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Paint Heat Lamp Power and Control System Senior Design (Dec 03-03) Project Final Design Report Client Faculty advisors Team Members H&S Autoshot, Inc. Attn: Dave Lenz, John W. Lamont Ralph E. Patterson Sui Kwan Ng Vincent Ong Operations Manager Glenn G. Hillesland Raymond Sidharta Joseph L Vetter December 17, 2003 Table of Contents I. Table of Contents…………………………………………………..….......i II. List of Figures…………………………………………………………….ii III. List of Tables……………………………………………………………..iii IV. List of Definitions..……………………….……………………..……..…iv 1 Introductory Materials 1.1 Executive Summary………………………………………...…..1 1.2 Acknowledgement……………………………………………...2 2 3 4 1.3 Problem Statement…………………………………………......2 1.4 Operating Environment…………………………………….….3 1.5 Intended User(s) and Intended Use(s)………………………...3 1.6 Assumptions and Limitations……………………………….…4 1.7 Expected End Product and Other Deliverables……………....5 Project Approach Results 2.3 Approaches Considered and One Used…………….…………6 2.4 Detailed Design………………………………………………..27 Resources and Schedules 3.1 Resource and Schedule……………………………….………33 Closure Materials 4.1 Project Evaluation…………………………………………….39 4.2 Commercialization……………………………………………40 4.3 Recommendations for Additional Work……………….……41 4.4 Lessons Learned………………………………………………44 4.5 Risk and Risk Management……………………………….…45 4.6 Project Team Information…………………………………....46 4.7 Closing Summary……………………………………………..47 4.8 References………………………………………………..……48 4.9 Appendices……………………………………………….……49 i List of Figures 1 2 3 4 5 6 7 UV Lamp……………………………………………………………………..…...1 UV Curing vs Thermal Drying……………………………………………..……2 UV Lamp II…………………………………………………………………..…..4 UV LED………………………………………………………………………..….5 Reflector…………………………………………………………………………..8 Wavelength of the MPMA Lamp………………………………………………..9 Autotransformer Circuit………………………………….................................10 8 9 10 11 12 13 14 15 16 First Proposal of Running Two Lamps Off of a Single Transformer…..……12 Two Winding Transformer……………………………………………………..13 Electronic Ballast……………………………………………………………….14 Effective Area Cured of 16 in. Diameter………………………………………15 Arrangement of Convex Lenses……………………………………………….16 Effective Area with Convex Lenses……………………………………………16 UV LED system…………………………………………………………………17 Components Associated with a Typical Laser System………………………..19 Simple Stepper Motor Controller……………………………………………...21 17 Testing Result of the Filter Glass………………………………………………24 18 Input & Output Current vs Time……………………………………………..25 19 Output Voltage vs Time………………………………………………………...26 20 Intensity vs Displacement……………………………………………………...26 21 A Circuit Diagram for the Current System……………………………………28 22 Area Cured by 8 Lamps System……………………………………………….30 23 Sample Circuit Diagram for Running 8 Lamps………………………………31 24a Gantt Chart of Major Tasks and Subtasks…………………………………...37 24b Gantt Chart of Project Deliverables…………………………………………..38 25 Example of a Curing System Using 3 Moving UV Curing Lamps…………..43 ii List of Tables 1-1 UV Laser Estimated Costs……………………...………………………………19 1-2 Components Used in Current System………...………………………………..29 1-3a Original Estimated Personnel Efforts Requirements……………………......33 1-3b Revised Personnel Efforts Requirements………………………………….....33 1-3c Final (actual) Personnel Efforts Requirements………………………………33 1-4a Original Estimated Other Required Resources……………………………...34 1-4b Revised Other Required Resources…………………………………………..34 1-4c Final (actual) Other Required Resources…………………………….............34 1-5a Original Estimated Project Costs…………………………………………......35 1-5b Revised Project Costs………………………………………………………….36 1-5c Final (actual) Project Costs……………………………………………………36 1-6 Components Used in Proposed 8 Lamp System……………………………….40 1-7 Cost for the new 8 Lamps System……………………………………………..41 iii List of definitions Autotransformer - An electrical transformer in which the primary and secondary coils have some or all windings in common. Capacitor - An electric circuit element used to store charge temporarily, consisting in general of two metallic plates separated and insulated from each other by a dielectric. Curing system – A system to prepare, preserve, or finish (a substance) by a chemical or physical process. Diode - An electronic device that restricts current flow chiefly to one direction. Electronic ballast – High efficiency ballast that uses electronic circuitry to provide proper starting and operating electrical conditions for discharge lamp, or multiple lamps. Fresnel lens - A lens that produces a smooth, soft-edged, clearly defined beam of light. It is composed of a number of small lenses arranged to make a lightweight lens of large diameter and short focal length. Fringe - Any of the light or dark bands produced by the diffraction or interference of light. Ignitor – An electronic device that provides a high voltage spike (at least 2500 Volts) to initiate an arc in the lamp. Laser - Any of several devices that emit highly amplified and coherent radiation of one or more discrete frequencies. One of the most common lasers makes use of atoms in a meta stable energy state that, as they decay to a lower energy level, stimulate others to decay, resulting in a cascade of emitted radiation. LED (light emitting diode) - A type of diode that emits light when current passes through it. Depending on the material used the color can be visible or infrared. LEDs have many uses, visible LEDs are used as indicator lights on all sorts of electronic devices and in moving-message panels, while infrared LEDs are the heart of remote iv control devices. Light spectrum - The several colored and other rays of which light is composed, separated by the refraction of a prism or other means, and observed or studied either as spread out on a screen, by direct vision, by photography, or otherwise. Magnetron - A microwave tube in which electrons generated from a heated cathode are affected by magnetic and electric fields in such a way as to produce microwave radiation used in radar and in microwave ovens. Medium pressure mercury arc (MPMA) - Radiation source containing mercury vapor at pressures ranging from 100 to several hundred kPa. Emits mostly from 310 to 1000 nm with the most intense lines at 300, 303, 313, 334, 366, 405, 436, 546, and 578 nm. Melanoma - A dark-pigmented, usually malignant tumor arising from a melanocyte and occurring most commonly in the skin. Metal halide - A type of high intensity discharge (HID) lamp in which the major portion of the light is produced by radiation of metal halide and mercury vapor in the arc tube. Micro-controller – A micro processor on a single integrated circuit intended to operate as an embedded system. Typically includes a small amount of RAM, PROM, timers, and I/O ports. Microwave - A high-frequency electromagnetic wave, one millimeter to one meter in wavelength, intermediate between infrared and short-wave radio wavelengths. Transformer - A device used to transfer electric energy from one circuit to another using magnetic or air coupling, especially a pair of multiply wound, inductively coupled wire coils that affect such a transfer with a change in voltage, current, phase, or other electric characteristic. Ultraviolet - The range of invisible radiation wavelengths from about 4 nanometers, on the border of the x-ray region, to about 380 nanometers, just beyond the violet in the visible spectrum. v Executive Summary Using ultraviolet (UV) light to cure paint is a new process in the field of auto body repair. Current systems used in small to medium-sized auto body repair facilities are limited in curing area due to the cost of components. H&S Autoshot, Inc., located in Centerville, Iowa, currently has a systems using UV technology with a single lamp that can only cure a small area roughly 16 inches in diameter. The goal of this project is to expand upon this system to cover a much larger area. The proposed final area is to be 3 to 4 feet on each side. This report documents the team’s proposed solution to safely add more UV lamps (Figure 1) to the system to increase curing area. Testing results and all research done on the existing system is included in this document. Other technologies such as UV LEDs, UV lasers, filtering glasses, electronic ballasts, a motorized curing system, and UV lenses were also explored and documented. These technologies were discarded due to failing to meet economic and curing requirements at this time. However, in the future, as the aforementioned alternatives become more practicable, they can be incorporated to improve the performance of the system and to save on cost and weight. The design of the team’s proposed system is located in this report, along with necessary resources the team used to compile this solution. Finally, a list of contacts for future reference can be located in the appendix of this report. Figure 1-UV Lamp 1 Acknowledgement The team would like to thank the following people in addition to the faculty advisors for their extensive help during this project: 1. Craig Poolman, General Manager of H&S Autoshot, for all the information and equipment he has donated for the project. 2. Dr. Vikram Dalal, ISU Professor, for information on UV LEDs and UV lasers. 3. Randy Freeman, Engineer for Howard Industries, for information on transformers and associated equipment Problem statement General Problem Statement H&S Autoshot, Inc. faces the problem of expanding the capabilities of an auto repair paint drying system that uses newly developed ultraviolet (UV) light activated paint. UV light cures paint at a much faster rate than conventional means with fewer emissions. (Figure 2) The current system is comprised of a special power transformer and capacitor, an ignitor, and a special UV-producing light. This device is capable of curing paint over a small area of about 16 inch diameter only. Each lamp requires 120V and costs $73.01 (including the reflector). The transformer has a cost of $30.50, and is bulky in size and weight. The team has concentrated its efforts into finding ways to run multiple lamps off of fewer transformers. This was done to increase curing size without increase the bulk and cost significantly. Figure 2-UV Curing vs Thermal Drying Another problem faced was that the surface to be dried was not a flat surface. UV light does not curve around uneven surfaces thus areas in the shadows will not be cured. The device the team has designed is able to flexibly adjust to cover all areas of the surface. 2 Furthermore, considerations were taken about the size of the device. Most of H&S Autoshot, Inc.’s customers are in the East or West Coast and due to the distance of the customers; care was taken not to make the device too large as to incur unnecessary freight charges. Thus, a balance was struck between reducing the number of transformers for a larger area and the size of the overall device. Solution Approach The DEC0303 group’s objective was to look for a suitable solution for replacing or upgrading the current system. The solution increased the size of area covered to 3’ X 4’ feet. The group tried to minimize costs by reducing the number of transformers or by reducing the voltage required by the lamp. That is why alternative solutions other than UV lighting were explored, such as LED lighting, UV lasers, or instruments to redirect UV light. These alternatives were discarded after much research was done on them. After deciding the appropriate solution, a system was designed using a combination of 8 of the existing lamps. These lamps have an intensity that is sufficient to cure the paint from a one-foot distance. The head of the lamps will be able to rotate using a rotator and the lamp will be controlled via manual switching means. After coming up with the basic design of the device and control system, simulations of schematics drawn from it shall be run. Operating Environment The target operators for this product are employees of auto body repair organizations. Its target-operating environment would be a sheltered garage or workspace. It is therefore assumed that the end product will not be exposed to rain or other outside elements. The average expected temperature for this product is to be between 60 to 120 degrees Fahrenheit. Another environmental problem is that the product is to be exposed to extreme noise, dusty conditions, and possibly hazardous and explosive gases. Intended User(s) and Use(s) The intended user of this product is an employee of a small to medium sized auto body repair shop. Despite being familiar with many paint technologies, the end user might not have knowledge of the internal workings of the UV lamp and its control components. Therefore, a simple and easy to use interface must be designed. 3 The function of the UV lamp (Figure 3) is to cure paint and will serve no other purpose in the auto body repair facility. The only paints to be used with this product are those designed for curing by UV light. Figure 3-UV Lamp II Assumption and Limitations The assumptions of this project include: The auto body repair employees are familiar with the operation of the device. The device cures 3 X 4 feet or smaller area of the automobile’s body. The device is moveable in order to cure different sections of the whole automobile’s body. The curing process lasts no longer than 2 minutes for the area to be cured. The overlapping fringes produced can also cure. The limitations of this project include: The device works with the 60 Hz/120 V/30 Amp standard electrical systems, since it is implemented in the US and this is the type of electrical connection most auto body repair shops have. Additional voltage or current requirements need to be taken care of by the auto body repair shop owner. The wavelength must be between 320 nanometers to 360 nanometers. Wavelengths higher than 380 nanometers are not used since they are in the skin cancer (melanoma) causing range. There is no excess of components that hinder the portability of the curing system. The cost of the system does not exceed the budget of most small to medium sized auto body repair shops. The device shall remain small enough in size/weight in order to be easily moved and transported. 