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Transcript
Dec 03-03 Paint Heat Lamp Power and Control System December 9, 2003 Team Members: Sui Kwan Ng Vincent Ong Raymond Sidharta Joseph L. Vetter Client: H & S Autoshot Faculty Advisors: Dr. John W. Lamont Prof. Ralph E. Patterson Prof. Glenn G. Hillesland Presentation Outline Project Overview Acknowledgement Problem Statement Operating Environment Intended Uses/Users Assumptions and Limitations Expected End Product Resources and Schedules Closing Materials Project Activities Accomplishments Approaches Project Definition Research Activities Design Activities Implementation Activities Resource Requirements Schedules Project Evaluation Commercialization Recommendations for Additional Work Lessons Learned Risk and Risk Management Closing Summary Definitions Curing – To preserve or finish a surface by a chemical or physical process Ultraviolet (UV) – Light radiation with a wavelength shorter than visible light but longer than X rays UV LED (Light Emitting Diode) – A type of diode that emits ultraviolet light UV Lasers – A device that emits highly amplified and coherent radiation light Acknowledgement Craig Poolman, H&S Autoshot General Manager Dr. Vikram Dalal, Iowa State University Professor Randy Freeman, Howard Industries engineer Advisors: Hillesland, Lamont, and Patterson Problem Statement Goal: An automotive paint UV Curing system with the following properties: – – – – UV light within 320 nm – 360 nm range Expand curing area (from 16” circle to 3’ by 4’) Portable Increased number of UV lamps used Operating Environment - Operated in a sheltered environment Run by an auto body shop Temperature range of 60 -120 Fahrenheit No personal contact with the device during operation Intended Users and Uses Intended users – Auto body repair shop personnel Intended uses – To cure an automobile’s body paint Assumptions The system operator is familiar with the device The device cures 3 X 4 feet or smaller area of the automobile’s body Moveable device to cure desired area 2 minutes curing process Limitations The device works with the 60 Hz/120 volt standard electrical systems Increased current load requires a new circuit to be installed 320 nm – 360 nm range of UV light is a must Wavelength higher than 380 nm cannot be used due to health reason Portability must be maintained Expected End Product A report recommending how to: – Increase curing area – Run multiple UV lamps clustered for increased curing area – Maintain portability – Remain economical for customers to purchase – Implement alternatives as they become feasible Present Accomplishments Defined the Problem Researched Alternatives Testing – UV Filter Glass – Transformer Voltage and Current – UV Intensity Ordered Parts Documented Research and Testing Approaches Considered UV LEDs UV Lasers Alternative Reflectors, Lenses, and Filter Glass Additional Lamps Using Existing Transformer Electronic Ballasts Motorized Curing System Expansion of Existing UV System – Grouping of multiple UV lamps and ballasts Approach Used Expansion on Existing System – Cluster 8 lamps to obtain desired curing area – Continue use of existing components – New control box to operate individual lamps – Upgraded power delivery circuit Project Definition Increase Area Cured – From 16” diameter circle to approx 3’ x 4’ rectangular Increase Number of Lamps Keep Unit Size Reasonable Use on Customer’s Existing Power Supply – Modification necessary for increased current load Research Activities UV LED – Pros Cheap, efficient, and small for typical LEDs Long life with no maintenance necessary – Cons No inexpensive LED exists for desired wavelength Intensity too low for curing purposes – Result: Not feasible at this time Research Activities (cont.) UV Laser – Pros Very specific wavelength output High Intensity – Cons Small curing area Large, expensive equipment needed Safety training necessary for operation – Result: Price exceeds budget constraints Research Activities (cont.) UV Lenses – Pros Additional method to increase area cured Long life with no maintenance necessary – Cons Lenses suitable