the corners of the boxes,
or at least on a longitude direction of the box. All of the dragon should be displayed
and both should be placed on the same level. He recognizes the dragon is a a traditional khmer symbol, like in pagodas, where its placed on top of a building and symbolizes strength and power.

Production reasoning

Both boxes are about equally easy to make. The shape of concept 3 is maybe a bit simpler, but will give problems when draft angles are applied and will maybe loose some of its character because the shape will get bigger
towards the back. Both will have the opening in the back

Assembly & accessibility of components

The assembly of components is easier in concept 3, as there is more space to manoeuvre and the display and
plug points freely accessible, since they are installed next to the battery, rather than above. The light however
of box 3 will make access to the display harder.

Product family

Concept 4 has a more distinct character, that can probably be better maintained when making the Homeboxes
for the large system. It also has a smaller width and ground surface making it easier to place on a table.

Decision

Both concepts score about equal in the concept surveys and when
comparing design criteria dont show significant benefits above the
other. When adding all up then:
Concept 3 looks more modern, distinctive and maybe even timeless, due to its round shapes, but is not recognizable as a powerhouse and not well appreciated by a large part of the target
group. It will be attractive to the young but rejected by the old.
Concept 4 is a real Cambodian SHS, a charismatic powerhouse
that respects Khmer values, balances neatly between modern
and traditional and is well appreciated by all.
The decisive factor is to make a western quality product with Khmer
styling. Therefore

Concept 4 is chosen.

Fig 8.13 CONCEPT CHOICE

65

9. FINAL DESIGNS

The final designs of the Solar Home Systems are described in this chapter and are mainly based on the designs of the medium SHS. The focus in the design descriptions is on the appearance design and functioning of
the Homebox, the composite design of the support structure and the SHS product family. The prototyping is
described in short in paragraph 9.5. For the technical functioning of the SHS I would like to refer to the pilot
product design in chapter 5 and the evaluation in chapter 7.

9.1 THE SHS


The SHS (fig 9.1) has become a true modern powerhouse for rural Cambodia. A distinctive desirable product
of superb quality that matches with the Khmers culture, styling, way of living, energy consumption and house
situation. The system is easy to install, durable and strong. A charge regulator, guarantees a safe use, an extended battery life and provides the users with the so desired energy feedback. Making the Kamworks solar
home systems a secure energy source available for all, for an affordable prize.
Initially the SHSs with full installation and a 1 year guarantee will be sold for the following prizes,
The Medium SHS (DC, 40Wp-48Ah) = 465$
The Large SHS (DC, 78Wp-96Ah) = 870$
The Large+ SHS (AC, 78wp-96Ah) = 990 $
This includes a 15$ cash back that they receive when they participate in a one day SHS end-users training. Since the SHS finances were not part of this project, the sales prize and strategy
should be re-evaluated, based on this project outcomes. Remarks concerning the cost prize can be found in Appendix R.
Kamworks wants to create trust and take responsibility for their
products by offering a 1
year guarantee. The SHS
components are therefor
not accesible for the endusers during the 1st year to
prevent abuse and consequential high maintenance
costs.

Fig 9.2 the panel and Homebox in context

The system is given face


with the bright yellow support structure outside and
the blue-yellow homebox
inside (Fig 9.2) , according
to Khmer preferences and in
the Kamworks-Kamunasal
house style colors. The
System is manufactured in
series entirely by Kamworks
and is principally made
from Glass fibre reinforced
polyester (GFRP). This is
a barely used production
technique with great potential in Cambodia, Kamworks
can gain expertise in working with GFRP and expand
its business activities in the
future [Reitenbach, 2007].

Fig 9.1 a 3D representation of the SHS

67

9.2 SHS BOX


Again the SHS box will be described based
on the small Homebox for the medium SHS.
The Homebox is the principal part and the
heart of the SHS, its design makes it a real
Cambodian SHS, a charismatic powerhouse
with respect for Khmer values, balancing
neatly between modern (western) and traditional values and is well appreciated by all.
The Homebox has an high aesthetic value in
creating a product desire, a commercial value in being distinctive and a functional value
in protecting the system components.
The box (Fig 9.3) is entirely produced, assembled and will be installed by kamworks.
This way Kamworks can guarantee a high
quality and excellent product, a sustainable
power source for the development of all.