4 Expected End Product and Other Deliverables The end project is going to be a final report that will inform the client: Why a transformer is needed for each lamp. How to increase the covered area to at least 3X4 feet. Advantages and disadvantages of alternative technologies. Other items in the final report that will be delivered to the client include: Research on the existing system Research on LED lamps (Figure 4) Research on UV lasers Research on electronic ballast Research on lenses New transformer design Arrangement of lamps in order to cover 3X4 feet Evaluation of research showing the pros and cons for all possible solutions Record of major correspondence to the team from industrial resources Figure 4-UV LED 5 Approach Used Design Objectives The Dec03-03 team has researched many different UV technologies (LEDs, Lasers, UV lamps, transformers) in order to arrive at an appropriate way to expand upon the existing system. The factors used to aid in selecting the right products to accomplish this goal are listed in the following sections. Functional Requirements for the End Product UV light will cure an area of 3x4 feet in a matter of minutes The current system employed cures paint in less than 2 minutes. Research will explore whether or not varying the intensity of the UV light can speed up the process. The area of the surface to be cured will be expanded from the current 16” diameter circle to 3’ X 4’, which is approximately the size of a fender. The lamp(s) will be moveable or the light emitted will be reflected appropriately Another problem faced is that the surface to be dried is not a flat surface. UV light does not curve around uneven surfaces thus areas in the shadows will not be cured. The device to be designed must be able to flexibly adjust to cover all areas of the surface. This shall be done by individually moving each lamp in order to properly cure all areas. In other words, the lamp heads are not solidly tied together. Design Constraints Operates on a maximum of 120 volts and a customized circuit of 30A This voltage is the conventional voltage used in the US. Auto body shops will need a custom built circuit of 30A built to run the system. Indoor use only The components used cannot be exposed to outside weather elements or immediate damage will result. Must be able to be shipped inexpensively Most of H&S Autoshot, Inc.’s customers are in the East or West Coast and due to the distance of the customers; care must be taken not to make the device too large as to incur unnecessary freight charges. 6 Technical Approach Considerations and Results The group split into sub-groups to research on different parts of the project, which included: Reflectors UV lamps Transformers Electronic Ballasts UV Lenses UV Filter Glass UV LEDs UV Lasers Motorized Curing System The following are the description for each part of the research and the team’s conclusion drawn from the research: Reflectors A UV reflector is one of the major components in a UV curing system. It is made of aluminum and shaped to fit certain specifications. The main purposes of using a UV reflector are: to focus UV rays, reflect UV radiation, and maximize UV exposure on the substrate. By doing so, the curing area will be improved as well. There are a number of types of reflectors, depending on the focusing method: Parabolic - UV light is reflected in nearly parallel beams. Elliptic - UV beams are nearly focused in one line in front of the bulb. Variable geometry - beams are created with the shape of a pincer. Cone-shaped - UV light is reflected in nearly a circular-shaped area. Semi-circular/half-cylindrical - UV light is reflected in a rectangular-shaped area. The elliptic reflector form delivers maximum intensity to the paint and substrate, while the parabolic reflector assures maximal energy transport. An example of a reflector commonly used in a UV curing system is shown below (Figure 5). 7 Figure 5- Reflector H&S Autoshot uses the cone-shaped reflector in their UV curing system. The current system has a circular-shaped curing area of approximately 16 inches in diameter. According to our client, the current reflector is the best in industry given the economical constraints, based on their German reflector vendor’s research. Therefore, the current reflector will be used. UV Lamps In UV curing system technologies, mercury pressure UV lamps are the most commonly used light sources nowadays. Different light sources alternatives such as UV LED and UV lasers also exist, but current technologies are not capable of providing the required intensity for proper curing. Ultraviolet reactive paints and coatings require a high intensity source of ultraviolet light to initiate a chemical reaction, which cures the paint or coating almost instantaneously. Ultraviolet light forms a small part of the electromagnetic spectrum, which ranges from radio waves at the long-wave end, to x-rays and gamma rays at the short-wave end. The ultraviolet wavelengths most suitable for curing paints and coatings lie between 200 and 400 nanometers. There are several types of lamps suitable for generating these wavelengths, such as mercury, gallium, or iron lamps. However, the most commonly used are high-pressure mercury-arc lamps, microwave-powered mercury lamps, and medium-pressure mercury-arc lamps. The high-pressure mercury-arc lamp is generally constructed as a capillary type tube and requires a water jacket to maintain correct running temperatures. These lamps are limited to short lengths only, and lamp life is usually less than 1000 hours. 8 In the microwave-powered mercury lamp, an arc is established by the generation of microwaves. This requires fairly large and expensive "magnetrons," which are placed at each end of the lamp. Again, these lamps can be produced in only short lengths. Considerably, the most widely used is the medium-pressure mercury-arc lamp (an MPMA lamp). This can be air or water-cooled, and can be manufactured in a wide range of lengths. Single lamps two meters (six feet) long are not uncommon, and the working life of MPMA lamps can be expected to be well over 1000 hours. The graph below shows the wavelength of the MPMA lamp (Figure 6). Figure 6- Wavelength of the MPMA Lamp H&S Autoshot requires a UV lamp with wavelength of 320 to 360 nanometers for their curing system. H&S Autoshot’s current curing system uses an MPMA lamp that is 400Watts at 120V. It seems that in accordance of the available current technologies, MPMA UV lamps are the best light sources to be used. Transformers Why is a transformer used in the circuit? The physical properties of the lamp dictate the need for a transformer. Due to the negative resistance property of the lamp, more and more current will flow into the lamp unless some sort of safeguard is provided. Transformers give this sort of protection by being a “choke” for excessive current flow. If there were no limit on current, immediate damage to the lamp itself would ensue. 9 What size of transformer is used in the current circuit? The circuit uses an autotransformer with multiple windings. As used in the current system, the transformer is connected 120 volts AC on the primary side and changes that to 120 volts AC on the secondary side. The transformer is matched to the lamp, with both items having a rating of 400 watts. What type of transformer is used in the current circuit? The current UV curing system uses a Howard Industries autotransformer. An autotransformer is a transformer like any other transformer; however the primary winding is connected to the secondary winding. In a normal transformer the primary and secondary windings are not physically connected together. In the case of the current circuit, the two windings are connected together by utilizing a capacitor in series with the connection. Figure 7 shows an example of an autotransformer circuit very similar to the one H&S uses in its current system. Figure 7 – Autotransformer Circuit Why is a capacitor used in the circuit? A capacitor is needed for power factor correction. Since a transformer is mostly an inductive device, its power factor operation is usually in the 50% range. A capacitor brings this power factor up to or over 90%. This type of connection with an autotransformer and capacitor is called a constant wattage autotransformer (CWA). A capacitor also protects against any slight changes in input voltage. For a 10% change in input voltage there is a 5% change in output for the lamp. For instance, if the voltage were to momentarily drop to 108 volts, the lamp used in the current system would put 10 out 380 watts. Capacitors help to avoid this slight drop and reduction of output power. In some extreme cases the voltage may drop enough to extinguish the arc in the lamp. This means that the lamp must first cool down before the arc can be restarted, which takes a considerable amount of time. Such an extreme is avoided with a capacitor. How does the lamp start operation? The lamp used in the current system is not like that of a conventional lamp. In a regular incandescent lamp, electricity is passed through a thin filament to create both heat and light. The lamp used in the curing system has no filament. Instead, light is created by gas being excited by an arc created between two electrodes supplied with electricity. When the UV lamp is cool, a high amount of voltage (3000 volts) is needed in order to start this arc. This is accomplished by using a device after the transformer called an ignitor. An ignitor provides this high amount of initial voltage, which is many times that of what is normally outputted by the transformer. This ignitor requires that an additional output be added to the windings of the transformer for proper operation. Once the arc is established the ignitor ceases operation and becomes an open path in the circuit, thus allowing normal output voltage from the transformer to flow into the lamp. An ignitor is shown in the circuit above in Figure 7. More specific information can be found on ignitors in Randy Freeman’s report located in the Appendix. Is it possible to run two or more lamps off of one transformer? For the type of transformer used in the current curing system, it is not possible to run multiple lamps off a single transformer. Randy Freeman of Howard Industries, which is the company that manufactures the transformer used in the current curing system, informed the team of the problems that may arise from running multiple lamps off of a single transformer. Due to the characteristics of the lamp and the ignitor used to start lamp operation, it is highly likely that only one lamp would ever start, thus taking all of the power and leaving nothing for the second lamp to start with. Since the transformers are sized for the load, using an 800 watt transformer to power two 400 watt bulbs will result in one 400 watt bulb receiving all 800 watts of power. The result of this is disastrous; the bulb will literally blow itself apart and cause damage to anything located in the area of the bulb. More information about running multiple lamps on a transformer can be located in Randy Freeman’s report in the appendix. Is there any way at all to run multiple lamps off of a single transformer? There is a special type of transformer that may work to power multiple lamps. This type of transformer is called a multiple winding transformer. In a multiple winding 11 transformer, there is one input but a number of outputs. These outputs are independent of each other, so the status of one output does not affect the others. Therefore, for a two-winding transformer, it doesn’t matter when each lamp starts operation – the power consumption of one lamp has no bearing on the other lamp. With two windings, a transformer rated for 800 watts input can produce two 400 watt outputs. Figure 8 below shows the team’s first proposal of running two lamps off of a single transformer. The transformer in the diagram is an Advance Transformer two winding transformer that can run two Metal Halide lamps. This transformer will not work with MPMA lamps due to a lack of provisions being provided to run the ignitor. Metal Halide lamps do not need an ignitor, thus the reason why this transformer will work with two non-MPMA lamps such as Metal Halide lamps (or any two lamps that do not require an ignitor). The specification sheet for this Advance Transformer can be located in the Appendix. 1 20 V ac Hour Meter Fan 1 Transformer (800W m in) UV lamp 1 Capacitor 1 Lamp Head Unit 1 Capacitor 2 Ignitor 2 Ignitor 1 COM Fan 2 UV lamp 2 Lamp Head Unit 2 Control Box Figure 8 - First Proposal of Running Two Lamps Off Of a Single Transformer An example of a two winding transformer that will work with the lamps and ignitors used in the current system is shown in the figure 9 below. As can be seen in the figure below, there is a provision on the winding (X3) to allow for proper operation of the ignitors. 