Solar Powered Chicken Wing Cooker

Prepared by:
Babacar Cisse

ACKNOWLEDGMENTS
The group would like to acknowledge several people that helped us a tremendous amount in our
design of the solar cooker. First we would like to thank Dr. Hall for organizing the course in an efficient
manner and meeting with us whenever we needed guidance. Secondly we would like to thank Zachary
Ball for meeting with us every week, and giving us helpful advice with our design questions, and
providing clarification on the assignments. Thirdly we would like to thank Dr. Olewnik for meeting with
us on a biweekly basis and helping us with the analysis and testing as well as providing many useful
recommendations. Lastly we would like to thank the graders Amrita Lall, Anmol Gupta, Amey Pradeep
Mathkar, and Praveen Kumare Gopalakrishnan, for providing fair grading in a timely manner throughout
the semester. We would like to say thank you to the teachers and faculty in the machine shop for guiding

1
us on using the machinery while we were prototyping. We would lastly like to thank our group members
for the continuous effort everyone put forth throughout the semester and congratulations on graduating.

TABLE OF CONTENTS
Acknowledgments.1
Table of Contents..2
List of Figures .................3
List of Tables ..............4
Executive Summary .........5
1 Introduction.... ..6
1.1 Group Identification.........6
1.2 Design Specifications.......8
2 Technology Review..9
2.1 Alternative Design Solutions.9
2.2 Patent Research.11
2.3 Patent Design Impacts....13
2.4 Analytical Approach and Impetus..14
3 Design Methodology.15
3.1 Conceptual Design/ Technical Processes...15
3.2 CAD Modeling...17
3.3 Governing Theory...18
4 Engineering Analysis...21
4.1 Theoretical Results.21
4.2 Testing Results...25
5 Economic Analysis28
5.1 Cost vs. Benefit.28
5.2 Large Scale....28
6 Conclusion and Recommendations30
7 References..31
Appendix A: Pro/Con List...32
Appendix B: Pughs Method35
Appendix C: Gantt Chart37
Appendix D: Flow Diagram38
Appendix E: Block Diagram..39
Appendix F:
QFD Matrix..40
Appendix G: Heat Transfer Matlab Code..41
Appendix H: Bill of Materials44
Appendix I
Part Drawings...45

LIST OF FIGURES
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13
Figure 14
Figure 15
Figure C.1.
Figure D.1.
Figure E.1.
Figure I.1.
Figure I.2.
Figure I.3.
Figure I.4.
Figure I.5.
Figure I.6
Figure I.7.
Figure I.8.
Figure I.9.
Figure I.10.
Figure I.11.

GoSun.........9
All American Sun Oven....10
All Season Solar Cooker and Trivet..10
SolSource Solar Cooker.....11
Flow Chart.....16
Conceptual Design.....17
Labeled CAD Model..18
Angled View.....18
Side View and Bottom View..18
Problem Set-up...18
Beam Angles..20
Heat Loss vs.Time..25
Test Results........26
Temperature Fringe Plot.....27
Solar Cooker Prototype...30
Gantt Chart.....37
Flow Diagram....38
Block Diagram.......39
Base..................45
Door Frame........45
Door Handle ......46
Fresnel Lens.......46
Glass..................47
Hinge.................47
Hinge Pin............48
Leg.....................48
Pot......................49
Screw.................49
Swing Rack.........50

LIST OF TABLES
Table 1. Analytical Results.......24
Table 2. Test Data........26
Table A.1. Pro/Con List....32
Table B.1. Pughs Method........35
Table F.1. QFD Matrix.....40
Table H.1. Bill of Materials..44

EXECUTIVE SUMMARY
The design problem was to develop a solar cooker that reaches a temperature of 175F or higher
using only energy from the sun. The solar cooker would have to not be too big so that it could be carried.
The solar cooker could also not be too small so that it could heat up a large amount of food. There are
numerous applications for the solar cooker. It could be taken on a camping trip, used for a barbeque in the
backyard, and it could also be used for tailgating. Another application was to use the solar cooker in
developing countries that have a lot of sunlight and high temperatures. We developed CAD models of the
solar cooker and provided hand calculations of the temperature. Theoretically maximum temperature of
the solar cooker is 563F when the ambient temperature is 60F. Our Creo Parametric analysis predicted a
maximum temperature of 631F. However, both of these calculations had the fresnel lens at its optimum
focal length and used the poly damp low emissivity foam as our insulating material, and used When we
actually tested it we got up to almost 200F. However during actual testing the fresnel lens was not at its
focal length, and we used wood instead of polydamp low emissivity foam. Also, our fresnel lens was not
very high quality. The idea was definitely feasible, and if we had more time and a better budget we are
confident that we could have achieved higher temperatures.