Production

Fig 9.3 The kamworks HomeBox

The Homebox is produced by hand-lay up GFRP, local at Kamworks. To enable a smooth reproduction of the
molds a draft angle of 2-3 degrees was added to all plains (except the base). This also has quite a big effect on
the appearance of the box so the final box shape was determined taken production into account. Further some
inserts will have to be applied to make for example the display light holes and the front-back connections of the
box and the back plate. The dragon shapes were already carved in the wooden positive mold and can therefore
easily be reproduced and filled with paint during the box finish. The various colored surfaces are not painted,
during production 3 colored polyester gelcoats are used. It is important though to work accurate to get sharp
transitions and a clean final product
Basic dimensions (Fig 9.4)

Fig 9.4 Basic dimensions of the small Homebox

68

Assembly

The locations for the components are


already marked in the composite box,
making it easy to, if necessary, drill the
holes and install the components in the
right locations. The parts all fit tight in the
box and have a small tolerance to directly
fixate them for transport (Fig 9.5). The
battery should be placed last, when all
connections are made. Then the system Fig 9.5 The box components, box cross-section and back view
should be properly tested before sealing
the box. The fuse can be used as an activation switch, to deactivate the SHS after assembly, until installation.

Opening the box

The box is designed in such a way that its


not obvious for the end-user to open it,
since it is perceived as a complete product (e.g. a TV). The back (Fig 9.6) can be
taken out for maintenance inside the box
and is secured with 4 sunk Hex or torque
screws to a metal insert in the box-back.
These screws dont stand out and cant
be opened with standard screw drivers.
For warranty reasons an additional warranty seal is put over the screws. If the
customer damages these stickers, they
loose their 1 year warranty right.

Fig 9.6 The box back, falls into the box and is secured with screws

Connecting devises

The box has two internal connection


points, for the solar cable and the fixed
light points. These are part of the system
and should not be freely accessible for
the customer. However they can not really damage the system by tampering with
the connection, they are fundamental for
proper functioning. A semi-fixed connection with special 12v plugs (like computer Fig 9.7 special 12v computer plugs for connecting the solar and load
plugs) is preferred (Fig 9.7). This simplifies installation, makes the box a real product, still prevents tampering and gives the users the freedom to
move the Homebox themselves during its 20 year long service. The connections of male and female 3way, 12v
computer plugs and connectors can easily be modified to prevent devises with similiar plugs to be connected.
The box has two external connections, for
the users to connect electrical appliances
to the system themselves. With these 12v
car plugs and connectors (Fig 9.8) they
can make easily secure connections without the risk of reversing polarity. They are
suitable for frequent use, since the Khmer
prefer to take to plugs to turn on/off the
electrical devise. The plugs should be
connected to the appliances during installation or later by a competent technician,
to guarantee a proper connection of +-

Fig 9.8 12v car plugs for the user to connect electrical devises

69

Integrated LED-lamp

A 1w directional LED lamp is delivered


with the system as an orientation light
to replace the use of the kerosene
lamp as a night lamp for comfort and
superstition. This light is integrated
into the Hombox (Fig 9.9) to reduce
costs, complexion of a detached installation and most important to give an
added value to the box in truly becoming a central power connection station.
By providing also light, the interaction
with the Homebox will increase and
the energy feedback display more frequently checked. Thus improving the
complete use of the system and its
energy.
Since LEDs have an extremely long lifetime, they dont (or only once) have to Fig 9.9 12v car plugs for the user to connect electrical devises
be replaced and can be installed fixed
in the Homebox. The light cover can be fully integrated in the production process by using transparent gelcoat
for this section. Another option is to glue a vacuum form cover onto the mold later. The composite lets light
thru relatively well, although the glass fibres are visible and the material seems pink when not illuminated.

Dragon decoration

The Homebox is decorated with two striking Khmer ornaments, giving character to the box and uniting the
shape as a whole. The ornaments seem carved into the box, combining the art of traditional wood carving and
a modern production process of making composites into one product. The shapes are carved once in the mould
with which the boxes are reproduced, taking full use of the potentials of composite production.
The decorations represent a so called dragon, or Naga, a mythical water serpent. It is a Buddhist symbol,
though not necessarily religiously related, more cultural specific for Cambodia. The dragon is usually placed on
the rooftops of temples and houses and points to the sky. The dragon gives protection, is magic and powerful
and in that way even relates to the function of the SHS and to what the Kamunasal brand wants to express. The
Khmer are very enthusiastic about placing the dragon on the box, and see it as a strong added value.