12 Figure 9 - Two Winding Transformer While the transformer shown in the circuit above does not seem complicated, several problems have arisen. After contacting a number of transformer manufacturers, it appears that no one commercially produces such a transformer. In addition, an 800 watt transformer such as this will cost three times as much as single winding transformer of the same rating. The weight is also much higher versus a comparable single winding transformer. Basically, it is cheaper and lighter to have two 400 watt transformers than a two winding transformer with two 400 watt outputs. Conclusion: The team has decided that there are no advantages at this time to use a different type of transformer. However, this may not necessarily be the case in the future if a suitable manufacturer of the transformer shown in the above figure is found. Please read the team’s recommendation for future activities on transformers, located later in this report. Electronic Ballasts Another alternative to be considered for the curing system is an electronic ballast. An electronic ballast has the advantages of being smaller, lighter, and more energy efficient than conventional magnetic ballast, which is used in the current system. Electronic ballasts also offer the advantage of a slightly longer lamp life. After doing research and contacting a number of electronic ballast manufacturers, it was discovered that no one at this time commercially produces a suitable electronic ballast to operate the type of lamp used in the curing system. Even if a suitable electronic ballast were to be found, at this time the cost of an electronic ballast to run the current lamp is approximately 6 to 12 times that of conventional magnetic ballast. Given that the current cost of the ballast is around $30, the savings in energy consumption, size, and weight do not make up for 13 this much of an increase in cost. The figure below shows an electronic ballast for a different type of lamp than what is used in the current system. Figure 10 - Electronic Ballast A list of electronic ballast manufacturers can be located in the appendix attached to this report. Lenses The usage of different lenses in order to increase the area cured by the UV lamp was explored. The basic theory is to strive to obtain a balance between the area cured and the intensity of the UV light. When diverging the UV rays to increase the area, the intensity of the UV light will naturally decrease. It will decrease until it reaches the minimum intensity requirements for curing. Fresnel Lenses The team explored Fresnel lenses and found it is suitable to diverge normal light rays so that it focuses on a smooth surface with a wider area. The Fresnel lens evens out the intensity of light from the center to all areas on the lens. Fresnel lenses work well on ordinary rays but not on rays in the UV region. 14 Convex lenses Convex lenses were also explored in order to increase the intensity of the fringes. If successfully done, the extra energy at the fringes could be converged and intensified using the lens. If successfully implemented, an area of 2 inches diameter more will be gained thus increasing the area cured to 18 inches. Further research was done and the one possible supplier of UV supported lenses is http://www.edmundoptics.com/IOD/DisplayProduct.cfm?productid=2027 . Lenses available in market are convex lenses only. These lenses do NOT show the results above as they are made especially for UV rays. A possible design of convex lenses was drawn should the prices of UV supported lenses drop in the future. Figure 11 shows the effective area cured of 16 in. diameter. If a multitude of convex lenses were focused at the fringes of the effective area to intensity the outside fringes (Figure 12), the diameter is increased by an effective area of 2 in. The results are outlined in Figure 13. Figure 11 - Effective Area Cured of 16 in. Diameter 15 Figure 12 – Arrangement of Convex Lenses Figure 13 - Effective Area Cured with Convex Lenses The price of such special lenses ranges from $70.00 to $213.00 depending on the diameter of the lenses and its focal point. 16 Conclusion: To achieve an increase of 2 inches radius, at least $500 needs to be spent on special UV lenses. It is recommended implementing these lenses should the prices of the lens drop in the future. Filter glass The team has researched on filter glass to determine if it is in any way hindering the ability to expand the system. The filter glass was sent to professor Dalal Vikram for testing and the results of the testing can be found in the testing part. Based on the testing results, the filter glass is most efficient given its economical constraints. The current filter glass will be used to expand the system. UV LEDs Additional UV lamps such as those used in the current system will require an increase in power consumption, not to mention an increase in cost. UV LEDs have an advantage of having much lower power consumption while outputting a very specific UV wavelength. However, it will take a large number of UV LEDs to cover the desired curing area. Also, the energy output of UV LEDs may not be of high enough intensity to properly cure the surface area. Figure 14 below shows a UV LED system used for curing a circuit board. Figure 14 - UV LED System 17 There is already a UV LED curing system on the market; however, the curing area is just small as a CD size, and the wavelength cannot fulfill the requirements for H&S Autoshot as well. The lowest wavelength LED lens used in curing system that can be found on the market is 390nm and costs about $375, but it cannot fulfill the energy requirement of 2.1J/cm2. It is possible to obtain LEDs of a lower wavelength (<390nm); however, it is very expensive and would cost around 2 million dollars to develop according to the group’s meeting with Dr. Dalal. Given current advancements in technology, one would expect big companies, like Sony, Panasonic, etc., would have a lower wavelength LED out in five years. 18 UV Lasers UV lasers are also another consideration in expanding the current system. Lasers are a relatively new technology and the cost to implement such a system is rather prohibitive to most users at this time. However, like most modern devices, the costs are decreasing annually while the technology is advancing. A table showing the estimated costs for several different models of UV lasers is shown below (Table 2). This table is sourced from a company specializing in lasers called Intelite, Inc (www.intelite.com). Table 1-1 UV Laser Estimated Costs U/price (nm) Pulse Energy (at 1KHz) Pulse Duration (at 1KHz) Max. Pulse Repetition Rate Average Output Power UVSQAOM355-5 $10,950.00 355 5 µJ < 10 nsec 10 KHz > 10mW UVSQAOM355-10 $11,350.00 355 10 µJ < 10 nsec 10 KHz > 15mW UVSQAOM355-20 $14,950.00 355 20 µJ < 10 nsec 10 KHz > 30mW UVSQAOM266-1 $11,950.00 266 532 1064 1 µJ < 10 nsec 10 KHz > 1mW Item No. Figure 15 below shows the components associated with a typical laser system. Figure 15 - Components Associated with a Typical Laser System To begin with, a laser, or light amplification by stimulated emission of radiation, is a device that controls the way energized atoms release photons. Atoms can be caused to be in different states of excitation. When an atom is supplied with sufficient energy, it is excited and henceforth, its electrons move to a higher state of energy. The atom eventually returns to its ground state energy level thus emitting photons, or light particles. The photon that any atom releases has a certain wavelength that is dependent on the energy difference between the excited state and the ground state. 19 In a laser, the lasing medium is provided energy via intense electrical discharges to get the atoms in an excited state. For UV lasers, there are basically 3 types of common mediums: argon fluoride (193nm), krypton fluoride (248nm) and nitrogen (337nm). Other typical types of lasers are: argon-blue (488nm), argon – green (514nm), helium – neon, green (543 nm), helium-neon, red (633nm), rhodamine 6G rye (570 – 650 nm), ruby – red (694 nm), nd: YAG (NIR) (1064nm) and carbon dioxide (FIR) (10600 nm). Hard lasers such as carbon dioxide are used to cut hard materials and grating. Research was limited to lower wavelength frequencies of laser within the UV range, as they are more practical and less prone to cancer causing complications. The price for a full UV laser system pre-assembled is over $10,000 that fits the requirements of a wavelength of 350 nm, energy of 5uJ, and area cured of 52 X 90 mm. The system is a nitrogen based laser that has an output of 337.1nm, an area cured of 3 X 6 mm, weighs 85 lbs, and has physical dimensions are 30 X 20.2 X 9.2 inches requiring 110V. Laser systems are generally used for miniature manufacturing and miniature processes. The strong point of laser technology is its ability to produce a beam (electromagnetic wave) with an extremely specific wavelength. The light released is monochromatic and no energy is wasted on production of waves of neighboring wavelengths. Scattering of light is non-existent. However, this trait is important only for micro processes that require this feature. Lasers wide wavelength producing ranges make them a good choice for any type of process be it microlithography, micromachining, UV laser annealing, and writing fiber Bragg gratings. However, beyond the microscopic level, UV lasers are not a practical alternative to the current UV light system because of its low area cured and its high costs. Other than that, laser diodes cannot be incorporated into the current system because UV lasers require a long nitrogen-filled tube, a laser compartment and a separate optics compartment. It will cost approximately the price listed above. Motorized Curing System In order to further reduce costs, the team has considered powering 3 lamps instead of 8 lamps and using a stepper motor to shift the 3 lamps along a track. Thus the cost of the system is reduced at a tradeoff for more time to cure the area. 20 Stepper motors behave differently from normal DC motors in their torque-speed relationship. They produce the highest torques in low speed. This characteristic is ideal for the curing system as the system only needs to move at a slow speed. Stepper motors also have another characteristic, that is, a holding torque, which allows the stepper motor to hold its position when not turning. Thus, the need for a braking system is eliminated. The motor will have a timer to indicate when to move, that is, approximately 2 minutes. This approach will be fully automatic since one only needs to push the on button to carry out the process and the system will shut itself off when a certain time has been reached. With this system implemented, the curing time, labor cost will be made efficient. Two ways of implementing this system are by using a commercially viable programmable controller or building a simple controller like the one shown in Figure 16 below. The first method enables C/C++ code to be inputted in order to control the system. They typical cost for a commercial controller available in the market is $390. The second method is building a simple control system that controls the stepper motor via input voltage pulses. Figure 16 - Simple Stepper Motor Controller The cost of the controller circuit shown above is less than $10. As for the stepper motor, the price varies depending on the torques that is produced. A typical stepper motor costs $60 and is commercially available in the market. 21 Approaches Conclusion After completing the research as shown above, the group has arrived at the following conclusions for each of the technologies: Reflectors The current reflector is the best possible reflector to use with the MPMA lamp used in the curing system. The group will continue to use this reflector. UV Lamp The team recommends sticking to the current mercury-arc lamps. Transformer If a manufacturer were to come out with an 800 watt - two winding transformer with two 400 watt outputs that is cheaper than two individual 400 watt transformers, then it is recommended that this type of transformer be purchased. This is due to fact that a single transformer can be installed in one control box for two lamps, versus two control boxes for two lamps. For now, the group will recommend sticking with the same transformer and ballast kit that is used in the current system, a Howard Industries MO400-71C-611. Electronic Ballast Due to the lack of commercially available electronic ballasts on the market at this time, the group can not recommend a particular electronic ballast to be used in place of the Howard Industries magnetic ballast currently used. It is highly possible that an inexpensive commercial electronic ballast could be released in the near future (within 1 to 5 years) that will be able to properly operate the MPMA lamp(s) used in the curing system. If the price of this electronic ballast were 1.5 to 2 times as much as the current ballast, the group recommends purchasing this electronic ballast due to a savings in size, weight, and power consumption, along with a slight increase in lamp life, versus using the current magnetic ballast. UV Lenses UV lenses as an alternative is not recommended because an increase of 2 inches diameter needs at least $12000 needs to be spent on special UV lenses. 