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 Dec 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 Project Activities  Accomplishments  Approaches  Project Definition  Research Activities  Design Activities  Implementation Activities Resources and Schedules  Resource Requirements  Schedules Closing Materials  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 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

Personnel Efforts

Financial Requirements Materials (Stand, Case, etc.) Materials (Stand, Case, etc.)$ Lamps Lamps$69.76 Transformer Transformer$30.50 Miscellaneous parts Miscellaneous parts$25.00 Project poster Project poster$47.69 Total$448.22

Other Resources

Schedules Schedule Gantt Chart

Project Evaluation  Research of All Possible Alternatives 100%  Testing of Existing Components 65%  New Parts Ordering55%  Testing of New System40%  Final Design Documentation25%

Commercialization Cost of Existing Curing Unit Cost of Existing Curing Unit$ Additional Lamp and Parts Additional Lamp and Parts$ Total for New System Total for New System$ 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?