Fig 9.10 The dragon on the SHS, on a roof, Kbach Angkor form creations and ornament as a decoration on a house

The Dragon ornament is a Kbach Angkor form (Fig 9.10), shaped as a lotus petal from the side, with the composition of a dragon inserted and initial divisions (jaik), and subsequent cuts (chaik) added to create an ornament
with an even degree of internal detail. This specific ornament is modernized version of a more traditional Dragon
and can be used without any problems for this context [Reyum , 2006].

70

Stickers

The SHS is finished by adding several stickers (Fig 9.11) to communicate the energy feedback, connections,
warranty and product specifications. It also gives the Homebox a more sophisticated look and more valuable,
which will improve the system appreciation and use. The stickers should be of sufficient quality, waterproof,
matching colors and appropriate size .

Fig 9.11 Stickers to finish the SHS and guaranty connections, not in scale

A short description of each sticker:


1. The warranty; this sticker is placed over the connections screws of the box-back and functions as a seal.
The sticker should be of paper, or have carvings, so it will break when it is attempted to take it off. This way
access to the internal components of the system is restricted to the Kamworks technicians and a 1 year
warranty can be given on the entire SHS.
2. Plug polarity; sticker placed inside the 12v car plugs, to indicate what side is + and - for future use
3. Fuse; Indicates the fuse location and covers its connection screws, the black part should be cut out.
4. Display; helps users to interpret the energy feedback and gives the Homebox a more sophisticated look
5. SHS content; the system specifications, components, date of installation, system serial code and Kamworks contacts are noted on the sticker for future reference.
6. Charge controller; a sticker that is placed inside the box for system assembly and future repairs, on the
back of the charge controller to mark its connections.
7. Kamunasal; A transparent sticker with the Kamunasal logo that is placed a bit sunk on the box front.
8. System connections; marks the connections of the solar cable and fixed light points to the back of the
box, to insist during installation and avoid the necessity of reopening the box

71

9.3 SUPPORT STRUCTURE


The solar panel support structure (Fig 9.12) is a strong, striking universal mounting system for 40Wp and 78wp Sharp solar panels on rural
Cambodian houses, easy to install, wind, water and corrosion resistant.
Due to its distinctive yellow color and design it is truly a signboard for
Kamworks.
The solar panel support structure design consist of a single layer composite shell and a short galvanized pipe and mounting profiles. The
pipe is mounted to a pole of the house and sticks thru the roof ridge.
On the roof, the composite shell is put over the pipe, orientated to the
south and bolted tight. Then the solar cable is connected and the panel
mounted to the composite shell. See Appendix S for the full installation
manual
Besides the high quality, strength and tight fit of the support, the final strength of the structure is defined by the accuracy of installation.
Therefore the support is designed in a way that it assist the installer in
mounting the structure correctly.

Production

The most important part of the support is the composite shell (Fig 9.13).
The support is made from GFRP in a single mold, with connection inserts, to obtain every time a similar strong and easy to install support.
The composite shell is designed in such a way that the shape itself ads to the strength of the product, as the
dynamic strength of just the composite material is hard to predict with the hand lay-up process. The support
consist of 4 hollow diagonal arms with the sides shaped as reinforcement ribs. The optimal orientation angle
of 17,5 degrees for the solar panel is incorporated in the shape of the support and is guaranteed by the fixed
placement of the galvanized pipe. The composite support has a central axis that 1st functions as a mould for the
installer to find the location for drilling mounting holes in the pipe and then can be used to bolt the support tight
to the pipe, thereby minimizing the clearance between the 2 parts and strengthening the structure.
Fig 9.12 The panel support structure

Solar panel mounting holes

Fixate pipe plug

Central axis

17,5 degree orientation angle

Reinforcement ribs

Fig 9.13 The composite support shell with details pointed out

72

Basic dimensions and orientation (Fig 9.14)


1

4
Fig 9.14 Basic dimensions and orientation, the panel is mounted to the topview
and the pipe to the bottom view of the composite shell