140 9mm lenses are needed and each costs $86.00. Filter glass Testing results show that there is only a 11% drop of energy at 360nm. This is 22 considered efficient due to the economical constraints involved. The team will continue to use the current filter glass. UV LEDs To sum it up, UV LEDs as a practical alternative is not recommended because there does not exist a UV LED that produces light in the required frequency. It costs millions of dollars to research and manufacture that new LED and the time it would be ready would be approximately 5 years. Furthermore, the price of a 390nm wavelength that might be cancer causing is $375. To implement a hundred UV LEDs to cure the paint costs $35,000 and is far more than the current system. UV Lasers As a practical alternative is not recommended because the light lasers produced is monochromatic and does not disperse. Its high cost of $350 per bulb only cures an area of 52 X 90mm. However, a complete system on the market with both the laser and optics components to control the laser has a grand cost of $10,000, which is far more than the current system. Motorized Curing System This approach is feasible and recommended to reduce the cost of expanding the curing system. However, it will take a longer time to cure the same amount of area as compared to the 8-lamps arrangement approach. Therefore, the decision for implementing this approach is left to the client to decide, based on the trade-off between time and cost. Testing Approach Considerations The team has performed several tests on the existing UV curing system in order to gain a better understanding of how each of the major components operate. It was with this knowledge the team was better able to fully understand any alternatives and additions to the system. Some of the major tests performed included: 1. Testing of the UV filter glass 2. Current and voltage measurements of the transformer 3. Light intensity testing with a photometer on existing system 4. Observations of the effects of adding lenses to the system For testing of the UV filter glass, the team has taken the filter glass from the current 23 system to find out its characteristics at the Applied Science Center. Professor Vikram Dalal was responsible of supervising the usage of the apparatus there. The figure below shows the results from this testing. Figure 17 – Testing Result of the Filter Glass As can be seen in the figure above, the team discovered that the filter glass reduces the output energy of the UV light by only 10% and will continue to use this glass. The group next tested the currents and voltages of the existing system components. 24 Using standard metering devices found in the lab, measurements were taken on the existing system when it is initially turned on and while the system was normally operating. These measurements included: 1. Voltage across the bulb 2. Current input to the transformer 3. Current output from the transformer The charts below show the results from the testing. The actual numbers found from testing can be located in the testing spreadsheet in the appendix. Input & Output Current vs. Time 7.0 6.0 4.0 Input Current 3.0 Output Current 2.0 1.0 54 0 45 0 36 0 31 0 28 0 25 0 22 0 19 0 16 0 13 0 70 10 0 50 35 5 20 0.0 0 Current (amps) 5.0 Time (seconds) Figure 18 – Input & output Current vs Time 25 Output Voltage vs. Time 120.000 Voltage (volts) 100.000 80.000 Output Voltage 60.000 40.000 20.000 3600 2400 1200 960 720 540 420 320 280 240 200 160 120 80 50 30 10 0 0.000 Time (seconds) Figure 19 – Output Voltage vs Time The team obtained a Lux-meter to test the intensity of UV on the surface of the paint. With that, the team accurately determined the intensity required to cure the 16in. diameter. According to the diagram below, the intensity reduces a lot from the center of the curing spot to the fringes of the region. If the area after 8 inches can be accumulated and intensified, the area cured by the system can be increased. Please note that the Lux-meter used tested light intensity of visible wavelengths, which differs from the wavelengths of ultraviolet light. 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 9 Displacement from center Figure 20 – Intensity vs Displacement 26 Approach selected After reviewing all of the alternatives and conducting testing on both the alternatives and the existing system, the team has selected to continue to use the existing system and expand upon it. The team has decided that a curing system using 8 of the existing UV lamps will provide for the desired curing area at the lowest cost. Detailed Design Current System Since the proposed system is to be an expansion of the existing system, the following section will describe in detail the parts used for the current system. A circuit diagram for the system can also be found below in figure 21. This figure is a scan sent to the group by Autoshot. Additional circuit diagrams as sent by Autoshot are included in the appendix, along with some pictures the group has taken of the current system. As can be seen in the table listed on the next page, Table 1-2, there are a number of components used to build the system manufactured by Autoshot. The major components used for the circuit include a switch, an hour meter, an autotransformer, and a UV lamp. These components, along with the additional ones necessary for the system to operate, are listed in the table along with their part numbers. 27 Figure 21 - A Circuit Diagram for the Current System 28 Table 1-2 Components Used in Current System Part UV Lamp # Used Manufacturer 1 MH-Strahler Bulb Specifications 400W/in 120V 4 Amps Part Num BQ-400E 45006363 Autotransfer 120V/120V 3.8Amps MO400-71C-611 Transformer 1 Howard Industries Capacitor 1 Parallax Power Components 330V 26uF 005-4048-P Lamp Ignitor 1 Howard Industries ST 1001 E-200-S59 Lamp reflector 1 Cone-shaped Aluminum Filter Glass 1 Size: Control Box 1 H&S Autoshot Steel Box Hour Meter on front Lamp Box 1 H&S Autoshot Steel Box Open Front Cable, Control Box to Lamp Box 1 6 Ft 18/4? C-113688 Cable, Power Cord 1 CT2-LL39965 Fan 1 Orion 6 Ft 14/3 115V Snap Switch 1 McGill 125V On/Off Switch 1 Eaton 125V 22A Lighted E4793 2603-1150 E-2702 2600HR11E Hour Meter 1 Fritz Kubler 100-130V 7 Amps 60Hz Type H57 E-128604 Internal Wiring 1 Listed by feet FFA-14(19)-600-BLUE - OA80AP-11-1WB 29 Proposed System Expansion of Current System After researching of alternatives and testing of the existing system (as can be found in the Approaches Used section of this document), it was determined that an expansion using the parts and components of the existing system would be the best approach. By using a combination of 8 lamps, the group can achieve the goal of curing an area of 3 by 4 feet. The figure below shows the arrangement to cure approximately 3 by 4 feet. Figure 22 – Area Cured by 8 Lamps System The yellow circles in the figure above indicate the 16 inches of curing provided by each lamp. Dotted circles just outside the yellow circles indicate the extra inch of fringes of curing. The team believes that these fringes can add together to provide for curing equal to the curing provided by the circles. The dotted box in the figure above indicates the area that will be positively cured by the curing device. The red triangles in between the 30 circles are areas that the team is uncertain of curing. With 8 lamps, a much greater current draw is to be expected on the circuit. According to the group’s research, each lamp needs approximately 5 amps to start lamp operation and 3.6 amps to operate the lamp continuously. Taking these values times 8, the group has found that starting all 8 lamps at the same time will require a 40 amps, and to operate continuously the system will need 28.8 amps. Therefore the group recommends starting each of the lamps individually and installing a separate 30 amp, 120 volt service for the curing system. The figure below shows a sample circuit diagram for running 8 lamps. Figure 23 - Sample Circuit Diagram for Running 8 Lamps As can be seen in the figure above, an individual control box is to be constructed to control all 8 of the lamps. The ballasts and the hour meter for each lamp will be housed in a separate ballast box that will plug into this control box. A master off and on switch will be used to control the whole system and each lamp will have an individual control 31 switch to control its operation. The team recommends that all switches be in the off position at the time the master switch is turned on, and that each lamp be turned on one by one with a minimum of 5 seconds interval between each of them. Timers can be incorporated into the control box for sequentially starting the operation of each lamp and controlling how long each individual lamp is on. This will help to automate the curing process a bit more. Also, this will keep the circuit for the entire curing system from being overloading from accidentally starting the operation of all 8 lamps at the same time. The team has not looked into timers and their operation at this time, but it is certainly a thought to be taken into account when implementing future systems. 32 Resources and Schedules Resources Requirement Table 1-3a shows the estimated efforts for each team member. Table 1-3b shows the revised efforts in hours that each team member made during the first semester. The numbers of hours are not the same, since every member put different amounts of time in working on the project. This is due to the variations such as: class schedule, other projects that team members are working on, and weekly availability of the team members. Table 1-3a Original Estimated Personnel Efforts Requirements Team Members Ng Sui Kwan Ong Vincent Sidharta Raymond Vetter Joseph L Total Project Plan 17 18 16 18 69 Project Poster 18 15 17 16 66 Project Design 16 17 18 16 67 Project Research 21 23 22 22 88 Prototype Construction 17 17 15 19 68 Estimated Effort 89 90 88 91 358 Table 1-3b Revised Personnel Efforts Requirements Team Members Ng Sui Kwan Ong Vincent Sidharta Raymond Vetter Joseph L Total Project Plan 20 23 19 20 82 Project Poster 9 8 10 10 37 Project Design 16 14 19 15 64 Project Research 28 30 26 30 114 Prototype Construction 0 0 0 0 0 Revised Effort 73 75 74 75 297 Table 1-3c Final (actual) Personnel Efforts Requirements Team Members Ng Sui Kwan Ong Vincent Sidharta Raymond Vetter Joseph L Total Project Poster 9 8 10 10 37 Project Design 18 16 21 17 72 Project Research 50 54 49 51 204 Project Testing 13 13 11 11 48 Project Documentation 40 42 41 44 167 Actual Effort 130 133 132 133 528 Table 1-3c shows the actual efforts that each team member made. Project plan and final design report are combined in the project documentation. More research was done during the second semester, along with project testing. 33 Table 1-4a lists all the estimated costs that will be needed in order to implement the project. All the numbers are not fixed, and they can change as the project progresses. Table 1-4b lists all the revised costs that were spent during the first semester of the project. Table 1-4a Original Estimated Other Required Resources Item Team Other Estimated Hours Hours Costs Equipment, such as: transformer, $2000 lamps, etc. Project Poster 66 0 $100 Project Implementation 88 0 $150 Project Documentation 135 0 $50 Total $2300 Table 1-4b Revised Other Required Resources Item Team Other Hours Hours Equipment, such as: transformer, lamps, etc. Project Poster 37 0 Project Implementation 0 0 Project Documentation 144 0 Total Revised Costs $374 (Donated) $47.69 $150 $4.96 $202.65 Table 1-4c Final (actual) Other Required Resources Item Team Other Actual Hours Hours Costs Equipment, such as: transformer, $374 lamps, etc. (Donated) Project Poster 37 0 $47.69 Project Implementation 0 0 $0.00 Project Testing Equipment, such as: 48 0 $65.00 lux meter, Fresnel lens, convex lens (Donated) Project Documentation 167 0 $9.92 Total $57.61 The team did some testing for the project, and the cost of it is described in Table 1-4. 