Download Resources and Schedules - Senior Design

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