Paint Heat Lamp Power and Control System Team Members: Sui Kwan Ng Vincent Ong Raymond Sidharta Joseph L. Vetter September 18, 2003 Client: H & S Autoshot

Paint Heat Lamp Power and Paint Heat Lamp Power and Control System Control System

Team Members:Team Members:

Sui Kwan NgSui Kwan Ng

Vincent OngVincent Ong

Raymond SidhartaRaymond Sidharta

Joseph L. VetterJoseph L. Vetter

September 18, 2003

Client: H & S Autoshot

Dec 03-03

Faculty Advisors:Dr. John W. Lamont Prof. Ralph E. PattersonProf. Glenn G. Hillesland

Presentation OutlinePresentation Outline

Project OverviewProject Overview AcknowledgementAcknowledgement Problem StatementProblem Statement Operating EnvironmentOperating Environment Intended Uses/UsersIntended Uses/Users Assumptions and LimitationsAssumptions and Limitations Expected End ProductExpected End Product

Project ActivitiesProject Activities AccomplishmentsAccomplishments ApproachesApproaches Project DefinitionProject Definition Research ActivitiesResearch Activities Design ActivitiesDesign Activities Implementation ActivitiesImplementation Activities

Resources and SchedulesResources and Schedules Resource RequirementsResource Requirements SchedulesSchedules

Closing MaterialsClosing Materials Project EvaluationProject Evaluation CommercializationCommercialization Recommendations for Recommendations for

Additional WorkAdditional Work Lessons LearnedLessons Learned Risk and Risk ManagementRisk and Risk Management Closing SummaryClosing Summary

DefinitionsDefinitions CuringCuring

– To preserve or finish a surface by a chemical or physical To preserve or finish a surface by a chemical or physical processprocess

Ultraviolet (UV)Ultraviolet (UV) – Light radiation with a wavelength shorter than visible light but Light radiation with a wavelength shorter than visible light but

longer than X rayslonger than X rays

UV LED (Light Emitting Diode)UV LED (Light Emitting Diode)– A type of diode that emits ultraviolet lightA type of diode that emits ultraviolet light

UV LasersUV Lasers– A device that emits highly amplified and coherent radiation lightA device that emits highly amplified and coherent radiation light

AcknowledgementAcknowledgement

Craig Poolman, H&S Autoshot General Craig Poolman, H&S Autoshot General Manager Manager

Dr. Vikram Dalal, Iowa State University Dr. Vikram Dalal, Iowa State University ProfessorProfessor

Randy Freeman, Howard Industries Randy Freeman, Howard Industries engineerengineer

Advisors: Hillesland, Lamont, and Advisors: Hillesland, Lamont, and PattersonPatterson

Problem Statement Problem Statement

Goal: An automotive paint UV Curing Goal: An automotive paint UV Curing system with the following properties:system with the following properties:

– UV light within 320 nm – 360 nm range UV light within 320 nm – 360 nm range – Expand curing area (from 4” by 6” to 3’ by 4’)Expand curing area (from 4” by 6” to 3’ by 4’)– Portable Portable – Increased number of UV lamps used with a Increased number of UV lamps used with a

single transformersingle transformer

Operating EnvironmentOperating Environment

- Operated in a sheltered environment Operated in a sheltered environment

- Run by an auto body shopRun by an auto body shop

- Temperature range of 60 -120 FahrenheitTemperature range of 60 -120 Fahrenheit

- No personal contact with the device during No personal contact with the device during operationoperation

Intended Users and UsesIntended Users and Uses

Intended usersIntended users– Auto body repair shop personnelAuto body repair shop personnel

Intended usesIntended uses– To cure an automobile’s body paintTo cure an automobile’s body paint

AssumptionsAssumptions

The system operator is familiar with the The system operator is familiar with the devicedevice

The device cures 3 X 4 feet or smaller area The device cures 3 X 4 feet or smaller area of the automobile’s bodyof the automobile’s body

Moveable device to cure desired areaMoveable device to cure desired area 2 minutes curing process2 minutes curing process

LimitationsLimitations

The device works with the 60 Hz/120 V/20 The device works with the 60 Hz/120 V/20 Amp standard electrical systemsAmp standard electrical systems

320 nm – 360 nm range of UV light is a 320 nm – 360 nm range of UV light is a mustmust