1.0 INTRODUCTION
1.1 Group Identification
The importance of our project is to design a product that can be used without the conventional
practices of relying on an energy supply. Cooking devices generally run on electricity or gas, both of
which is not always readily available or is in limited supply. This solar powered chicken wing cooker will
be able to cook food from using energy supplied by the sun. The important aspect of this is that energy
from the sun is free and there is an unlimited supply of which can be accessed from anywhere no matter
how remote of an area you are in. This means that you do not have to rely on non-renewable resources for
it to function.

Our expected outcome is to design a working solar cooker that can be tested and supported with
theoretical analysis. Through theoretical analysis we hope to determine necessary specifications related to
design and material properties which will allow for the most efficient solar collection. Deliverables will
include our theoretical analysis along with a materials listing and a working prototype.

A Pro/Con list (Appendix A) and Pughs method (Appendix B) were used to choose the best
possible concepts from the brainstorming session, but there were a lot of ideas that we will not be able to
test or examine properly that we would like to if we had more time. In addition, the prototype production
will be limited due our limited access to resources and our time constraints. For our Manufacturing
protocols we will look into producing smaller and larger models of the solar cooker. Smaller models
would have more appeal for hikers and larger models would have more appeal for barbeques in a back
yard.

1.2 Design Specifications

This device will operate strictly on solar power, and it is feasible for the cooker to be used in the
daytime because this is when solar energy can be collected for use. In order to do this, heat loss must be
minimized. In order to sufficiently cook food so that it is edible, the cooker must be able to maintain a
sufficient temperature for an ample length of time. Most bacteria are killed at, or exceeding a temperature
of about 150F. A safe guideline for cooking chicken is a temperature of 175F for several hours.
Therefore, the minimum objective set for the chicken wing cooker would be to reach a temperature of
175F. In order to meet this requirement, the cooker needs to be sufficiently insulated. Therefore, the
walls enclosing the device must consist of a highly insulative material, and if a lense is used to focus the
suns light, it must be powerful enough to generate the necessary heat.

Size and weight constraints are also a concern. It is required that the cooker be portable, therefore
the cooker cannot be designed with material that is too heavy or too bulky or else consumers would not be
able to transport it.

There are manufacturing constraints that need to be taken into account. The final design of the
cooker will be manufactured in the machine shop and the materials of the prototype need to be obtainable
for the group. The prototype of the final design can have different materials substituted in for cost
purposes as long as they do not compromise the design. Some materials will be too expensive and too
custom to acquire in our available time frame.

Because this device will be designed to use in instances such as camping, tailgating, general
outdoor grilling/cooking, etc, it is necessary that the cooker meets the performance specifications
although the weather conditions may not be ideal. Along with the summer, consumers cook outside in the
Fall and the Spring as well. In order for the cooker to perform when the weather is slightly cooler out, it

7
needs to be sufficiently insulated so that the heat does not escape. The device also needs to be designed so
that it can make the most of the little sunlight available on days that are cloudy. This would mean the
lense would need to be very good at focusing the sunlight, and the angle of the lense could be changed to
capture the available sunlight.

2.0 TECHNOLOGY REVIEW

2.1 Alternative Design Solutions
The GoSun cooker is a current device that uses parabolic reflectors to focus the heat on a
borosilicate glass tube [1]. It can convert almost 80% of available sunlight into useable heat [1]. The
GoSun cooker can cook a variety of foods such as vegetable meat, and starches. The oven is not very big
and cannot cook a high quantity of food. The GoSun also does not require a lot of adjustment from the
user. It can cook as meal in as little as 20 minutes, and reach temperatures of up to 550 F [1]. It can also
cook on cloudy days, and the exterior is cool so it will not burn you. The GoSun is also lightweight and
portable. The Gosun needs to be turned in order to cook the food evenly.

Figure 1: GoSun
Another modern solar cooker is the All American Sun Oven. This device is essentially a box with
4 solar reflectors that fold out [2]. It can cook a lot of food and achieve temperatures of over 350 F [2].
The oven also has a leveling rack which can swing freely to prevent the spilling of the food.The rack can
also fold up and sit on the floor of the solar cooker so that larger pots and pans can fit inside. The All
American Sun Oven also comes with ground stakes which can prevent the solar cooker from blowing
over [2].

Figure 2: All American Sun Oven

Another current device is the is the All Season Solar Cooker and Trivet. The solar cooker is
portable and can fold up. The material used is fluted polyethylene and it both waterproof, durable, and has
high tensile strength [3]. Pure aluminum tape is also used, and it is both a strong and durable material [3].
The solar cooker only weighs about 6 pounds [3]. The trivet can raise the cooking pot so that light can hit
the bottom thus increasing the effectiveness of the solar cooker.

Figure 3: All Season Solar Cooker and Trivet

Another current device is the SolSource Solar Cooker. This solar cooker can reach temperatures
as high as 550 F [4]. It can also heat up food five times faster than a charcoal grill [4]. This device uses
parabolic mirrors to maximize sunlight. It is approximately 40 pounds so it is not the best for transporting,
however it can be easily disassembled for transportation [4]. Assembly of the SolSource can be done in
approximately 20 minutes [4]. It is easy to align the SolSource because the user simply has to rotate the

9
SolSource towards the sun until the sun is aligned with the cookware in the alignment aid mirror. Then
the user must use the adjustment pole to move the dish until the black focal point can be seen on the
center of the cookware bottom [4].