34 Table 1-5a shows the estimated costs for the project. It lists the costs with or without labor. The labor rate is fixed and will be maintained throughout the progress of the project. Table 1-5b shows the revised project costs. It shows the actual money that was spent during the first semester of the project. During the second semester, the hours spent to carry out the project increased, which also caused an increase in labor and total cost. The actual project cost is described in Table 1-5c. Table 1-5a Original Estimated Project Costs Item W/O Labor With Labor Parts and materials Lamps $275.00 $275.00 Transformers $99.00 $99.00 Miscellaneous parts $25.00 $25.00 Poster $50.00 $50.00 $449.00 $449.00 Subtotal Labor with $10.30 per hour $916.70 Ng Sui Kwan $927 Ong Vincent Wen-Yuan Sidharta Raymond $906.40 Vetter Joseph L $937.30 Subtotal $3687.40 Total $4136.40 35 Table 1-5b Revised Project Costs Item W/O Labor With Labor Parts and materials Lamps Donated Donated Transformers Donated Donated Miscellaneous parts Donated Donated $4.96 $4.96 $47.69 $47.69 $52.65 $52.65 Documentation (printing) Poster Subtotal Labor with $10.30 per hour Ng Sui Kwan $751.90 Ong Vincent Wen-Yuan $772.50 Sidharta Raymond $762.20 Vetter Joseph L $772.50 Subtotal $3059.10 Total $3111.75 Table 1-5c Final (actual) Project Costs Item W/O Labor With Labor Parts and materials Lamps Donated Donated Transformers Donated Donated Miscellaneous parts Donated Donated $9.92 $9.92 $47.69 $47.69 $57.61 $57.61 Documentation (printing) Poster Subtotal Labor with $10.30 per hour $1339 Ng Sui Kwan Ong Vincent Wen-Yuan $1369.90 Sidharta Raymond $1359.60 Vetter Joseph L $1369.90 Subtotal $5438.40 Total $5496.01 36 Schedule Figure 24a shows the schedule describing the timeline of major tasks and subtasks. The team has followed the schedule as listed. The black lines indicate our progress as compared to the original schedule planned. The team has completed the final design of the product, the results of all findings and a recommendation to the client as listed. Figure 24a - Gantt Chart of Major Tasks and Subtasks 37 Figure 24b shows the schedule describing the timeline of major tasks and project deliverables. The black lines indicate our progress as compared to the original schedule planned. The team completed the scheduled deliverables for the whole project as listed. Figure 24b - Gantt Chart of Project Deliverables 38 Project Evaluation Research of All Possible Alternatives 100% Research of all possible alternatives has been 100% completed. Everything with the slightest connection to what the team is doing has been thoroughly researched upon and its findings documented. These cover powering 2 or more lamps via 1 transformer, using UV LEDs, using UV lasers, modifying the reflectors, modifying the lenses, incorporating a Fresnel lens, incorporating a stepper motor, and using an electronic ballast. Testing of Existing Components 100% All parts of the system have been thoroughly tested in order to understand its characteristics and the way it functions. The filter glass, UV lamp intensity, voltage and current in various parts of the system have all been tested and its findings documented. New Parts Ordering 55% Most of our parts came from our client and university resources. The team contacted various clients for various different technologies and most of the specialized products are not for sale unless they are bought in large quantities. Therefore, the new parts of the system have not and will not be ordered until the price of components drop. Testing of New System 40% Testing of the new system could not be done as the team found that powering two lamps by a single transformer is not feasible. As for running the lamps in series, only an electronic ballast can give such micro second precision in igniting the lamps simultaneously, but such a ballast does not exist at this time. Final Design Documentation 100% A final design of possible methods to be implemented has been drawn up. These include using a stepper motor, an electronic ballast or an 8 lamp system. The team recommends implementing these systems as the most feasible one given the current economical constraints. 39 Commercialization The table below lists the individual parts necessary for the proposed system. Please note that most of the existing parts will be used for the new system. Table 1-6 Components Used in Proposed 8 Lamp System Part UV Lamp # Used Manufacturer 8 MH-Strahler Bulb Specifications 400W/in 120V 4 Amps Part Num BQ-400E 45006363 Autotransfer 120V/120V 3.8Amps MO400-71C-611 Transformer 8 Howard Industries Capacitor Lamp Ignitor 8 Parallax Power Components 330V 26uF 8 Howard Industries ST 1001 Lamp reflector 8 Filter Glass 8 Ballast Box 8 H&S Autoshot Control Box Lamp Box 1 8 H&S Autoshot Cable, Control Box to Lamp Box 8 6 Ft 18/4 C-113688 Cable, Power Cord 1 CT2-LL39965 Fan 8 Orion 6 Ft 10/3 115V Snap Switch 1 McGill 125V On/Off Switch 8 Eaton Master On/Off Switch Hour Meter 1 8 Fritz Kubler 125V 22A Lighted 125V 40A 100-130V 7 Amps 60Hz Type H57 E4793 2603-1150 E-2702 2600HR11E Internal Wiring - 005-4048-P E-200-S59 Cone-shaped Aluminum Size: - Steel Box Hour Meter on front Steel Box Open Front Listed by feet OA80AP-11-1WB E-128604 FFA-14(19)-600-BLUE 40 Table 1-7 Cost for the 8 Lamps System 8 lamps $34.88 x 8 = $279.04 8 reflectors $38.13 x 8 = $305.04 8 ballasts $30.50 x 8 = $244.00 Master Switch $5.00 Master Control Box $15.00 New Power cord $20.00 Housings for lamps, ballast (inc. fans) Total for new system Reselling price $100 $968.08 $1,600.00 The table above lists the breakdown of costs involved to develop a full 8 lamp system which can cure 3 X 4 feet. An extensive inquiry and research process was done to find if there are any competitors out there marketing the same product. It was found that a company in UK is selling a similar multi lamp UV curing system curing only 1.3 ft X 1.3 ft for the cost of ₤2,950.00 ($4,978.36 USD). Therefore it is extremely profitable should the current design of the product be produced and marketed. Potentially, the product is marketable to any auto body shop interested in reducing the time to cure paint of their customers’ cars. They have been identified as the main market to be targeted. Recommendations for Additional Work Prototype Construction and Testing The group did not construct or test a working prototype for the 8 lamp curing system at the time of project completion. Due to this, it is uncertain what the exact curing area is that can be cured. Building a prototype would allow for testing to find the proper size for curing area and also bring out any flaws in the design of the system. 41 Transformer As stated earlier, if a manufacturer were to come out with an 800 watt - two winding transformer with two 400 watt outputs that is cheaper than two individual 400 watt transformers, then it is recommended that this type of transformer be purchased. This is due to fact that a single transformer can be installed in one control box for two lamps, versus two control boxes for two lamps Electronic Ballast The group have all the specification they need to produce electronic ballast; however, no companies are making it inexpensively in the market. The estimated cost for one electronic ballast would about 6-12 times as much as the current transformer. However, in the future, if the price would drop to no more than 2 times as much as the current transformer, the team is highly recommend purchasing the electronic ballast instead of the current transformer, since it is much smaller and lighter in weight in order to reduce shipping cost. Convex lenses The group found that using convex lenses can focus the fringes in order to increase the curing area by 2 inches diameter. However, a 9mm diameter UV convex lens would cost around $86.00, and need around 140 lenses, so the total cost would be $12,040. If the price of lenses would drop dramatically in the future, the team would recommend adding on some lenses to the current system. UV Fresnel Lenses The intensity of the curing area from the current system is un-even - the intensity in the center of the curing area is much higher than that in the edge of that area. In order to even the intensity and increase the curing area, the team recommends putting a Fresnel Lenses in front of the filter glass, which is just the same kind of lenses use on a normal projector. However, the team is not sure when the UV Fresnel Lenses would available in the market, and they are not sure about the price too. Moveable Curing System The group would like to use micro controllers and motors to control the movement of a group of UV lamps as well as the curing processing. The design would have 4 lamps line up on the same column, and computer would control that column of lamps to shift 42 every 2 minutes so that even big items like a hood would cure automatically. That design may increase the cost of the whole system, but it would reduce the labor used to move the lamps every two minutes; additionally that system may also be sold as an add-on product when customers are buying 4 or more lamps. The figure below shows an example of a curing system using 3 moving UV curing lamps. Figure 25 - Example of a Curing System Using 3 Moving UV Curing Lamps UV LED UV LED curing system would be the best curing system to go for when it become available in the market. UV LEDs are small in size, light in weight, and their life is many times greater than a MPMA lamp. LEDs can be clustered to obtain a desired curing area. 43 Lessons Learned The team learned valuable lessons while conducting the project. What went well: - The team communication and interaction - Variety of ideas were able to be delivered - The team time management and organization What did not go well: - Building the prototype due to time and budget constraints Understanding the desired project result What technical knowledge was gained: - Power consumptions and applications - More understanding of basic circuit devices applications, such as: lamps, transformers, capacitors, LED - Magnetic and electronic ballast information What non-technical knowledge was gained: - UV laser applications UV safety procedure Communication with clients and suppliers What the team would do if the team had to do the project over again: The team would have liked to have had a better understanding of what the desired result for the project was. By the team it was agreed upon that a prototype is to be built, it was too late to do so. The team feels that far too much time was spent on researching alternatives that are not feasible in the immediate future. 44 Risks and Risk Managements Several anticipated risks that may occur during the project, and the actions the team would make to correct them: Loss of team member(s) - The team put all the documentations at a central location, such as web server Late arrival of parts and equipment - This is anticipated by ordering parts in advance - Alternatives companies are also considered just in case of failure of one company Equipment damage - Back up equipment is kept in order to replace damaged items Missing deadlines - The team is required to be organized and a schedule must be followed The team did not encounter any of these anticipated potential risks. However, to be safe the team regularly updated a web server with important documents and took care when handling the curing system parts. Some of the unanticipated risks encountered by the team include: Unable to find an electronic ballast manufacturer - Discard the idea of using electronic ballast, but documented all the possible solutions using electronic ballast in the future. Unable to find a two winding transformer manufacturer - Documented all the possible solutions using a two winding transformer for future use, if and when it is available on the market Resultant changes in the team’s risk management included creating several back up ideas in case a suitable manufacturer was not found for system components and documenting reasons why approaches were not feasible. 45 Project Team Information Client H&S Autoshot, Inc. Attn: Dave Lenz, Operations Manager 1318 Max Joseph Road P.O. Box 623 Centerville, IA 53544 (641) 856-8968 (voice) Faculty advisors John W. Lamont 324 Town Engineering Building Electrical and Computer Engineering Iowa State University Ames, IA 50011 Team Members Sui Kwan Ng (EE) 245 North Hyland #204 Ames, IA 50014 Phone: (515) 441-0228 E-mail: [email protected] (641) 856-8968 (fax) E-mail: [email protected] Phone: (515) 294-3600 Fax: (515) 294-6760 E-mail: Vincent Wen-Yuan Ong (EE) 233 North Sheldon Ave [email protected] #22 Ames, IA 50014 Phone: (515) 460-2703 Ralph E. Patterson 326 Town Engineering Building Electrical and Computer Engineering Iowa State University Ames, IA 50011 Phone: (515) 294-2428 Fax: (515) 294-6760 E-mail: [email protected] Glenn G. Hillesland 1111 Coover Hall Electrical and Computer Engineering Iowa State University Ames, IA 50011 Phone: (515) 294-7678 E-mail: [email protected] E-mail: [email protected] Raymond Sidharta (EE) 123 Sheldon #21 Ames, IA 50014 Phone: (515) 268-9645 E-mail: [email protected] Joseph L. Vetter (EE) 308 Village Dr. Ames, IA 50014 Phone: (515) 451-3271 E-mail: [email protected] 46 Closing Summary The goal of this project was to expand the surface area of an object to be cured by a UV light system for H&S Autoshot. This was to be done using a minimum of new components and with a minimum of power consumption. Any possible ways of doing this were explored and the best method was selected. Research was done on the existing components to see if any additional parts could be added to the system. Research was also done on alternatives such as LED lamps, UV lasers, lenses, UV filter glasses, and electronic ballasts to see if they could be incorporated into the final design. After all of the research and test results were compiled, ideas for a final design were composed. The final design was constructed from these ideas based on choosing the best possible components and technologies that research has made apparent. The final design of this project consists of a report informing Autoshot of which components to be used and how to properly integrate them into their paint-curing product. Autoshot’s end product built from this design shall be relatively inexpensive compared to other alternative technologies, easy to use, and easy to transport, while still serving its purpose. 