Parts

Fig 9.15 An exploded


view of the support
structure parts

The support structure consists of 4 parts (Fig 9.15), who will be put together on site with screws and bolts.
1. A 1,2m long galvanized pipe of 42mm diameter, and 1-2mm thickness, 3 holes should already be drilled
at kamworks. 2 for connecting the mounting profiles and 1 for a additional screw to the house pole for extra
rigidity at a 90 degree angle opposite of the others (Fig 9.16).
2. Metal profiles to mount the pipe to the house (Fig 9.17); 2 metal L-profiles, 150mm long, 2mm thick and
1 flat piece of metal 150x10mm, 1 mm thick. All should have identical holes of 8mm, 2 on each side, not
aligned so the bolt and screws can easily be tightened. The pieces should be painted to prevent corrosion.
3. The composite support, if necessary with topfix, which should already, before installation, be glued in the
support with polyester at Kamworks.
4. The 40wp Sharp solar panel (Fig 9.18).
The pipe is strongest mounted when mounted on the corner of a wooden house. On
site can be evaluated if the
preferred combination of a Lprofile and flat metal is used
or 2 L-profiles.

Fig 9.18 The solar panel with


support structure

Fig 9.16 The galvanized pipe and


mounting profiles

Fig 9.17 The support structure mounted


to a house

73

Fig 9.20 The topfix is an additional composite reinforcement part for the composite shell made by kamworks

Topfix

The principal design of the composite support is similar for both the small and the large solar panel (Fig 9.19).
However since the weight and the torque forces of a larger solar panel will be bigger the support should be
made stronger and a larger wall thickness for the pipe should be used. To reinforce the support an additional
glass fibre layer should be laminated and a topfix (Fig 9.20) glued with polyester into the existing mould.
Thereby making it more rigid and adding a 2nd connection point between support and the metal pipe. The topfix
can be used standard for mounting the small solar panel as well, as it functions as a cap, restricting the distance
of the pipe to the panel during installation.
To match the mounting holes of the composite support with the large panel and enlarge the connecting surface,
different end pieces on the arms can be made. This is just a small adjustment to the mold that Kamworks should
experiment with in finding the most suitable solution.

Fig 9.19 The small 40Wp and the large 78wp sharp solar panel, mounted with similar support structures

74

9.4 PRODUCT FAMILY

Fig 9.21 The SHS product family

Kamworks is bringing 3 types of SHS to the market (Fig 9.21, Fig 9.22). Although this project has concentrated
itself on the medium system, the design of the Large and Large+ system always have been taken into account
and have finally been created as well.
The SHSs are clearly related and belong to the same product family. The large system, doesnt only provide
double the amount of energy it also looks bigger, stronger and more valuable next to the medium system, this
was an important design criteria, since social status is an major issue in the Cambodian society. The 220V power
socket has been placed prominent on the box front for the same reason, Ac-power has a higher status.

Fig 9.22 The SHS types with components, from left to right; The medium 40Wp, 48Ah SHS, The Large
78Wp, 96Ah SHS and The Large+ 78Wp, 96Ah SHS with inverter

75

Fig 9.23 The Large SHS

Fig 9.25 The Large+ SHS, with 220V socket

The Large SHSs

The Large Homebox (Fig 9.23) is an extrapolation of the


Small box, taking into account the aesthetic value, proportions and placement of the system components (Fig
9.24). The same components are used, with an additional battery and a larger fuse and fit tight in the box. The
box dimensions are kept a small as possible, to make it
easier to find a suitable installation location for the box.
The Large+ Homebox (Fig 9.25) is identical to the large
box but with a different backside an additional 220V
socket in the front of the box. The inverter is attached
inside the box to the backside, to make the System a
whole but still offer enough ventilation for the considerable heat that the part produces.
Fig 9.24 The System components of the Large SHS

Basic dimensions (Fig 9.26)

Fig 9.26 The basic dimensions of the Large Homebox. With the Large+ SHS, the cover for the inverter will
be pointing out at the back.

