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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
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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 4” by 6” to 3’ by 4’)
Portable
Increased number of UV lamps used with a
single transformer
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 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
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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
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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?