47 References The UV lamps curing technology: http://www.radtech.org/uv_eb/myths.html http://www.primarcuv.com/primarcuv/aboutuv.htm. The UV LED curing system information: http://www.uvprocess.com/products/led_cure-all.asp UV lamps information (prices, lamps life, schematic, power consumption): http://www.neu-tech.net/UVCuringLamps.htm http://www.primarcuv.com/primarcuv/estimator.htm http://www.hanovia-uv.com/catalog7.html Transformers information: http://www.summit.com/Industry-resources/Industry_techinfo/lamp-ballasts.html http://www.advancetransformer.com/literature/pdf/HID_Pocket_Guide.pdf http://hyperphysics.phy-astr.gsu.edu/hbase/electric/lighting.html#c2 UV and IR reflectors: http://www.miltec.com/UV_Reflectors.htm#Reflector%20Liner http://www.radtech-europe.com/uvcuringgawg.html http://www.dotrix.be/products_technologies/technologies_uv_curing.asp Electronic ballasts: http://medielectronics.com/htmlfiles/electronicballast.htm http://www.nictec.com/ballasts.html http://www.ballastdesign.com/index.shtml http://www.kaj.dk/electronic-ballast.htm http://www.digitalballast.com/ http://www.advancetransformer.com/dynavision/ Stepper motor: http://www.eio.com/jasstep.htm#operation http://www.eio.com/jasstep.htm#sources http://www.aaroncake.net/circuits/stepper.htm 48 Appendices Figure A.1 Current Transformer Nameplate 49 Figure A.2 Current System Schematics 50 Figure A.3 Advance Transformer Specification Sheet 51 Figure A.4 Lamp and Reflector Figure A.5 Transformer and Components 52 Figure A.6 Transformer and Components 53 The following document was sent to the team by Randy Freeman, an engineer for Howard Industries. It was from this report that a great deal of information was gained about the existing transformer used, and about transformers and ballast kits in general. Running two lamps on a single standard ballast is not possible. A standard ballast only has one secondary or output coil. (Figure A.7) I will be describing a 400-Watt Metal Halide Standard Lamp and Ballast (Non-Pulse Start Lamp), for the example below. Mercury Lamps work the same as Metal Halide Lamps, with the exception that they require less open Circuit Voltage To Start. Figure A.7 - A standard ballast If two lamps were put onto this circuit in parallel (Figure A.8) both lamps would see the Open Circuit Voltage (OCV) of approximately 300 Volts RMS and 580 Volts Peak at the same time, but most likely one is going to strike before the other. Once this happens the output voltage of the ballast is going to drop to nearly 0 until the lamp comes up to full brilliance. Once the first lamps comes up to full brilliance the output voltage of the ballast will be approximately 135 Volts RMS. For this lamp to start it takes an OCV of approximately 300 Volts RMS and a Peak Volt between 540 – 600 Volts. (This Higher Peak Voltage is archived by putting a slot in the steel under the Secondary coil.) So, therefore the 2nd lamp would never come on. 54 Figure A.8 – Two Laps in Parallel If two lamps were put onto this circuit in series (Figure A.9) Figure A.9 – Two Lamps in Series 55 But, before I go into this circuit I will need to explain a little on the lamp (Figure A.10). The lamp consists of 3 pins. Pins 1 and 3 are on the same side of the gas tube, about ½ inch apart from one another. Pin 3 is connected to Pin 2 through a resistor. Pin 2 is on the other side of the gas tube. When the ballast is energized the OCV is seen between Pin 1 and Pin 3 of the lamp (at this point Pin 1 and Pin 3 is the path of least resistance). This OCV of about 300 Volts causes an arc between Pin 1 and Pin 3. This arc will excite the gases inside the gas tube causing the path of least resistance for current to be between Pin 1 and Pin 2. At this point the lamp has started and will take approximately 10 minutes to get up to full brilliance. With the lamps connected in series the OCV of the ballast will between Pin 1 of Lamp 1 and Pin 3 of Lamp 2. Therefore neither lamp will start. Figure A.10 – MPMA Lamp The only way to Power 2 lamps is to have a Ballast constructed with 2 Secondary Coils and 2 output caps (Figure A.11). In this circuit the lamps will be running in the same phase, but independently from one other. Each Secondary Coil Would has to have slot in the steel under them. 56 Figure A.11 – New System Could Drive Two Lamps You would only need a starter if you were trying to run a Pulse Start Lamp. A Pulse Start Lamp is just like the lamp in Figure A.10, except it only has Pin 1 and Pin 2. So, it takes a much higher Voltage to cause an arc to excite the gases, usually between 3000 to 4000 Volts Peak. A typical Ignitor or Starter, is constructed of 1each capacitor (usually between .1 and .5 uF), 1 each Power Resistor (usually between 6 to 20 K ohms), 1 each sidac (Voltage Break Over (VBO) 240 – 265 Volts Peak), 1 each Inductor (55 mH), and 1 each bleed off resistor (470 Kohms) (Figure A.12). 57 Figure A.12 - Typical Ignitor There are 2 main differences in the construction of a Pulse Start Ballast as compared to a standard non-pulse start ballast. (Figure A.13) The first difference is the placement of the output capacitor. It is moved from the output of the secondary to the connection point between the primary and secondary. This is done so that the ignitor pulse will not get across the output capacitor. The output capacitor will not be able to handle 3000 – 4000 Volt for very long. The “CAP” lead on the finish of the secondary is then replaced by a “LAMP” lead. The “CAP” lead is moved to the start of the secondary. The second difference is the “X3” connection on the secondary. The “X3” is a tap on the secondary that is approximately 35 turns from the Lamp lead. The total turns on the secondary are about 445. Figure A.13 – System with Pulse Start Ballast The key thing that makes the Ignitor work in the circuit is the sidac. The sidac works like a switch, with it normal mode being an open. When the sidac see a peak voltage of it VBO it becomes a short. The sidac will stay a short until the it falls below it’s holding current (typically 50 mA), at which time it will become an open again until the next half cycle reaches it’s VBO. The sidac is connected to the X3 of the Ballast. When the ballast is energized the open circuit voltage is applied between lamp and common or neutral. The capacitor in the lamp lead is then charged up until the OCV reaches the VBO of the sidac, at which time 58 the sidac becomes a short and the capacitor discharges between the lamp lead and the X3 lead. At this time the Lamp to X3 act like the primary of a step up transformer and the X3 to COM acts like the Secondary of the step up transformer. The pulse can be measured at between the lamp lead and the COM lead. This must be done with a Oscilloscope with a 1000 time voltage probe. The resulting pulse can be calculated by the following formula: Pulse = OCV + (VBO x (1+N1/N2) x k) OCV = Open Circuit Output Voltage VBO = Break Over Voltage of Sidac N1 = total turns on Secondary N2 = Turns X3 to Lamp K = coil coupling factor – as N2 goes down the k will normally go down as well. K is usually between 0.5 to 0.9, but I have seen them as low as 0.25 An example would: OCV = 270 VBO = 245 N1 = 465 N2 = 32 K = .85 Pulse = 270 + (245 x (465/32) x .85 Pulse = 3504 Volts Not sure what you mean by household transformers. If you mean one that you put 120 in and get 2 separate 240 volts out, this will not work. First off, it will probably not have enough OCV to kick over the lamp. If you were able to get the lamp to start with this type of transformer (maybe by using an inductive kick ignitor), the transformer would not be able to limit the amount of current that the lamp is looking for, therefore over drive the lamp and burning it out. One key thing about all magnetic ballast that I have not discussed is the shunts. See Figure A.14. The shunts are laminated steel placed between the primary and secondary. They are used to steer the proper amount of current to the secondary. 59 Figure A.14 - Shunts Figure A.15 shows the physical details of a 2 secondary ballast as in figure A.11. 60 Figure A.15 - Physical Details of a 2 Secondary Ballast Hope this helps, Randy E. Freeman Engineering Lab Manager Howard Industries, Inc. Magnetic Ballast Division Phone 601-847-6199 Fax 601-847-6105 Email [email protected] 61 Table A.1 – Current and Voltage Testing Dec03-03 Current and Voltage Testing Performed 9/23/2003 Time Time Input Voltage Output Voltage Input Current Output Current X3 Voltage (sec) 0 1 2 5 10 15 20 25 30 35 40 45 50 55 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 360 390 (min) 0.0 0.0 0.0 0.1 0.2 0.3 0.3 0.4 0.5 0.6 0.7 0.8 0.8 0.9 1.0 1.2 1.3 1.5 1.7 1.8 2.0 2.2 2.3 2.5 2.7 2.8 3.0 3.2 3.3 3.5 3.7 3.8 4.0 4.2 4.3 4.5 4.7 4.8 5.0 5.2 5.3 5.5 6.0 6.5 (volts) 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 (volts) 0.000 0.000 0.000 14.300 15.700 16.700 17.500 17.900 20.300 20.300 27.600 27.600 37.300 37.300 46.400 59.800 79.900 87.300 92.300 96.900 100.300 102.900 104.800 105.900 106.600 106.900 106.975 106.920 106.850 106.780 106.688 106.590 106.500 106.430 106.337 106.283 106.214 106.130 106.060 105.980 105.900 105.834 105.661 105.515 (amps) 0.0 5.0 4.0 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.0 3.0 3.1 3.2 3.3 3.4 3.4 3.5 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.6 (amps) 0.0 6.2 5.5 4.3 4.3 4.3 4.3 4.3 4.3 4.2 4.2 4.2 4.2 4.1 4.1 3.9 3.9 3.9 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 (volts) 0.000 28.000 27.000 27.300 27.400 28.200 29.900 32.000 34.000 39.000 47.000 50.000 55.000 66.000 76.000 87.000 93.000 98.000 100.000 101.000 101.400 101.500 101.600 101.600 101.500 101.522 101.490 101.415 101.379 101.349 101.318 101.301 101.287 101.250 101.228 101.190 101.175 101.151 101.120 101.090 101.600 101.018 101.056 101.018 62 420 450 480 510 540 570 600 660 720 780 840 900 960 1020 1080 1140 1200 1500 1800 2100 2400 2700 3000 3300 3600 7.0 7.5 8.0 8.5 9.0 9.5 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 55.0 60.0 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 105.385 105.285 105.197 105.114 105.009 104.889 104.835 104.713 104.608 104.528 104.468 104.423 104.368 104.358 104.389 104.365 104.319 104.063 103.777 103.593 103.373 103.209 102.408 101.937 101.547 3.6 3.6 3.6 3.6 3.6 3.6 3.6 3.8 3.8 3.8 3.8 3.8 3.8 3.8 100.983 100.979 100.995 100.978 100.993 100.981 100.898 63 Electronic Ballast Information Resources The following companies and individuals listed below deal with electronic ballasts used for a variety of different bulb types, specifically HID lamps. Unfortunately at this time none are manufacturing a suitable electronic ballast to operate an MPMA lamp. http://medielectronics.com/htmlfiles/electronicballast.htm http://www.nictec.com/ballasts.html http://www.ballastdesign.com/index.shtml http://www.kaj.dk/electronic-ballast.htm http://www.digitalballast.com/ 64 E-mail responses from client and companies Kissak Sarajian ([email protected]) www.epsi.com Mar. 11th, 2003 Dear Brian We are in a masking business, and we would like to help your group in any possible way for your, " research on UV lamp curing systems for H&S Autoshot in Iowa, need details on UV lamps and the transformers, UV curing systems" Your findings and effect of masking on production line is a compliment of our work and we would like to be part of your findings and effect of any masking. The high spot of heat and concentration of heat in certain areas are some problems in production. We offer our help for any findings you might need. Please visit our website http://www.epsi.com and if you need any samples of no charge to you or your school for your research program feel free to call. Kind regards Kissak Sarajian 65 Mark Novotny ([email protected]) www.nordson.com Mar. 11th, 2003 Brian, A good source of info regarding UV is the Radtech organization www.radtech.org Best Regards, Mark Novotny 66 Gerald Heydt ([email protected]) Arizona State University Nov. 3rd, 2003 No -- I have not heard of those high voltage types. You might contact the Phillips Corporation in the Netherlands -- they make a very large number of things like this. They must have a web site. Oct. 22nd, 2003 Ng -- I have not heard of a 4000 V ballast. 40 W 120 V ballast in the USA cost commercially about 3 US dollars. Probably in volume this is less than 1$. Oct. 15th, 2003 I am sure that there are electronic ballasts well into the kilowatt range. I would use the 120 W design with values scaled up to accommodate 400 W. I have not worked with mercury arc lamps -- but -- there are some excellent books on illumination and lighting. And they would give you generic circuits. Conventional fluorescent lamps start at about 1000 V and so probably electronic ballasts for mercury arc lamps would have similar ballasts. You need to find out what voltage is needed to start these lamps. Without going to the library and looking this up, this is about all I can say. Good luck in the project. 67 Paul Jackson ([email protected]) www.uv-light.co.uk Oct. 22nd, 2003 Dear Brian, Thank you for your enquiry. Please find following the answers to your questions. 1. All the technical information and specification for both systems can be found on the website site. Please visit www.uv-light.co.uk.With each product you will see a more product information button. This is where you will find the information. 2. With regards to the amount of UV energy from the two systems please advice as to what UV lamp you are currently using? What type and wattage is it? 3. With answer to question three each UV system we sell has its own lamp and it is own power supply. required. Sometimes we build them into a single enclosure if 4. The type of bulb that you use in your system depends on the chemistry of your materials. Please send details of your material. 5. With regards to the filter chooses please see the website www.uv-light.co.uk and you will see the different transmitting ranges for the filter glasses. 