76

9.5 PROTOTYPE BUILDING


Prototyping was a red thread in this graduation project ,formed a major part of the design process and took a
considerable amount of the time. The production of the SHS with GFRP composites was an important design
criteria at the project start. Therefor the production method was taken into account already early in the process
and much experience in working with composites in the Cambodian climate was obtained. This way a SHS ready
for the market, making optimal use of the production design possibilities, could be created.
Since much expertise and material knowledge in working with composites was build up, the final design of the
medium SHS, box and support could be translated in not just a prototype but directly into a 1st series product.,
something that was desired greatly by kamworks, since customers were urgently waiting.
The




principal objectives of the final prototyping were:


Translating the final 3D Solidworks drawings into a real product
Finding the optimal way of producing, color transitions, inserts and assembly
Production training for Kamworks employees, to obtain continuity after the project end
Detailing the SHS design and test its strength
Making a 1st series product.

During the final prototyping the composite Homebox and Support were created. The prototype process is described visual in short with photos on the next pages, to create a complete image of the crucial steps and its
complexity in obtaining a reasonable serial product, in Figure 9.27 the Final result is displayed.

Fig 9.27 The 1st prototypes of the Final SHS design

77

THE SUPPORT STRUCTURE

The design of the Support structure is rather complex for a composite product and due to its function sufficient
strength is crucial. The model building drawings have to be carefully translated to the positive mould, since the
final orientation of parts, strength and draft depends on it. Additional inserts are added and oriented in a extra
mould, for connecting the support later to the pipe and panel easy.

The positive mould

The mold is made


from MDF wood

Holes are filled with putty and sanded smoothly

The angle of support


and pipe are verified

The wooden mold is sealed


with layers of varnish and
mould release wax is applied

The composite
materials

The negative mould

Applying 2 gelcoat layers

Then laminate with 1 layer


of glass fibres and polyester

Separating
the moulds

The negative mould


has to be cleaned

The mould is prepared


and waxed again

Inserts

making a extra The mould is fixated in a


mould for inserts extra mould for inserts

The pipe and central axis are The product will later be The workshop
placed in the right angle
mounted here to the panel

The final product

Applying 2 layers
of gelcoat

78

Laminating the mold taking 1st the inserts are taken out, then
special attention to the inserts product is separated from the mould

Luckily all fits perfectly


together

THE HOMEBOX

The Homebox is made in a similar way as the Support structure, therefore the description will focus more on
making, the finish and assembly of the final product

The positive and negative mould

The positive mould

Carving the Dragon ornament

Applying 2 gelcoat layers Laminating the box with


glass fiber and polyester

The negative
mould

Inserts & Coloring

The inserts for the display charge controller

The display
insert

Taping the mould


for coloring

Gelcoat applied to
blue box sections

Yellow gelcoat, top


right is transparent

the entire mould


is laminated

The final product

separating the mould Color transitions are messy due to


and end product
wrong use of tape in production

The charge controller installed

Box with Light and


12v connectors

The workshop

The main SHS parts

The

79

10. PROJECT EVALUATION

In this last chapter the final SHS design and the entire graduation project is evaluated. The final product is
presented to one of the test families and the continuation of the SHS by Kamworks is described. The design
is assessed on the design criteria and recommendations about the SHS are given. The initial proposed design
process is discussed and the final conclusions about the graduation project stated

10.1 PRODUCT - USER INTERACTION


Although much experience was build up with working with composites. Mould making posed many set backs
whereby eventually prototypes of the final design of the SHS could be created. Therefore both the Homebox
and the support structure could not be installed by a test family.
The new empty Homebox was presented to miss
Chum Voung of test family 2 and some feedback on
the improved SHS design was received (Fig 10.1).
Since a bond of trust had been build up with the
test person due to the frequent visits during the
project, her reactions can be assumed as honest
and authentic.

Fig 10.1 Family Chum Voung with the new Homebox

Some remarks:
Miss Chum Voung was very enthusiastic about the Dragon box and said that knowing the old design, she
could not have imagined such a nicer product and immediately assumed that the new box would also preform better.
She indicated to really like the new appearance of the box and liked the color setting and the fact that the
box looked as a real product, rather than a weird cookie box.
She was still stunned by the carvings of the dragons, even as they where not colored and she had seen its
design in the concept survey and really liked them.
She also expected to take better note of the display, since the light are visible from a distance, without
specifically needing to check them. Although the new, proper display sticker was not yet available, she did
not comment on this (Fig 10.2).
See found it useful to have the directional light in the box but regretted that she would miss then the LED
light see has now installed in the small bedroom.
See found it an appealing design and recognized the Khmer aesthetics immediately.