Figure 4: SolSource Solar Cooker

2.2 Patents Research
Every patent search has it distinct quality. Some inventions focus on the use of mirror reflector;
others emphasize on insulation to trap energy. Another unique method is the radiation as a easy oven cook
method. Each product also has unique method of cooking

Patent US4082079A:
The patent US4082079A uses a portable solar oven and grill method. The structure is a diagonal
shaped oven box with walls of heat insulators Rodgers [5]. A glass panel is mounted across the open face
of the oven box and the glass panel is inclined to retain heat Rodgers [5]. There is a glass plate mounted
to a rectangular wooden frame Rodgers [5]. The interior base plate is made out of aluminum and it is
loosely hinged Rodgers [5]. The aluminum plate rests on a hinge fastener, whose purpose is to heat the
grill plate Rodgers [5]. The grill plate is in contact with the aluminum plate so the aluminum plate can
heat the grill plate Rodgers [5]. This patent does not use water, rather a grilling method which will avoid
hassle and can be a great suggestion to consider.
Patent CN204721639U:

10
The patent CN204721639U is another portable solar cooker method, the idea behind the device
favors outdoor campers, for its size and ability to carry. One if its main feature is its expandability and
ability to adjust the solar panels faces the sun. A folding wall expands and is connected to the chassis by a
support rod [6]. Electrical energy is stored in a battery plate and used to power an electric heating layer
which cooks the food [6]. The wires in this device are flexible, allowing it to be easily folded and
unfolded. The downside to this is an excess uses of material which might be expensive.
Patent US5195504A:
The US5195504A is another portable solar oven method, but its main benefit is achieving
cooking temperatures in at all time of the day, and even winter. This design focuses on decreasing heat
loss and cooking duration. The design assembly is made of a round cooking top which allows the cooking
chamber to collect sunlight from any angle and increase the heat distribution across the heating surface to
create a more even distribution of heat Lane [7]. A reflector frame which can rotate 360 degrees is able to
direct the sunlight into the cooker at any angle Lane [7]. This cooker has a detachable and folding arms on
each side for convenient storage and portability which is a key component to incorporate into our design
Lane [7].

Patent US5617843A:
The patent US5617843A created an articulating base that can be reoriented throughout the day to
take advantage of the most intense solar rays at any given time of day Erwin [8]. This is a very novel
design that adequately solves a problem faced by most solar cookers. Because the patent has expired, the
design is free to be adopted or adapted by the design team as a part of its final design of a solar chicken
wing cooker. This would provide the team with a good and solid base upon which improvements can then
be made.

Patent US5054467:

11
The patent US5054467A is a hotdog cooker. The base is covered with a top generally transparent
to solar energy waves and placed in the sun Videtto [9]. At that moment, depending on the solar intensity
it will take the hot dogs about 20 minutes to cook sufficiently Videtto [9]. The cooker is reusable and may
work even when there is partial exposure to the sun. This design is handy, inexpensive, relatively quick
and safe for the customer to use which are our groups goals in term of meeting customers satisfaction.
There is room in this design for our group to implement our own ideas, and as a result we will be able to
reach our goals for our product
Patent US5090399:
The US5090399A is a solar cooker with a parabolic reflector. Its design is a parabolic reflector
with two stripes enjoined by bands, the structural frame can be used and rotate upon convenience Tarcici
[10]. The strip connected by are liable to cause maladjustment, the support of the grid is also not held
vertically in a reliable way which led to Tarcicis motivation to overcome disadvantages Tarcici [10]. The
cooker take two forms of unfolded operational position and the folded position which will increase
mobility allowing it to be carried and transferred about as necessary. The downside of this device might
be the cost.
2.3 Patent Design Impacts
This information wide variety of reasonable design solution, which makes it a bit harder to
narrow down to one decision. The patent US-5195504A minimize heat loss which is one of if not the
biggest quality in the design. The US4082079A and US-5195504A focus on an oven and grill design
encourages the method of baking and helps prevent the usage of water. The downside to this is that the
grilling is not considered healthy because of the burnt charcoal pieces and use of oil, however cooking in
oil does help speed up cooking time. Devices that emphasis on minimizes cooking time are US5617843A
and US5617843A, they possess ability to focus on sun, one even have a 360-degree rotation. The
CN204721639U and US5090399A have a strong storage and portability quality which is beneficial for
camping and traveling purposes. Images of the patents may be found in the Appendix.