6. The 50% to 100% switch able power is when the units switches power of each lamp from 50% to 100% 7. The curing area of the UV systems is on the website www.uv-light.co.uk under the product information for each system. Please send me your full contact details. Perhaps you could ring me on 0044 121 423 2000 so we can discuss your application further. I will look forward to hearing from you soon. Best regards Paul Jackson UV Light Technology Limited The Light House 582-584 Hagley Road West Birmingham, B68 0BS 68 Tel: 0121 423 2000, Fax: 0121 423 2050, Email: [email protected] Website: www.uv-light.co.uk Craig Poolman < [email protected]> H&S Autoshot Fri, 7 Nov 2003 11:12:23 The 4 head idea with a stepper motor sounds very innovative but I'm not sure that many shops would have the room or want to pay the expense to do this. Your first idea of 8 heads would be feasible but are we still looking at separate transformers for each bulb? The control box would have a large terminal block for the main power and feed each transformer ballast kit from that. The market is very concerned about cost, this is coming from the paint manufactures because the UV product is new and their paint can not be cured unless the customer buys a lamp. If the lamp is too expensive and the shop will not invest then they will not sell any product and Millions of dollars have gone into formulating and testing these new paints. To start cost is the main concern. Craig Thursday, October 30, 2003 4:32 PM Dear Craig, Thank you for the update, it certainly provided us with a few leads. We do have a few suggestions from our findings to present to you. We believe an electronic ballast used with fluorescent lamps, possibly with an energy control system might be used in place of the current system. Would you be familiar with this idea or tried it already in the past? Would your supplier be interested in this different type of technology? We think that also, with an 8 lamp system to cure a 3X4 feet area, there is a need for a 40-50A circuit built specifically for that. Thus, a few changes need be made for example, using a 10-Copper extension cord/plug in for the unit, building a new specific circuit, etc. Another suggestion would be to build a 4 lamp system that could be automated to move after a certain time by using a stepper motor. We'd like to know which of these 2 ideas you would prefer. 69 Regards, Vincent Ong Monday, October 13, 2003 13:05 Dear Senior Design Group: I have reviewed your end product design report and feel you are doing a very good job. I do have a few comments that I hope will help you. I find that you are investigating a number of areas and would like to point out some you may not be able to change. The current lamp you have is a cone reflector as you stated in your report, this has been tested by engineers in Germany and the U.S. to provide the best output for the bulb we are using. We have tested this bulb with other reflectors we manufactured but do not increase the cure area. We have cured a 16 inch diameter circle with the unit you have. Our objective is to bank a number of lights to cure a larger area. We have found that UV different than IR will increase at the outer perimeter if another light is added. What I mean is if we need a minimum of 10mw to cure UV paint and one lamp will cure 16 inches by adding another lamp beside it, we pick up output on the outer edges that would not cure and gain a few more inches of curing. Hope I explained this well enough. UV LED's will be the next step I to have not found and that generate enough output to cure unless we our right on top of the product. The main objective is to try and operate more than one lamp off of a single transformer to save cost on a 2 or 4 headed lamp. This you already know. I called and talked to Advance Transformer and found that their transformer only put out 3.5 volts and would not provide enough output for our bulb to generate full power. They also were not interested in developing a transformer and also said our bulb would need and ignitor. Sincerely, Craig Poolman Thursday, September 18, 2003 11:31 70 We are getting you parts and information together but I need to verify, when you ask for a curing unit that's a head and control box ready to plug in and run. I want to make sure we are talking about the same thing; do you want a head with the reflector and bulb so all you need to do is wire it to a control box to see if you can get 2 lamps to run on one power service? Please verify the request for 1 more lamp. I will send information on our bulb, along with an extra ignitor and ballast for your testing. Craig Wednesday, October 17, 2003 09:33 Vincent, our main objective of this project was to see if we could find or you develop a transformer that would operate more than one lamp. The reason was so that we could cure larger areas needing multiple heads. I have read some of the report but not all and should let you know that the advanced transformer will not operate our lamp and it would need an igniter. Below is a list of cost and the company phone numbers and contacts as requested. Heraeus BQ400E - 45006363 Metal Halide Lamp; Tom Evens (770-623-5630 ext.6237) price $34.88 each Same UV reflector for 400 watt lamp price $38.13 each Howard Industries, ballast kit MO400-71C-611; Jason Cook (601-847-6120) price $30.50 each at 1,000 quantity Tuesday, September 9, 2003 Vincent, how many actual units do you need? Just one and some extra parts? I can pull all the vendor information for you and send you the parts once you let me know. Craig. 71 Laurent Hodges <[email protected]> Physics Department, Iowa State University Fri, 12 Sep 2003 I am not expert enough at lenses to be able to answer your question about the best type of lens to use, or whether the lamp and its filament is part of the problem. You might contact Keith Ver Steeg at mailto:[email protected] (he is a Lecturer in our department, and particularly knowledgeable about optics). You might also find some information online. For example, Edmund Scientific sells many types of lenses (and other optical instrument), and they might have useful data on their web site. Keith Ver Steeg Physics Department, Iowa State University [email protected] I don't know what is causing the "star shaped" pattern of your beam, but most inexpensive fresnel lenses are made out of plastic, which doesn't transmit well in the UV. You might want to try a glass like BK7 which has a > 90% transmittance at wavelengths >= 340nm. ******************************************* Keith Ver Steeg, PhD Iowa State University Department of Physics and Astronomy Room 12 Physics 294-0660 ******************************************* 72 Sales at Nicollet <[email protected]> www.nictec.com Wed, 29 Oct 2003 We do not manufacture this class of electronic ballast. Check with Warner Power Inc. ----- Original Message ----From: Raymond Sidharta <[email protected]> To: <[email protected]> Sent: Tuesday, October 28, 2003 5:46 PM Subject: Electronic Ballast information To whom it may concern, We would like the contact information for an engineer in charge of >electronic ballasts. We have a 400W MPMA pulse start lamp to be >powered and regulated by the electronic ballast. Thank you. Regards, Raymond Sidharta Ian Hiskens <[email protected]> University of Wisconsin, Madison Fri, 17 Oct 2003 Hi Raymond, Unfortunately I cannot help you. You question is way out of my field of expertise. Ian At 03:31 PM 15/10/2003, you wrote: Dear Prof. Hiskens, My name is Raymond Sidharta, a senior in Electrical Engineering at Iowa State University. My project advisors, Prof. John Lamont recommended your department at 73 your university for reference. Therefore, if you could give the information needed, I would greatly appreciate it. I am currently conducting a project on UV curing system. The main problem/goal for this project is to expand the curing area, and we do that by increasing the number of UV lamps. My question is, is it possible to power 2 UV lamps with only 1 transformer? If it is, what type of transformer would be needed? The UV lamps that we use are 400 Watts Medium Pressured Mercury Arc (MPMA) lamp. And that type of lamps needs a pulse-start voltage of about 1000 - 3000 V. I have contacted several transformer companies, and all of them said that it is not possible to power 2 lamps with only 1 power supply, unless a new type of transformer is created (which will cost more than what we want). If you have any idea or suggestion, I would greatly appreciate it. Thank you very much for your time. Sincerely, Raymond Sidharta ----------------------------------------------------------------------Assoc Prof Ian A. Hiskens, | Ph: +1-608-261-1096 Dept of Electrical and Computer Engineering, | Fx: +1-608-262-5559 University of Wisconsin - Madison, 1415 Engineering Drive, Madison, WI 53706, USA http://energy.ece.uiuc.edu/hiskens ----------------------------------------------------------------------Do not be anxious about anything, but in everything, by prayer and petition, with thanksgiving, present your requests to God. Phil 4:6 ----------------------------------------------------------------------- 74 Patrick Chapman <[email protected]> University of Illinois, Urbana-Champagne Wed, 15 Oct 2003 Sir, I'm afraid I don't know. I've never worked with UV lamps, so I can't say why you couldn't do with one transformer; I'm sure it is very special application. I wouldn't expect the transformer manufacturer to know all the nuances. -----Original Message----From: Raymond Sidharta [mailto:[email protected]] Sent: Wednesday, October 15, 2003 3:25 PM To: [email protected] Subject: requesting information Dear Prof. Chapman, My name is Raymond Sidharta, a senior in Electrical Engineering at Iowa State University. My project advisors, Prof. John Lamont recommended your department at your university for reference. Therefore, if you could give the information needed, I would greatly appreciate it. I am currently conducting a project on UV curing system. The main problem/goal for this project is to expand the curing area, and we do that by increasing the number of UV lamps. My question is, is it possible to power 2 UV lamps with only transformer? If it is, what type of transformer would be needed? The UV lamps that we use are 400 Watts Medium Pressured Mercury Arc (MPMA) lamp. And that type of lamps needs a pulse-start voltage of about 1000 - 3000 V. I have contacted several transformer companies, and all of them said that it is not possible to power 2 lamps with only 1 power supply, unless a new type of transformer is created (which will cost more than what we want). If you have any idea or suggestion, I would greatly appreciate it. Thank you very much for your time. 75 Sincerely, Raymond Sidharta Hiro Yano <[email protected]> www.yoe-inc.com Thu, 9 Oct 2003 Dear Mr. Raymond Sidharta: Thank your for your e-mail. Question => Would it be possible to use 2 of your UV lamps out of 1 power supply? Answer ==> No. Each lamp requires each power supply. Hiro Yano YOE Inc. ----- Original Message ----From: "Raymond Sidharta" <[email protected]> To: <[email protected]> Sent: Thursday, October 09, 2003 4:08 PM Subject: Requesting information Greetings, My name is Raymond Sidharta, an electrical engineering senior from Iowa State University. I am currently conducting a research and design project about UV lamps and power supply. Right now, our current UV curing system uses 400 watts UV Medium Pressure Mercury Arc Lamp that requires a pulse start ballast. We would like to expand our curing system to include 2 lamps run of 1 power supply, but it is not possible with a pulse start bulb. Would it be possible to use 2 of your UV lamps out of 1 power supply? We would like to stick in the 320 - 380 nm range. Please send any information to this email address. Thank you for your time, 76 Raymond Sidharta [email protected] Tom Evans <[email protected]> www.heraeusnoblelight.com Mon, 13 Oct 2003 Hi Raymond, I do know that it is possible to power two lamps with one power supply but in all honestly I am not sure how it is done. I will see if I can find out more info on this and get back to you. Thanks, Tom -----Original Message----From: Raymond Sidharta [mailto:[email protected]] Sent: Monday, October 13, 2003 9:17 AM To: Evans, Tom Subject: UV lamps questions (2) Dear Tom, Thank you for the reply. I am just wondering if it is possible to power 2 UV lamps (either metal halide or metal vapor) with only 1 power supply? My current project is to expand the system, i.e. use 2 lamps with only 1 power supply. Moreover, will the intensity change if I change the type of UV lamps (does the metal halide or metal vapor produce the same intensity as the medium pressure mercury arc lamp?) I believe the current system has 2 Joule/cm^2. Thank you very much for the help. I really appreciate it. 77 Sincerely, Raymond Sidharta Mon, 13 Oct 2003 Dear Raymond, Yes we are familar with the unit you are working with for H&S Autoshot. While the lamp you are working with is not a metal halide lamp we do make these particular items. Please let me know if we can be of any help. Kind regards, Tom Evans -----Original Message----From: Raymond Sidharta [mailto:[email protected]] Sent: Thursday, October 09, 2003 3:25 PM To: [email protected]; [email protected] Subject: UV lamps questions Dear sir/madam, We are from Iowa State University and currently are conducting a project regarding UV curing system. We have some questions I need to ask. Do your company make UV metal halide lamp or UV metal vapor lamp (both of these lamps don't have a pulse start)? The current lamp that we are using for our UV curing system is Heraeus 300 Watt UV MPMA (Medium Pressure Mercury Arc) Lamp. We just want to know if UV metal halide lamp and UV metal vapor lamp really do exist in the market. Thank you for your help, we greatly appreciate it. Sincerely, Raymond Sidharta 78 Vincent Ong Joseph Vetter Brian Ng Vladimir Lebedev <[email protected]> Nicollet Technologies Corporation www.nictec.com Wed, 3 Dec 2003 Hi, Joseph! Thanks for your response. Of course, you have to decide yourselves what is the most applicable for your project from the standpoint of the facility organizing, single or multiple wiring and ,of course, money. But speaking about power quality, if you are concern about it, could you tell me what is your active power usage in comparison to reactive power, what is your power factor and how much you pay for the demanded disbalance? Also could you tell me how much electrical "noise" are making your magnetic ballasts? And what is the level of the Total Harmonics Distortion? I do not want to show up, but our EBS is the most advanced product on the today's market and there is no competition for this product. Speaking about series-parallel topology: for the parallel connection the power transformer must be designed to hold the sum of the current for all bulbs together which means a huge increase of the size and weight of the winding wires/copper/and the ballast itself. A series connection topology requires just one grade of the current equal to the one bulb rating and one voltage output for all of the bulbs which means only enforced internal insulation between windings. So we can make a slim design to meet customer's cabinet dimension or any other enclosure. Best regards. Vladimir. 