Fig 10.2 Discussing the new design

Fig 10.3 The new Homebox placed

81

Fig 10.4 Mounting the composite support and solar panel

First SHS serie product

Since the Four HOPE families in Pursat, that were visited during the orientation research, were also waiting for
the new medium Solar Home Systems, Kamworks zealous continued with the production of the system. Meanwhile the four SHSs have been installed according to the new design successfully!
Although no extensive debriefing about the installation took place yet, some remarks are communicated and
several photos . The installation went according to plan. Installing the support structure to the house was easy
and fast (Fig 10.4). With, one system however the galvanized pipe was not placed straight directly, this probably
due to inexperience of installing. The families were impressed by the quality of the installation of the lights with
switches and joked that maybe Kamwoks hoped in selling a lot of these systems if they did their best now

Fig 10.5 The installed Homeboxes, for now all installed on the floor

The families were happily surprised by the appearance of the Homebox as they are all known with the open
installation of the Khmer solar systems. They seemed to accept the enclosed system, due to trust in the HOPE
organization that selected Kamworks and the appealing design of the Homebox, time will show if this is actually true. Three families could not place the Homebox on a table or cupboard and proposed themselves to get
something to put the Homebox on, as it looked much to nice, to put on the floor, where its gets dirty and maybe
damages. They also wanted to keep a close eye on the display. As they were curious about the system performance and stated this was easier when the box was placed higher.

82

10.2 DESIGN OPTIMIZATION


Since Kamworks desired to take the new SHS design quickly into production, there has been much communication after my return to the Netherlands to assist Kamworks in actually producing the new SHS design in series
(Fig 10.6). Although one of the Kamworks employees, Sarin, had been trained in working with composites and
partly in mould making during the project, still many mistakes were committed due to unknown details and inaccurate working. Additional tips on composite production were given, mould making drawings, improved stickers,
SHS manuals and an installation manual were also presented.

Fig 10.6 The first four SHSs ready for installation

The moulds for the support structure could directly be used for producing multiple composite supports. The
moulds for the Homebox were improved and prepared for a small series production. The back of the box, that
could not be finished during prototyping was created and as the desired connection plugs were not available yet
a simple connection block was used for connecting load and panel.
Still some points of optimization remained, most were taken for granted for now
Color transitions; during production it is now difficult and laborious to precisely apply the color layers to
reach straight transitions. This is now solved by using white painters tape and wiping off mistakes with a
wet cloth. A long term solution could be to add small seams in the mould, at the color transitions, to which a
temporarily mould can be placed when applying a colored gelcoat. A thin rubber thread can also be pressed
in a seam at the color transition of the final product or a special taped applied over.
The dragon looks nice, but should be made by a professional if a new mould is made.
The blue color is to dark and sometimes appears to the users as black; the blue pigment should therefore
be mixed with white gelcoat, whereby a brighter blue can be obtained.
The material strength of the composite support should be evaluated and the box to shocks and bumps.
They both seem sufficiently strong but this should be tested.
The use of inserts worked very well, and should be elaborated for
all connections to the box, to limit processing the composite and
need for a finish even further.
Creating an accurate transparent area and assembling the light
correctly in the box is now to complex and should be further
elaborated. An option is to glue in a vacuum formed cap after the
box is produced and revert the current area to the inside of the
box, to create an sealed off area for installing the light.
Currently kamworks is working on the production of the large SHS,
based on additionally provided model building plans and experiences
in making the medium SHS (Fig 10.7).