for UV too expensive – Result: Not feasible at this time Research Activities (cont.) Filter Glass – Filters out non-UV wavelengths – Tested at Applied Sciences Complex by Dr. Vikram Dalal – Approximately 15% of energy lost – Result: Current filter glass will continue to be used Research Activities (cont.) Transfer Rate of UV Filter Glass Research Activities (cont.) Reflector – Cone-shaped currently used – Circular output, desirable for curing – Result: Continue using current reflector UV Lamp – Medium Pressure MercuryArc (MPMA) lamp – 400 Watts – UV light and other light wavelengths – Result: Best light solution at this time Research Activities (cont.) Electronic Ballasts – Smaller and lighter vs. magnetic ballasts – Decrease in energy consumption – Wide range of control for output – Very expensive at this time for MPMA lamps – Result: Continue using magnetic ballast until price declines Research Activities (cont.) Transformer – Currently use Howard Industries autotransformer – 120 VAC input, 120 VAC output – Capacitor used for power factor correction/voltage stability – Ignitor used for starting lamp operation – Voltages and currents tested Both input and output – Result: Current transformer will continue to be used Research Activities (cont.) Motorized Curing System – Move 3 lamps over curing area (fewer lamps) – Stepper motor and control circuit needed – Longer time for desired curing area – Result: Client will decide on longer curing time vs. less components needed Technical Design 8 Lamp Ballast and Control Box Technical Design (cont.) 8 Lamp Curing Arrangement Implementation Activities Order Additional Lamps – From H&S Autoshot – Exact same as lamp currently used Test Alternative Lenses Design Switching for New Lamps – Mechanical Switches Selected Final Report – Document all research and team’s solutions Testing Activities Test 1: UV Filter Glass – Dr. Dalal, Ames Laboratory Test 2: UV Intensity – Spectrometer courtesy ISU Physics Dept. Test 3: Alternative Lens – Fresnel Lens – Convex Lens Test 4: Transformer Voltages and Currents – Input and Output Intensity Test Results Intensity vs. Displacement Intensity (W/m^2) 10 8 6 10in From Surface 4 16in From Surface 2 0 -9 -6 -3 0 3 6 Displacement from center 9 Current and Voltage Testing Results Personnel Efforts 60 hours 50 40 30 20 10 0 ng ter sign arch on i i t s t e ta es Po t De s n T t e e R ct ec ec j t e j um j c o o c r o e r r o P P oj P tD Pr c oje r P Ng Sui Kwan Ong Vincent Sidharta Raymond Vetter Joseph Financial Requirements Materials (Stand, Case, etc.) $275.00 Lamps $69.76 Transformer $30.50 Miscellaneous parts $25.00 Project poster $47.69 Total $448.22 Other Resources $65.00 $9.92 Equipment Project poster $0.00 $47.69 $374 Project Implementation Project Testing Equipment Project Documentation Schedules Schedule Gantt Chart Project Evaluation Research of All Possible Alternatives Testing of Existing Components New Parts Ordering Testing of New System Final Design Documentation 100% 100% 55% 40% 100% Commercialization Cost of Existing Curing Unit (Market Price) Additional Lamp and Parts $374.00 $764.57 Total for New System $1138.57 Estimated Resale Price $1600.00 Additional Work Adapt alternative devices (LEDs or lasers) as they become more economically feasible Implement alternative lenses if there is a price decrease Implement alternative power supplies – Two-winding transformers – Electronic ballasts Lessons Learned Time Management Communication Organization Major Specific Information – Power Consumption – Basic Circuit Devices (Lamps, Transformers, Electronic Ballasts, Capacitors, LEDs, etc.) Non-major Specific Information – – – – Stepper motors and controllers UV Lenses UV Lasers UV Light Safety Risk and Risk Management Loss of Team Member(s) – Central Location for all Documents Late Arrival of Parts and Equipment – Order in Advance – Select Alternatives Equipment Damage – Keep Back Up Equipment on Hand Closing Summary New UV Curing System will: – Increase Curing Area vs. Current System – Be Portable and Easily Shipped – Economical for Auto Body Shops to Purchase and Use Questions?