79 Mon, 1 Dec 2003 Hi, Joseph! Now the situation is clear so far and I can tell you that initial price for such a ballast size in quantity of 1 to 4 would be around $2300.00.I guess you pay more for the all four magnetic ballasts, don’t you? But if you are going to put a larger order - the price will drop, of course. Speaking about lamp size of one inch ARC - to be honest, I’ve never tested such a size but I know definitely that the smaller size the harder to ignite. But I've tested a lot of gallium, metal halide and iron doped lamps so I'm sure we can run these small lamps too. To exclude any misunderstanding in customer's relationships I tell you what we usually do. When customers ask us about building ballast, we ask customer to send us the lamps which this ballast supposed to run and we are testing both – ballast and lamp together to make sure this combination is working properly and, besides, I can set the control board and the igniter precisely to this application and make the fine tune-up. So, after receiving the ballast you have to just hook up the lamp and utility input and you are ready to go. Of course, along with a ballast I'll send you the test results as well as documentation and set-up package. So, in your case you need: 1. Two ballasts at the 1.6 kW power range; 2. 120 or 240 Volts primary input( actually, we can make multi-input for both - 120 and 240 Volts, it's up to you, what you prefer, but I would recommend higher input,240 Volts or even higher, if you have it in your facility -it will improve your active power utilizing ); 3. 480 Volts output for the 4 lamps in series. If we will succeed easily in this test - I need to see how these lamps will ignite, may be it would be possible to build one ballast at 3.2 kW power level to run all 8 lamps. I guess that's all I came up with and I hope for your response. Regards. Vladimir. 80 Wed, 26 Nov 2003 Hi Joseph! One more thing I forgot to ask you about. What is the lamp arc length? What is the lamp chemistry? /Mercury, metal halide, gallium or something else? What is you utility input voltage? How do you connect your ballasts? Is this industrial, facility or office environment? Vladimir. Tue, 25 Nov 2003 Hi Joseph! Sorry for the late response but I was in a business trip so I just arrived. It is possible to run a few lamps in series just the secondary voltage supposed to be in accordance with the lamp quantity. I'm not sure about all 8 lamps from the one ballast and I tell you why. 8 lamps will require about 960 Volts + 15 % overhead = 1104 Volts secondary output. Such high voltage will require a special hi-voltage terminal block for the interconnection and these blocks are expensive. Besides, you will need special hi-voltage stuff also such as wires, proper insulation, etc. That's why I asked you about your application detail - may be it would be more efficient use two ballasts instead of one to run four lamps at a time. Speaking about control - it's up to you, you can use it or not. I just informed you about our control board’s capability. And about striking voltage - as I said before, you can set our igniter board up to 12 kVolt strike pulse, so there is no question about it. Just keep in mind that such a voltage requires an appropriate wiring from the standpoint of safety. Hope I was useful for you. Regards. Vlad. Mon, 10 Nov 2003 Hi Joe! I guess you do realize what means STEPLESS REGULATION and magnetic ballast doesn't have this ability so I think the price for the electronic ballast will never be the same except in one case - blank order in large volume which means the materials and 81 labor will drop which means the ballast price will drop too. Speaking about advantages - our control board is capable to monitor ballast and lamp condition in real time as well as the lamp monitor circuit can monitor the scaled lamp output data such as power, voltage and amperage. All these data can be used to write software for the whole UV process so you'll be able to automate the whole process for your application. But this is just for your knowledge and may be for the future projects. Answer for your second question is YES - our ballast is capable to run several lamps in series even with different chemistry-that's what I'm doing in our test lab. I'm running mercury and gallium lamps in different combinations but the voltage and amperage for all lamps must be identical, of course. Speaking about additional info I need from you: lamp voltage, amperage, ARC length, wattage per inch and total power level and also what striking voltage you need to run this lamp and what kind of control are you using or planning to use. Would be nice also to know about quantity you are planning to order – this will help in the price adjustment. Regards, Vlad. Wed, 5 Nov 2003 Hi Joe! We are the company who makes such an electronic ballasts to run any type of the UV lamps, even combination of the several different lamps in series. To be more precise in my estimate I need more technical info about your application, but my first impression is that you are running very low power machine and our start power level is around 1.2 KWatt. Below this power level the single project machine is too expensive to make considering the electronics itself-control and igniter boards-which are around $500.00. But our control board gives you an ability to control lamp power from 100 % up to 20-30%, this control is step-less and you can use as a control input signal either DC voltage - 0-5 V, 0-10 V, or current loop 4-20 m A, or just a potentiometer 0-10 K Ohm for the manual adjustment. The striking voltage is also adjustable from 600 Volts up to 12 K Volts! If you have more questions please do not hesitate ant contact me or you can obtain some info in our web-page: www.nictec.com. Regards, Vladimir Lebedev. 82 From: Kaj Jensen [email protected] http://www.kaj.dk Tue, 4 Nov 2003 Electronic ballasts have of cause build starters. Electronic ballasts are typical 6 - 12 times more expensive than mechanical ballasts. The cheapest way for you to get your 400W lamp running, may be to buy a mechanical ballast and starter for a mercury street lamp. Best regards, Kaj Jensen 83 Randy Freeman [email protected] Howard Industries http://www.howard-ind.com Fri, 3 Oct 2003 1. How much would it cost to produce a transformer with two 400 watt secondaries? I really don't have the information on this. After checking a competitor's website, I see that the stack height of the core on a 2 secondary ballast will almost double compared to a standard one secondary ballast. This will cause the material price to be about 3 times as much for 2 secondary ballast. The main factor is that the 2 secondary ballast uses a lamination size of 4.25" x 6.00" and the one secondary ballast uses a lamination size of 4.25 x 4.75. This will mean more steel and more copper in the ballast. 2. Do you currently produce such a transformer? If not, would it be possible for your company to do so and what would it take? A certain amount of orders, perhaps? Currently no one, that I know of, produces a ballast to pulse start 2 lamps. Advance transformer produces one for non-pulse start that runs 2 M-59 400 Watt Metal Halide. The input voltage for this ballast is 277 or 120 volt. This ballast will also run 2 H-33 400 Watt Mercury Vapor Lamps. This is not very popular ballast, due to the fact that it is more expensive than 2 single lamp ballast. At present, we do not even produce this product. The demand for the ballast is very low in the Q. I don't even think we have ever had anyone inquire about it before this. I have attached a pdf file of the Advance Ballast. 3. Is it possible to produce a transformer with 3 secondaries to power 3 400 watt MPMA bulbs? How about 4 if the input voltage is 240 volts? In the previous email, Figure 9 shows an example of a 2 secondary setup. You will notice that the primary is in the middle of the two secondaries. With the primary located in the middle, the output of each secondary will be symmetrical. A 3 or 4 secondary ballast could possibly be produced, but there is going to be a lot of things to consider. First, the stack height of the steel will have to almost double for every secondary that you add. The weight of a 4 secondary ballast would weigh about 100 pounds, where 4 single secondary ballast weigh about 50 lbs. This would have to be done to accommodate the amount of wire and coils the ballast would 84 have to hold. The more core stack you have the less turns you will need, therefore the bigger wire and/or more coils you can accommodate. All secondaries would have to have it's own capacitor and starters and all secondaries would have to have a slot in the steel under them. Finally, one or two, for the secondaries for a 3 or 4 secondary ballast are not going to have very good coupling to the primary. They or it will be behind another secondary. This can be over come by adding turns to that/those secondary(s) to improve the output watts and OVC. Tue, 30 Sep 2003 Joe, The drawing that you sent would not work. It is on the same principal as figure 2 in the other document that I sent, except you are running 2 secondaries in parallel, but the same thing will happen. One lamp will start dropping its secondary voltage down to almost zero and since, they are running in parallel, the other secondary voltage will drop down to almost zero as well. The sidacs on the 2nd lamp will not fire anymore and therefore never start. The only way I can see it working is if both lamps started within about 1 to 4 micro-second of each other, which is about how long a starter pulse will last. I have enclosed a modified version of your drawing that will work. The secondaries are run independently of one another, so that one does not affect the other. For cost I will give the example for material cost, which does not include cost of development, tooling, labor, or overhead. This is comparing one 2 lamp transformer to 2 one lamp transformers. The things that will stay pretty much the same will be Copper in secondaries, the starters, the capacitors, and the lamps. These things as far as material cost will be pretty much the same. The primaries will be almost the same; you will have to double the size of the wire in the 2 lamp transformer compared to the on lamp transformer, due to the fact that you will be doubling the current seen by the primary. The things that will change the most will be the steel, you will have a longer steel length and you will have to go up on stack height. But you should be able to decrease the steel weight of 2 transformers by about 25%. Hope this helps, 85 Randy E. Freeman Howard Industries, Inc. Engineering Lab Manager P-601-847-6199 F-601-847-6105 Mon, 7 Apr 2003 Joseph, I remember talking to you a few weeks ago. Although, I did not realize, which I may have just missed it, that we were talking about the M0400-71C-611 (pulse start lamp ballast (PSB)). I thought you where talking about the M0400-71C-211 (non-pulse start lamp ballast (NPSB)). There is commercially available ballast that runs 2 lamps on one ballast from Advance Transformer, but it is a NPSB. Their Cat. Number is 71A6382. I have attached a PDF flyer for this ballast. It may be possible to use this ballast on a Pulse Start Lamp, but you would have to use an external 2 wire ignitor system. No one, as far as I know, offers a similar ballast in PSB. In order to do this you would have to have 2 secondaries on the same ballast, each secondary would have to have an ignitor attached to start each lamp. PSB have a 3 wire ignitor system. If you have 277 Voltage available, you may want to try reactor ballast. Reactor Ballast is smaller than the autotransformer. They are also, more efficient and have a lower current crest factor, which translate into longer lamp life. The only draw back to the reactors is it doesn't regulate very well. For every 5% you input volts drop, the output wattage will drop by 10%. You will be able to put several of these into an electrical box and run the output wires through plastic PVC pipe to the lamp head(s). If you will send me your mailing address I would be glad to send you one of our reactors free of charge, to see if this will work for you. 86