Fig 10.7 Preparing the mould for the


big Homebox

83

10.3 RECOMMENDATIONS
The outcome of this project is very descriptive for Kamworks, in how to continue with the SHS. Some specific
recommendations are described bellow
Production
The yellow pigment might possibly be contaminated with Lead, which is health hazardous for the workers
and users and should therefore be tested.
Improve the working conditions, both for the health of the workers and the quality of the products. Standardize the production method, if production volumes increase.
Installation
When a system is installed, take a registration from, to note the basic info of the system like the panel
and charge controller serial number, the date of installation, the number of box and additional notes and
remarks. Hereby future maintenance will be made easier, and Kamworks can learn form previous installations and develop the SHS further.
components
It is advised to Kamworks to make an more extensive profile of possible malfunctions in the SHS, both in
the internal components as the structural design of the system. Note their solutions to be able to react accordingly to troubleshooting and train future installers and micro entrepreneurs.
Take a well considered decision if a ground should be added to the SHS, especially for the AC, 220V system.
It ads considerable costs, but in case lightning hits a Kamworks SHS the consequence can be considerable,
even with the battery fuse added to the system. What these consequences can be and how big the risk is
should be looked into more carefully.
Kamworks should investigate further in the actual power consumption and education of the people in order
to match the expectations of the SHS. Especially the altered Televisions that take 150w to operate can pose
a serious threath to the SHS appreciation as the users dont understand the concept of power variations.
The LED lamp is expensive, is not entirely used what its meant for whereby the installation becomes to
extensive. Therefor the LED light was placed in the box. Kamworks should rather develop a series of leds
for in the Box themselves than to use the current expensive LED light bulbs
The use of cables in installing the lights should be minimized to reduce costs. This should be made clear
also to the customer, when the light points are chosen. Additional the switches can be used as connection
boxes also.
Sales
The SHS sales strategy should be carefully considered. How to present the system, its main features, how
to appeal to the user and create the product desire. One sales strategy could be to provide one principal
family, for example the village chief with a SHS, as demonstrating the system is the best marketing strategy
in Cambodia. There is the strong urge to desire, want and purchase what the neighbor has and preferably
even better. Sometimes even no matter the costs.
The SHS should be presented as a basic system, making clear what is provided with the system and that
additional cable, lights, remote installation will cost additionally. This is important to keep the already small
profit margin high.
The SHS is designed as if its plug and play. This can enable a much wider reach of the product in the future,
as the SHS will leave Kamworks certified and sealed, with installers and micro entrepreneurs installing the
system, far beyond the reach of kamworks now.
In time a complete SHS catalog could be created. With additional options for a different color box, features ,
accessories to the system and replacement parts. Hereby creating a bridge to the other Kamworks products
and give the customers the opportunity to distinguish themselves.
Carefully evaluate the datalog info for future product development and sales strategy.
An nice product opportunity was seen in creating a mobile led lamp, that can be plugged directly into the
12v car socket. Where it is charged and can stationed at night, and can be taken out if a mobile light is
desired for going to the toilet or check the cows at night.

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Recycling composits

A major drawback of GFRP is its recyclability. This is difficult since the glass fibres remain intact during normal
incineration and many poisonous gasses occur. In western countries the material can be granulated to powder
and used as a reinforcement material or supplemented as a fuel in large compostion plants. However, in Cambodia these technologies are not yet that advanced [Reitenbach, 2007].
The use of natural fibres could therefor pose a suitable alternative, since no residual material remains after
incineration. The ideal solution would be the use of 100% natural composites, like NPSPs Nabasco, but this
technology is not yet mature enough. A constrained of using natural fibres is that a different, more complicated
production process should be used. This also posses many problems in Cambodia, as appeared from two tests
with Vaccuum assisted RTM at Kamworks.
For future applications, when expanding the range of composite materials, Kamworks can consider to transfer to
the automated RTM composite process or to install an injection machine for the use of composite materials.