12

2.4 Analytical Approach and Impetus

After in depth research on the current devices already on the market and patent research, we will
use the research and discoveries made thus far to decide on a physical model that we want to build. This
includes the size shape and uniqueness of our prototype based on what we believe will be the most
effective and cost efficient design based on our research and consumer survey results . Also, taking into
consideration the complexity to model and physical prototype. This will be represented with a hand drawn
descriptive model. Next, is selecting the materials that will be used for our design going by what current
devices have had the most success with. Heat absorption and heat insulation along with overall cost will
have the most influence on the material selection. Following materials will to next develop a CAD model
to represent our design. Then we can conduct heat transfer analysis based on our CAD design and
implementing our chosen material properties to accurately determine specific heat characteristics of our
designed solar cooker in certain testing conditions. Being comfortable with our heat transfer conclusions
and that our design is going to be effective, the process of purchasing materials and building the prototype
can begin. Then finally after the prototype has been built, testing can begin and after some data collection
we compare our prototypes performance to the heat transfer calculations and compare the results. Lastly,
if there is time, we can do some further research and design changes to improve upon our design.

3 DESIGN METHODOLOGY
3.1 Conceptual Design/Technical Processes
The research on current devices was helpful in coming up with ideas, features and materials to
implement into our design. We chose to go with a circular base with a flat top box design with aluminum
wrapping around. Similar to how the current devices use their solar reflector mirrors to direct radiation,
the aluminum will reflect the radiation and hopefully help with insulation and keeping the radiation inside
the cooker. The cooker will stand on legs and be able to be tilted back and forth to account for the

13
movement of the sun. Researching glass for the top we came across a fresnel lens which would help direct
the sunlight into the solar cooker onto the food. This will enable us to concentrate the sunlight onto the
food to increase temperature and decrease cooking time. The fresnel lens will sit on top of the glass door
and can be removed to inspect the food while its cooking. We decided that this concept would be easier
to build in the machine shop and not require expensive materials or custom ordered components. We also
decided to go with a free hanging rack inside the cooker similar to the All American Sun Oven device, to
keep food level in case the box was to be tilted or moved. Polydamp Low emissivity foam was chosen to
the material for the side walls as it is a good insulator and is lightweight. For simplicity, plywood is
chosen as the side wall material for prototyping because it is more easily accessible and cheaper to obtain
based on our budget. A model of what our design would look like with all the anticipated materials was
then sketched.

14

Figure 5: Flow Chart

The flowchart represents the iterative processes that we used to make the solar cooker.
We set a problem definition and gathered a lot of information. Then we generated ideas and used
concept screening to narrow down our ideas. We created a schedule of when to get work done on
the Gantt chart, and we all contributed money so that we could get the materials. We also did
parametric design and selected the ideal materials for our project. We developed our concept and
tested it with hand calculations. We also made a Detailed Design using CAD models on Autodesk
inventor.

15

Figure 6: Conceptual Design

3.2 CAD Modeling
We developed the prototype on Autodesk Inventor first making the circular base and wooden legs
and along with the aluminum sheet and getting the parts assembled. Then making the door and glass
attached by the two hinges with a handle on top. The assembly is a fully working assembly as the door
can open and close and the solar cooker can rotate to match the angle of the sun. A free hanging rack to
support the food and a black tray to simulate food being cooked inside the cooker was also created. The
Fresnel lens which we would place on top of the glass window and two side handles to make the cooker
easier to lift and carry. Additional assembly and part drawings may be found in the appendix.

16

Figure 7:
Labeled CAD
model

Figure 8: Angled View

Figure 9: Side View and Bottom View

3.3 Governing Theory

17

Figure:10 Problem Set-up

A set of initial assumptions must be applied and parameters known in order to complete the
analysis. Since the solar cooker will be able to rotate, we can assume that the angle that the UV radiation
from the will always be perpendicular to the glass surface of the cooker. Since the fresnel is a semitransparent medium, when a beam of radiant energy hits the surface, some of the energy is absorbed by
the lens, reflected back up into the atmosphere and transmitted through the lens into the inside cooking
volume of the cooker, Mitalas [11]. Energy from the sun will be about 1375 W/m^2 on a clear sunny day,
Mitalas [11].
Assumptions:

Parameters:
2

T sur =60 F=288.7 K @t=0 sec

A Lens=16 ' ' x 11 ' '=0.113548 m

T inner =60 F=288.7 K @t=0 sec

K lens=1.4

A Lens=16 X 11 0.113548 m2

nlens =1.52

Test Time=30 min=1800 sec

t lens =0.125

1=0 degrees

Focal Dialens=1 0.0064516 m2

2=0 degrees

Solar Constant =5501025

W
mK

W
m2

Fresnels formula [12] gives the ratio of the intensity of the reflected beam and the incident beam
for parallel and perpendicular.

