Paint Heat Lamp Power and Control System Team Members: Sui Kwan Ng Vincent Ong Raymond Sidharta Joseph L. Vetter December 9, 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 16” circle to 3’ by 4’) –Portable –Increased number of UV lamps used

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 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  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 Mercury- Arc (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

Current and Voltage Testing 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 100%  New Parts Ordering55%  Testing of New System40%  Final Design Documentation100%

Commercialization Cost of Existing Curing Unit (Market Price) Cost of Existing Curing Unit (Market Price)$ Additional Lamp and Parts Additional Lamp and Parts$ Total for New System Total for New System$ Estimated Resale Price $

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  Time Management  Communication  Organization  Major Specific Information –Power Consumption –Basic Circuit Devices (Lamps, Transformers, Electronic Ballasts, Capacitors, LEDs, etc.)  Non-major Specific Information –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?