Wavelength higher than 380 nm cannot be Wavelength higher than 380 nm cannot be used due to health reasonused due to health reason

Portability must be maintainedPortability must be maintained

Expected End ProductExpected End Product

Increased curing areaIncreased curing area Use of a single transformer for multiple UV Use of a single transformer for multiple UV

lampslamps Portable Portable EconomicalEconomical

Present AccomplishmentsPresent Accomplishments

Defined the ProblemDefined the Problem Researched AlternativesResearched Alternatives TestingTesting

– UV Filter GlassUV Filter Glass– Transformer Voltage and CurrentTransformer Voltage and Current– UV IntensityUV Intensity

Ordered PartsOrdered Parts

Approaches ConsideredApproaches Considered

UV LEDsUV LEDs UV LasersUV Lasers Alternative Reflectors, Lens, and Filter Alternative Reflectors, Lens, and Filter

GlassGlass Additional Lights Using Existing TransformerAdditional Lights Using Existing Transformer

Approached UsedApproached Used

Expansion on Existing SystemExpansion on Existing System

Limit Number of Bulky Transformers UsedLimit Number of Bulky Transformers Used

Ensure No Overloading of Customer’s Ensure No Overloading of Customer’s Electrical CircuitElectrical Circuit

Project DefinitionProject Definition

Increase Area CuredIncrease Area Cured– From 4” x 6” to approx 3’ x 4’From 4” x 6” to approx 3’ x 4’

Increase Number of Lamps per TransformerIncrease Number of Lamps per Transformer Keep Unit Size ReasonableKeep Unit Size Reasonable Use on Customer’s Existing Power SupplyUse on Customer’s Existing Power Supply

Research ActivitiesResearch Activities

UV LEDUV LED

Research Activities (cont.)Research Activities (cont.)

UV LEDsUV LEDs– ProsPros

Cheap, efficient, and small per LEDCheap, efficient, and small per LED Long life with no maintenance necessaryLong life with no maintenance necessary

– ConsCons No LED exists for desired wavelengthNo LED exists for desired wavelength Intensity too low for curing purposesIntensity too low for curing purposes

– Result: Not feasible at this timeResult: Not feasible at this time


UV LaserUV Laser


UV LasersUV Lasers– ProsPros

Very specific wavelength outputVery specific wavelength output High IntensityHigh Intensity

– ConsCons Small curing areaSmall curing area Large, expensive equipment neededLarge, expensive equipment needed Safety training necessary for operationSafety training necessary for operation

– Result: Price exceeds budget constraintsResult: Price exceeds budget constraints


ReflectorReflector UV LampUV Lamp


ReflectorReflector– Cone-shaped currently usedCone-shaped currently used– Circular output, desirable for curingCircular output, desirable for curing– Result: Continue using current reflectorResult: Continue using current reflector


UV LampUV Lamp– Medium Pressure Mercury-Arc (MPMA) lampMedium Pressure Mercury-Arc (MPMA) lamp– 300 Watts300 Watts– UV light and other light wavelengthsUV light and other light wavelengths– Result: Best light solution at this timeResult: Best light solution at this time


Filter GlassFilter Glass


Filter GlassFilter Glass– Filters out non-UV wavelengthsFilters out non-UV wavelengths– Tested at Applied Sciences Complex Tested at Applied Sciences Complex

by Dr. by Dr. Vikram DalalVikram Dalal

– Approximately 15% of energy lostApproximately 15% of energy lost– Result: Current filter glass will continue to be Result: Current filter glass will continue to be

usedused


Transfer Rate of UV LightTransfer Rate of UV Light


TransformerTransformer


TransformerTransformer– Currently use Howard Industries autotransformerCurrently use Howard Industries autotransformer– 120 VAC input, 120 VAC output120 VAC input, 120 VAC output– Capacitor used for power factor correction/voltage Capacitor used for power factor correction/voltage

stabilitystability– Ignitor used for starting lamp operationIgnitor used for starting lamp operation– Voltages and currents testedVoltages and currents tested

Both input and outputBoth input and output

– Result: Current transformer will continue to be usedResult: Current transformer will continue to be used

Technical DesignTechnical Design

Implementation ActivitiesImplementation Activities

Order Additional LampsOrder Additional Lamps– From H&S AutoshotFrom H&S Autoshot– Exact same as Lamp Currently UsedExact same as Lamp Currently Used

Alternative LensesAlternative Lenses– Testing ContinuesTesting Continues

Design Switching for New LampsDesign Switching for New Lamps– Mechanical Switches Selected Mechanical Switches Selected

Testing ActivitiesTesting Activities

Test 1: UV Filter GlassTest 1: UV Filter Glass– Dr. Dalal, Ames LaboratoryDr. Dalal, Ames Laboratory

Test 2: UV IntensityTest 2: UV Intensity– Spectrometer courtesy ISU Physics Dept.Spectrometer courtesy ISU Physics Dept.