18

r par =

tan 2( 12 )
ta n2 (1 +2)

(1)

r par =

si n2 ( 12 )
sin 2( 1+ 2)

(2)

Figure 11: Beam Angles [13]

and are the angles that the beam makes with the normal to the interface in the air and in the fresnel lens
respectively and are related by Snells Law, Davis [12];

sin( 1)=nssin(2)

(3)

where n is the index of refraction of the fresnel lens. Since the assumption is that the sun will always
shine perpendicular to the top of the cooker, the angle between the radiant beam and the vertical will be 0.
This also means that the angle of refraction will also be 0 resulting in, [11]

19

1= 2
And

n1 2
=energy reflected
n+1
r par =r per =r=

(4)

where n is the index of refraction of the glass (dimensionless). The fraction of energy that is absorbed by
the glass of thickness L, is given by, [11]

nKL
n2si n ( )
2

(5)

1e
)
a=(1r )
1

where K is the absorption coefficient of the fresnel lens. Assuming the beam intensity is unity on the glass
surface, the beam intensity that penetrates through the glass into the volumetric cooking space of the
cooker is, [11]

nKL
n2sin ( )
2

(6)

e
)
I =(1r )
1

4.0 Engineering Analysis

4.1 Theoretical Results
Beginning the calculations we use the r equation to find reflectivity, which is a dimensionless value we
can change to a percentage of reflection of the beam.

(1.521) 2
=0.043 4.3
(1.52+1)
r =

(4)

Therefore 4.3% of the radiant beam will be reflected from the glass back upward into the atmosphere.
Now finding the fraction of energy absorbed,

20
1.521.40.003175

a=(10.043)(1e

1.52

2sin (0 )

)=0.0052 0.52

(5)

Therefore 0.52% of the radiant beam will be absorbed by the glass, heating the glass. Next determining
the fraction of radiance that will be transmitted through the glass into the cooking space of the solar
cooker, I
1.521.40.003175

I =(10.043)(e

1.52

2si n (0)

)=0.951 95.1

(6)

Therefore 95.1% of the radiant beam energy contacting the top surface of the glass will actually be
transmitted into the cooker increasing the inside air temperature and cooking the food. We can neglect the
Q equation and simply multiply the percent transmitted by the solar constant hitting the glass surface at
a perpendicular angle with respect to the glass surface and the sun of 1375 W/m^2 and multiplying by the
area of the glass to obtain J/s.

Qtrans=1375

Qtrans =1307.625

W
W
0.951=1307.625 2
2
m
m
W
J
2
=0.367 m =479.89W =
2
s
m

Assuming we are looking to obtain an inside air temperature of the cooker 30 minutes after being outside
t=1800 seconds will be the testing time.

J
479.89 1800 s=863.80 kJ
s
After 30 minutes of heating, 863,802 Joules has been added to the inside of the cooker. Using the density,
specific heat parameters for air we find the amount of temperature increase inside the cooker per unit
volume.

21

C p =0.716
air

pair =1.3

kJ
kgK
kg
m3

863.8 kJ
=618.48 kgK
kJ
0.716
kgK
618.48 kg K
K
=804.03 3
kg
m
1.3 3
m
Therefore we have an inside temperature change of 804.03 K/m^3. Being that our solar cooker has a
cylindrical base we can multiply this volumetric temperature change by the inside volume of the cooker
to obtain a temperature increase.

r cooker =23.75 0.603 m

hcooker =24 0.6096 m
K
0.603 m0.609 m
3
m
804.03
=279.8 K
2
Finally we have obtained our temperature increase inside the cooker after 30 minutes of direct sunlight at
an ambient temperature of 288.7 K (60F). Giving a total inside cooking temperature;

T inne r

30 min

=288.7 K +279 K=568.5 K=563.63 F

It has been concluded that after 30 minutes we have reached a cooking temperature of 563.63 degrees
Fahrenheit after starting at 60 degrees Fahrenheit and heating for 30 minutes with direct sunlight.
Keeping in mind this analysis is based on ideal conditions and simplifying the analysis to not factor in
any heat loss from convection and assuming perfect insulating conditions inside the cooker.

22

Being that the thermal conductivity of aluminum is 205 W/mK, and the thermal conductivity of
pine wood is 0.12 W/mK, the conductive heat loss from the aluminum is going to be much more
significant than the conductive heat loss from the wood. The conduction formula is, [14]

Q kA (T hot T cold )
=
t
d

Where,
d = thickness of material
A = surface area of material
Q/t = Watts = Joules/second
T_hot = inside cooker temperature
T_cold = ambient temperature (60 degrees Fahrenheit)

(7)

23

Table 1: Analytical Results

24

Figure 12: Heat Loss vs. Time

Taking our max temperature achieved in 30 minutes of 563.63 degrees Fahrenheit and using the
conduction equation along with the heat gain found of 479.89 J/s we can formulate an excel table and
graph to represent the heat loss over time. We can see that over time the heat loss begins to converge
toward our heat gain from the solar constant and we start losing heat at the same rate as we are gaining
heat causing our temperature increase to level off and we reach a maximum temperature of 568.5 degrees
Fahrenheit. The graph of the calculated analysis is shown above and the table of data can be found in
Appendix F

4.2 Testing Results

25

Table 2: Test Data

Figure 13: Test Results

Our testing results allowed us to achieve a temperature of 200F in 18 minutes. This exceeded our goal of
175F. The solar cooker can slow cook food and it heats up relatively quickly. The ambient temperature
was 72F and there were no clouds in the sky so we had very good conditions when we tested.