10.4 PROJECT REFLECTION


The initial project set up could already be classified as daring and extensive. Already early in the design process
a prototype would be created to implement a practical experience with the SHS into the final SHS product design. The SHS would that way be designed, so to say thru production, in context and in close contact with its
end-users. Thereby obtaining first hand results, not only about the system, but also about its future production
and use.
I could say that i succeeded in that initial set up and the end result is very satisfying. But i have been struggling
not to drown in the broad content of the project. The project size and process expanded far beyond the reasonable boarders of a graduation project quickly. Making it extremely difficult to follow the initial set up, due to the
local restrictions and the additional work that was added by related issues. Kamworks was struggling to keep up
and could often not provide the necessary support and circumstances for a smooth project progress. Something
that was anticipated on forehand by doing a project abroad, but the sketched circumstances seemed sufficient
at the time to attempt the process as described.
Additionally there was already a strong pressure on delivering a final producible product from week 1 on, as
Kamworks had already made some commitments. This made me besides a researcher, product developer and
engineer also a marketeer, book keeper, elctro-technician and production employee. A very diverse nice mix of
tasks, but many times conflicting due the simple restriction of available time, This pressure is also something i
may have proclaimed on myself, with the desire and the urge to create something suburb and the weakness of
planning and always saying yes.
Back to the process evaluation. Early in the process the development of the pilot SHS was delayed, preparing the
dataloggers and finding the test families additionally added to the set-backs. It was decided however to continue
with the initial set-up since much time had already be invested in making the pilot SHS and every time solutions
with the dataloggers and test families seemed to become available. Because the 1st design process of the pilot
system took so much time and the design research period spread over a many weeks. The 2nd process of creating the final design was compressed in time. Added with often the lack of electricity and internet for reporting,
the final decisions have been taken very rapidly and the creation of the prototypes done in a very short time. It
doesnt seem that mistakes have been made in creating the final design, but now looking back certain decisions
should be more carefully evaluated as described in the recommendations and product optimization.
Still, the daring design process resulted in a very interesting project, of which i indeed enjoy a lot, by being so
close to the Khmer and the Kamworks employees i can reflect on a successful project.

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10.5 FINAL CONCLUSION


The result of this project is the design of three types
of Solar Home Systems as one product family and one
complete product. The SHS has become a true modern
powerhouse for rural Cambodia. A distinctive desirable
product of superb quality that matches with the Khmers
culture, styling, way of living, energy consumption and
house situation. The system is easy to install, durable
and strong. The technical components are enclosed in
the Dragonbox, a user friendly connection station with
a high aesthetic value in creating a product desire, a
commercial value in being distinctive and a functional
value by protecting the system components. A charge
regulator furthermore guarantees a safe use, an extended battery life and provides the users with the so
desired energy feedback. Making the Kamworks solar
home systems a secure energy source available for all,
for an affordable prize.
The Solar Home System was created by an elaborate
analysis of the local context, where many Cambodian
families were visited to map their energy needs, desires
and living situation. Then a number of pilot SHSs were
created on basis of a preliminary design, to evaluate the
technical functioning of the system and practically test
the system in operation. The experiences of installation
and production of a SHS could that way also already
early in the design process be taken into consideration.
Three systems were evaluated in the field by test families, whereby the product use, performance and appreciation was monitored technically by datalogging and
practically by a series of surveys. Based on this extensive design research the pilot SHS was further elaborated to a final SHS product design, ready for production.
Mostly by improving the production and the aesthetics
of the Dragonbox, and the complete installation and
product design of the support structure. Thereby creating a unity in the systems appearance and use.
Kamworks had the desire to bring the SHS on the market soon, the outcome of this project enabled them to
do so. During the project already 3 preliminary systems
were sold and installed. The moulds of the final prototypes could now easily be improved and modified to produce the first SHS product series of the medium SHSs.
Four systems have already been sold and installed, according to the new SHS product design. Kamworks was
very enthusiastic about the SHS designs and is determined to continue with the production of the systems in
the framework set by this project. Currently the Large
SHS is being created, since many customers are eagerly
waiting to what could be seen as the new generation of
Solar Home Systems in Cambodia

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REFERENCES
Literature
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MIT, 2007; Sloan-GLabTeam;. Kamworks final presentation
Reitenbach M. (2007). Design of a mobile solar kiosk, for Cambodian micro-entrepreneurs. Graduation report.
TU Delft
REF, (2007), Rural Electrification Fund, Cambodia; Technical specs REF voor SHS, 08-22/2007
Hensen L. (2008). Market opportunities of natural Composites, Graduation report. TU Delft
Rotman, M. (2006). Exploratory research for appropriate Product Market Combinations in Cambodian rural areas. Internship report. Universiteit Twente.
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July 8th, 2008
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12th 2008
Wikipedia, www.wikipedia.org, accessed feb 15th 2008

Interviews / Surveys
HOPE, 2008; SHS evaluation and future users, march 21-22th 2008, Pursat Cambodia
Concept Choice, 2008; concept choice survey with test families, june 16-17th 2008, Sre Ampil
Composite tests, 2008; a intial series of test to tackle composite problems, March 17-18th, Sre Ampil

Note: Some pictures in this report are provided by courtesy of Jan Ellen, Kirsten Rijke and Stephanie Wirth.

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Copyright by Tom van Diessen - August 2008

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