Test 3: Alternative LensTest 3: Alternative Lens– Fresnel LensFresnel Lens– Convex LensConvex Lens

Test 4: Transformer Voltages and CurrentsTest 4: Transformer Voltages and Currents– Input and OutputInput and Output

Intensity Test ResultsIntensity Test Results

Intensity vs. Displacement

0

2

4

6

8

10

-9 -6 -3 0 3 6 9

Displacement from center

Inte

nsi

ty (

W/m

^2)

10in From Surface

16in From Surface

Personnel EffortsPersonnel Efforts

0

5

10

15

20

25

ho

urs

ProjectPlan

ProjectPoster

ProjectDesign

ProjectResearch

Ng Sui Kwan

Ong Vincent

Sidharta Raymond

Vetter Joseph

Financial RequirementsFinancial Requirements

Materials (Stand, Case, etc.)Materials (Stand, Case, etc.) $275.00$275.00

LampsLamps $69.76$69.76

TransformerTransformer $30.50$30.50

Miscellaneous partsMiscellaneous parts $25.00$25.00

Project poster Project poster $47.69$47.69

TotalTotal $448.22$448.22

Other ResourcesOther Resources

$50

$47.69

$150$374

Equipment

Project poster

ProjectImplementation

ProjectDocumentation

SchedulesSchedules

Schedule Gantt ChartSchedule Gantt Chart

Project EvaluationProject Evaluation

Research of All Possible Alternatives Research of All Possible Alternatives 100%100% Testing of Existing Components Testing of Existing Components 65%65% New Parts OrderingNew Parts Ordering 55%55% Testing of New SystemTesting of New System 40%40% Final Design DocumentationFinal Design Documentation 25%25%

CommercializationCommercialization

Cost of Existing Curing UnitCost of Existing Curing Unit $374.00$374.00

Additional Lamp and PartsAdditional Lamp and Parts $102.88$102.88

Total for New SystemTotal for New System $476.88$476.88

Estimated Resale PriceEstimated Resale Price $565.02$565.02

Additional WorkAdditional Work

Adapt Alternative Devices (LEDs or Lasers) Adapt Alternative Devices (LEDs or Lasers) as They Become Available on the Marketas They Become Available on the Market

Research Alternative ReflectorsResearch Alternative Reflectors Additional Testing for Increasing Device to Additional Testing for Increasing Device to

Surface Distance Surface Distance Research Alternative Power Supplies Research Alternative Power Supplies

Lessons LearnedLessons Learned

Time ManagementTime Management CommunicationCommunication OrganizationOrganization Major Specific InformationMajor Specific Information

– Power ConsumptionPower Consumption– Basic Circuit Devices (Lamps, Transformers, Basic Circuit Devices (Lamps, Transformers,

Capacitors, LEDs, etc.)Capacitors, LEDs, etc.) Non-major Specific InformationNon-major Specific Information

– UV LasersUV Lasers– UV Light SafetyUV Light Safety

Risk and Risk ManagementRisk and Risk Management

Loss of Team Member(s)Loss of Team Member(s)– Central Location for all DocumentsCentral Location for all Documents

Late Arrival of Parts and EquipmentLate Arrival of Parts and Equipment– Order in AdvanceOrder in Advance– Select AlternativesSelect Alternatives

Equipment DamageEquipment Damage– Keep Back Up Equipment on HandKeep Back Up Equipment on Hand

Closing SummaryClosing Summary

New UV Curing System will:New UV Curing System will:– Increase Curing Area vs. Current SystemIncrease Curing Area vs. Current System– Be Portable and Easily ShippedBe Portable and Easily Shipped– Economical for Auto Body Shops to Purchase Economical for Auto Body Shops to Purchase

and Useand Use

Questions?Questions?