Being that a standard cooking temperature is 350 degrees Fahrenheit we have exceeded this
substantially. In a real world application, we would not reach this high of a temperature in only 30
minutes, however overly exceeding the standard cooking temperature in the analysis sets us up well for
factoring in real world conditions and heat losses when we test our prototype. If all goes well and our
analytical analysis is closely approximated, we should still reach an adequate cooking temperature.

26

Figure 14: Temperature Fringe Plot (F)

Importing our model into Creo Parametric, thermal FEA analysis on the model using to create a
fringe diagram of our solar cooker undergoing radiation and to determine what our testable temperatures
would be. The thermal analysis was able to tell us that the middle of the solar cooker will experience the
greatest heat and after 1800 seconds (30 minutes) we will reach a temperature of 631 degrees Fahrenheit.
The lower temperature around the outside could be due to conduction losses.

5.0 Economic Analysis

5.1 Cost Vs. Benefit
Assembly took a total of 15 hours which was distributed into three five hour days. First day of
prototype was used to cut and dimensionalized the material relative to the purchased Fresnel lens. The
dimensions of the wood and aluminum are the frame exterior. Two semi oval pieces were cut from the
wood with the band saw, for the sides and the aluminum sheet cut in the shear and bent to a parabolic
shape. The wood and aluminum were assembled together by screws on the first day. Third day consisted
of purchasing more wood, hinges, and screws. A piece of plywood was cut for the door and the door
hinges were screwed into the door and back of the cooker. The final day was for gluing the glass window

27
and sealing any openings with a caulk sealer to help with insulation. Minimum wage is constantly rising
up and currently $9.00 in New York, compensating two engineers will result to $90.00 each.

If

considering a large scale, programmed machine will be used to drill and cut which takes a matter of
seconds. With a total cost of $165.00 and $180 for labor gives a sum of $345.00. The price is a bit
preposterous but the design team felt the test result were worthwhile therefore it compensates for absurd
price. For this reason, manufacturing the product on a large scale will generate more revenue.
5.2 Large Scale
Manufacturing the solar cooker on a large scale will require a lot of negotiation with part
manufacturer. Discount will be requested bulk and mass purchases. As stated prior the price of the Fresnel
Lens varies upon quality, different editions of the cooker will be made to satisfy the customers budget
and desire. For customers will to pay less of about $150-$200, the quality of the Fresnel lens used for the
prototype will be used. The few downside to this is that the minimum depth of pot must be 20 according
to the focus length, which leads to portability discomfort. Any length smaller than the fixed will result in
longer cooking time for the cooker. For customer looking for faster cooking time will be willing to pay
over $200.00. Similar manufacturing procedure for the prototype will be emulated to with the exception
of labor work. It would be best it be manufacture in a warehouse with many instrument rather a small
machine shop like the one in UB Jarvis Hall machine shop. To compensate for the machine tool, oil and
gear. $10.00 will be account. The advantages of large scale are its automatic ability to do beyond humans
physical ability meaning its able to estimate microscopically. There are also little to no labor cost, rapid
production and most importantly total cost per unit product is decreased, result to more money in the
pocket. The disadvantages still stand where machines are expensive hence machine time could be
expensive and machine malfunction is still very common.

6.0 Conclusions and Recommendations

Our solar cooker worked pretty well as it was able to reach almost 200F which exceeded our goal
of 175F. The prototype proved that the concept could work with some modifications. The prototype was

28
also easily portable and not that heavy. Some concerns were that we never tested the solar cooker on a
cloudy or windy day so we dont know how well it would perform in different conditions, and we also
didnt try to slow cook any actual food. Future work could be done on the prototype such as adding legs
and elevating the fresnel lens as the focal point was 4 inches shorter than the recommended distance
which definitely hindered our temperature. Also replacing the wood with polydamp low emissivity foam
would make the prototype lighter and minimize conduction heat loss. Also, we could try to use
borosilicate glass instead of just the regular glass that we bought at Lowes.

Figure 15: Solar Cooker Prototype

7.0 References
[1] GoSun Stove: Fast, Portable and Practical Solar Cooker, GoSun Stove. [Online]. Available at:
http://www.gosunstove.com/. [Accessed: 01-Mar-2016].
[2] All American SUN OVEN, Sun Oven The Original Solar Oven Solar Cooker. [Online]. Available
at: http://sunoven.com/all-american-sun-oven/. [Accessed: 01-Mar-2016].
[3] All Season Solar Cooker, All Season Solar Cooker. [Online]. Available at:
http://www.allseasonsolarcooker.com/. [Accessed: 01-Mar-2016].
[4] SOLSOURCE - The Ultimate Solar Cooker. (n.d.). Retrieved May 09, 2016, from
https://www.oneearthdesigns.com/solsource-solar-cooker/?gclid=CN6wkKKjzswCFVBZhgodIpIFqA

