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Dec 03-03 Paint Heat Lamp Power and Control System September 18, 2003 Team Members: Sui Kwan Ng Vincent Ong Raymond Sidharta Joseph L. Vetter Client: H & S Autoshot Faculty Advisors: Dr. John W. Lamont Prof. Ralph E. Patterson Prof. Glenn G. Hillesland Presentation Outline Project Overview Acknowledgement Problem Statement Operating Environment Intended Uses/Users Assumptions and Limitations Expected End Product Resources and Schedules Closing Materials Project Activities Accomplishments Approaches Project Definition Research Activities Design Activities Implementation Activities Resource Requirements Schedules Project Evaluation Commercialization Recommendations for Additional Work Lessons Learned Risk and Risk Management Closing Summary Definitions Curing – To preserve or finish a surface by a chemical or physical process Ultraviolet (UV) – Light radiation with a wavelength shorter than visible light but longer than X rays UV LED (Light Emitting Diode) – A type of diode that emits ultraviolet light UV Lasers – A device that emits highly amplified and coherent radiation light Acknowledgement Craig Poolman, H&S Autoshot General Manager Dr. Vikram Dalal, Iowa State University Professor Randy Freeman, Howard Industries engineer Advisors: Hillesland, Lamont, and Patterson Problem Statement Goal: An automotive paint UV Curing system with the following properties: – – – – UV light within 320 nm – 360 nm range Expand curing area (from 4” by 6” to 3’ by 4’) Portable Increased number of UV lamps used with a single transformer Operating Environment - Operated in a sheltered environment Run by an auto body shop Temperature range of 60 -120 Fahrenheit No personal contact with the device during operation Intended Users and Uses Intended users – Auto body repair shop personnel Intended uses – To cure an automobile’s body paint Assumptions The system operator is familiar with the device The device cures 3 X 4 feet or smaller area of the automobile’s body Moveable device to cure desired area 2 minutes curing process Limitations The device works with the 60 Hz/120 V/20 Amp standard electrical systems 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 Increased curing area Use of a single transformer for multiple UV lamps Portable Economical Present Accomplishments Defined the Problem Researched Alternatives Testing – UV Filter Glass – Transformer Voltage and Current – UV Intensity Ordered Parts Approaches Considered UV LEDs UV Lasers Alternative Reflectors, Lens, and Filter Glass Additional Lights Using Existing Transformer Approached Used Expansion on Existing System Limit Number of Bulky Transformers Used Ensure No Overloading of Customer’s Electrical Circuit Project Definition Increase Area Cured – From 4” x 6” to approx 3’ x 4’ Increase Number of Lamps per Transformer Keep Unit Size Reasonable Use on Customer’s Existing Power Supply Research Activities UV LED Research Activities (cont.) UV LEDs – Pros Cheap, efficient, and small per LED Long life with no maintenance necessary – Cons No LED exists for desired wavelength Intensity too low for curing purposes – Result: Not feasible at this time Research Activities (cont.) UV Laser Research Activities (cont.) UV Lasers – 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.) Reflector UV Lamp Research Activities (cont.) Reflector – Cone-shaped currently used – Circular output, desirable for curing – Result: Continue using current reflector Research Activities (cont.) UV Lamp – Medium Pressure Mercury-Arc (MPMA) lamp – 300 Watts – UV light and other light wavelengths – Result: Best light solution at this time Research Activities (cont.) Filter Glass 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 Light Research Activities (cont.) Transformer 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 Technical Design Implementation Activities Order Additional Lamps – From H&S Autoshot – Exact same as Lamp Currently Used Alternative Lenses – Testing Continues Design Switching for New Lamps – Mechanical Switches Selected 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 Personnel Efforts 25 20 hours Ng Sui Kwan 15 Ong Vincent Sidharta Raymond 10 Vetter Joseph 5 0 Project Plan Project Poster Project Design Project Research 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 $50 Equipment Project poster $150 $374 $47.69 Project Implementation Project Documentation Schedules Schedule Gantt Chart Project Evaluation Research of All Possible Alternatives Testing of Existing Components New Parts Ordering Testing of New System Final Design Documentation 100% 65% 55% 40% 25% Commercialization Cost of Existing Curing Unit $374.00 Additional Lamp and Parts $102.88 Total for New System $476.88 Estimated Resale Price $565.02 Additional Work Adapt Alternative Devices (LEDs or Lasers) as They Become Available on the Market Research Alternative Reflectors Additional Testing for Increasing Device to Surface Distance Research Alternative Power Supplies Lessons Learned Time Management Communication Organization Major Specific Information – Power Consumption – Basic Circuit Devices (Lamps, Transformers, Capacitors, LEDs, etc.) Non-major Specific Information – 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?