29
[5] Rodgers, John, 1978, Portable Solar Oven and Grill. United States, US4082079A.
[6] Portable Solar Food Cooker, CN204721639U. [Online]. Available at:
https://patents.google.com/patent/cn204721639u/en?q=solar powered. [Accessed: 08-Feb-2016].
[7] B. Lane, Patent US 5195504 - Portable solar oven, Google Books, 23-Mar-1993. [Online]. Available
at: http://www.google.com/patents/us5195504. [Accessed: 03-Apr-2016].
[8] Erwin, Samuel F. 1997-04-08, Solar oven with orienting apparatus, U.S. Patent 5617843A.
[9] Videtto Jr. Donald W., Oct 8, 1991, Solar HotDog Cooker
[10] Tarcici, A. (1992, February 25). Patent US5090399 - Solar cooker with a parabolic reflector.
Retrieved March 09, 2016, from http://www.google.com/patents/US5090399
[11] G. P. Mitalas and D. G. Stephenson, Absorption and Transmission of Thermal Radiation by Single
and Double Glazed Windows, http://web.mit.edu/parmstr/Public/NRCan/rp173.pdf.
[12] A. Davis and F. Khnlenz, Optical Design using Fresnel Lenses, 01-Dec-2007. [Online]. Available
at: http://www.wiley-vch.de/berlin/journals/op/07-04/op0704_s52_s55.pdf. [Accessed: 20-Mar-2016].
[13] Waves Tutorial 6 Reflection, Refraction, and Optical Fibres, Waves Tutorial 6. [Online].
Available at: http://www.antonine-education.co.uk/pages/physics_2/waves/wav_06/waves_page_6.htm.
[Accessed: 10-May-2016].
[14] Thermal conduction, Wikipedia. [Online]. Available at:
https://en.wikipedia.org/wiki/thermal_conduction. [Accessed: 16-Mar-2016].
Appendix A
Pro/Con List

Pro

Con
Borosilicate Glass Cylinder

-Low Coefficient of thermal expansion

-Can handle high heat
-Easy to fabricate

- Borosilicate glass may have too much

thermal resistance
- other options can withstand higher
temperatures

Fused Quartz Glass Cylinder

Low coefficient of thermal expansion
Can withstand extremely high
temperatures

Fused Quartz may have too much

thermal resistance
Fused Quartz is difficult to produce

30

Fused Quartz is commonly manufactured

Would be tough to get the desired

cylindrical shape

Tilting Mechanism
Ability to get more direct sunlight
Potentially makes transportation easier

Mechanism could fail

User has no way of knowing how to find
the optimum angle

Aluminum Swing Rack

Prevents food from sliding off when we tilt
the cooker

Increases design complexity

Parabolic Mirrors that fold up

Effective way to focus the suns energy on Parabolic mirrors are expensive
the food
MIrror could break and potentially be
We could use a protective film to attach to dangerous
the back surface of the mirror to protect it
The folding allows for easy transportation
of the entire device
Fresnel Lense
Can be easily attached to the solar
cooker which would simplify the design
Low amount of material used
Lightweight

Could be difficult to get the size that we

need
Probably not as good as the parabolic
mirror for focusing sunlight

Cylindrical frame
Cylindrical Geometry would allow the
Cylindrical Geometry would be more
cooker to tilt more
difficult to manufacture
Cylindrical Geometry is more aesthetically
pleasing
Rectangular Frame
Easy to manufacture
Easy to prototype with

Not aesthetically pleasing

Restricts the tilting of the solar cooker
Wheels on the bottom

Suitable for a larger design that would be

to heavy to carry

Not suitable for a smaller design which

would be easy enough to carry

31

Battery
Would be able to store energy and cook
at night or on cloudy days
Could allow users better control of the
temperature of their food
Could allow a more uniform heat
distribution

Increases complexity of design

Some energy would be lost when
converted from light energy to electrical
potential energy

Using a heat transfer fluid like anti freeze

Could store energy
Could allow better control of temperature
Could allow a more uniform heat
distribution

Requires complex design and a

pressurized system
The fluid would have to be changed every
few years
Energy lost when heating up the fluid

Use a grill design

Would result in more flavorful meat

Would require a battery set up to

distribute the heat
Meat would have to be flipped since grills
do not heat up the meat evenly
Not good for cooking vegetables and
starches

Use an oven design

Heats all around food so meat would not
have to be flipped
Good for cooking meats, vegetables and
starches

Could lose flavor on the meat

Use of a stove design

Would allow the ability to cook fried foods
such as fried eggs

Would require a battery set up to

distribute the heat
Meat would have to be flipped since
stoves do not heat up the meat evenly

Pot Design
Very simplistic design
Allows for variety of foods

Not very aesthetically appealing

Tilting mechanism and swing rack would
be more difficult to implement

Pin and hold idea for tilting mechanism

32

Simplistic design
Easy to use

User could lose the pin

Takes away from the aesthetic appeal of
the solar cooker
Table A.1 Pro/Con List

Appendix B
Pughs Method

Criteria

Fresnel
Lense

Pin and
hold idea
for tilting
mechanis
m

Oven
design

Aluminum
Swing rack

Borosilicate
glass cylinder

Heating
Mechanism

+1

+1

-1

+1

Insulation

+1

-1

+1

Portability

-1

+1

-1

+1

-1

Flexibility

+1

+1

Duration

+1

+1

+1

Safety

-1

+1

-1

Cost

+1

+1

-1

-1

+1

Ease of
keeping
clean

+1

-1

-1

-1

+1

Pluses

Minuses

33

Neutral

Total

-1

Continue?

Yes

Yes

No

No

Yes

Criteria

Pot
design

Wheels on
bottom

Tilting
Mechanism

Battery

Using heat
transfer fluid
like antifreeze

Heating
Mechanis
m

+1

+1

+1

+1

Insulation

-1

Portability

+1

+1

+1

-1

Flexibility

+1

+1

+1

+1

+1

Duration

+1

+1

Safety

+1

-1

-1

+1

-1

Cost

-1

-1

+1

Ease of
keeping
clean

-1

Pluses

Minuses

Neutral

Total

Continue?

Yes

Yes

Yes

Yes

Yes

Table B.1 Pughs Method

34

Appendix C
Gantt Chart

Figure C.1 Gantt Chart

35

Appendix D
Flow Diagram

Figure D.1 Flow Diagram

36

Appendix E
Block Diagram

Figure E.1 Block Diagram

37

Appendix F
QFD Matrix

Table F.1 QFD Matrix

38

Appendix G
Heat Transfer Matlab Code
clear all
clc
Heat Transfer Calculations
T_sur= input('Enter the value of the outside air temperature in Kelvins ');
T_inr = T_sur; %[K] Assume the temperature inside of the cooker is equal to the
%temperature of the glass
time_min = input('Enter the cooking time length in minutes ');
time = time_min*60; %Convert time from minutes to seconds
A = .367; %[m^2]
cp = .716; %[KJ/KgK] Specific Heat of air
p = 1.3; %[kg/m^3] density of air
K = 1.4; %Absorption coefficent of glass
n = 1.52; %Index of refraction of the glass
L = 0.003175; %Length of glass
Solar_Constant = 1375; %[W/m^2]
%Angles the beam makes with the normal to the interface in the air:

39
theta1 = 0;
theta2 = 0;
r = ((n-1)/(n+1))^2; %Energy Reflected
a = (1-r)*(1-exp((-n*K*L)/sqrt((n^2) -(sin(theta1)^2)))); %Fraction of energy
%absorbed by the glass
I =(1-r)*(exp((-n*K*L)/sqrt(n^2 -sin(theta1)^2))); %Beam intensity that
%penatrates through the glass
Q = (Solar_Constant*I*A)*time*10^-3; %[kJ] heat energy transmitted
Temp_change = Q*cp*p; %[K/m^3] Inside temperature change
radius = 0.603; %[m] radius of the cooker
height = 0.6096; %[m] hieght of the cooker
delta_T = Temp_change*(pi*radius*height)/2; %[K] Temperature increase
%inside the cooker after 30 minutes
T = T_inr + delta_T; %[K] total inside cooking temperature
T_cel = T-273; %Convert temp from Kelvin to Celsius
X = ['Resulting temperature inside cooker in Celsius ',num2str(T_cel)];
display(X)
Error using input
Cannot call INPUT from EVALC.

Error in Heat_Transfer_Calc (line 6)

40
T_sur= input('Enter the value of the outside air temperature in Kelvins ');
Frensel Lens Calculations
clear vars

SW = input('Enter a value for Solar Flux ');

A_lens = 0.113548; %[m^2] Size of lens
A_focal = 0.0064516; % [m^2] Size of area light is focused to
f = A_lens/A_focal; %Light is focused from the surface area of the lens to
%the focal point
sigma = 5.67*10^-8; %[W/m^2K^4] Stefan Boltzman Constant
e = 0.09; %Cookers is lined with aluminum
j = SW*A_lens; %Emmisive Power
T = ((j*f)/sigma)^(1/4); %[K] Temperature the lens generates
Temperature = T*(1-e)-273; %[deg C] Accounts for the heat absorbed by the
%aluminum and converts to degrees Celsius
X = [num2str(Temperature),' Degrees Celsius']
display(X)
Published with MATLAB R2013b

Appendix H

41
Bill of Materials

Table H.1 Bill of Materials

42

Appendix I
Part Drawings

Figure I.1. Base

Figure I.2 Door Frame

43

Figure I.3 Door Handle

Figure I.4 Fresnel Lens

44

Figure I.5 Glass

Figure I.6. Hinge

45

Figure I.7 Hinge Pin

Figure I.8 Leg

46

Figure I.9 Pot

Figure I.10 Screw

47

Figure I.11 Swing Rack