Paint Heat Lamp Power and Control System

1. Figure 1: UV Curing System Figure 5: Existing UV Lamp Circuit Diagram Total = 350 hours Figure 2: Personnel Effort Figure 6: Schedule gantt chart Total = $1250.00 Total = $4855.00 Figure 3: Estimated Resources w/o Labor Figure 4: Estimated Resources w/Labor Paint Heat Lamp Power and Control System Dec 03-03 Client Information H&S Autoshot, Inc.1318 Max Joseph RoadP.O. Box 623 Centerville, IA 53544Autoshot@lisco.net Group Members Sui Kwan Ng                         brianng@iastate.edu            EE Vincent Wen-Yuan Ong        vinceong@iastate.edu          EE Raymond Sidharta                 raymond@iastate.edu          EE Joseph L. Vetter                    jlvetter@iastate.edu            EE Faculty Advisors John W. Lamont jwlamont@iastate.edu Ralph E. Patterson repiii@iastate.edu Glenn G. Hillesland hilles@iastate.edu Abstract Project Requirements Using ultraviolet (UV) light to cure paint is a new process in the field of auto body repair. H&S Autoshot, Inc., of Centerville, Iowa, currently produces a small curing system (Figure 1) using a single UV lamp that can cure only an area of approximately 16 by 16 inches. The purpose of this project is to research methods for H&S to increase the curing area to roughly 3 by 4 feet. Expansion can be accomplished by adding more lamps, or by utilizing new technologies such as UV LEDs and UV lasers. The final design of the project shall report a grouping of components that will provide for a large curing area while having an economical cost to both H&S and their customers. • Design Objectives • Create a curing system to cure larger areas of automobile’s paint • Reducing the number of transformer s used to bring the cost down • Explore alternative technologies (UV lasers and LEDs) to create upgraded and advanced curing system • Functional Requirements • Cures approximately 3 by 4 feet area • Light output wavelength of 320 to 360 nanometers • Moveable • Design Constraints • The device works with the 60 Hz/120 V/20 A standard electrical systems • Minimum distance from device to curing surface is 10 inches • Low power consumption • Measurable MilestonesThe following milestones will be used to measure the progress of the project: • Phase 1: Alternative UV technology research Phase 2: Criteria generation, evaluating advantages and disadvantages Phase 3: System design with constraints Phase 4: Design implementation/ prototype building Phase 5: Data compiled into project documentation Introductory Information • Problem Statement • Expanding the capabilities of an auto repair paint drying system that uses newly developed ultraviolet (UV) light activated paint. This includes increasing the surface area treated, reducing the number of components used, and ability to flexibly adjust to cover all areas of the surface. • Operating Environment • Operating conditions are a typical auto body repair shop. Normal traits are temperatures of between 80 to 120 degrees Fahrenheit, extreme noise, dusty conditions, and hazardous gases. • Intended Users and Uses • Users of the curing system will be auto-body repair facility employees. • The curing system will be used with UV-curable paints only. • Assumptions • The clients are familiar with the operation of the device • The device is moveable and able to cure large areas • The curing process is approximately 2 minutes • Limitations • Current UV technologies and team members knowledge • The project must be completed within the client’s budget and time • Contact with client is limited due to travel distance • Expected End Product and Other Deliverables • This project presents a study of alternative ultraviolet curing system. The final product will be a report to H&S Autoshot documenting research and showing the benefits and drawbacks for various types of curing systems. Proposed Approach and Considerations • Proposed Approach • We first met with client to see what end product they want and define our project, and then we started doing research on alternatives solutions. From the research we will choose one of the best solution and go into design stage. Finally, we will work on the report with our final design and all the alternative solutions as well. • Technologies Considered • The main technologies considered for this project: • Research on the existing system (Figure 5) to see if expansion is possible • Research on UV LEDs technologies • Research on UV laser and other solid state devices to see if they can incorporated into the current UV curing system • Testing Considerations • Test prototype to be built and tested under various conditions • Communication maintained with client concerning key issues via email Estimated Resources Shown below are charts that give estimated values for the resources to be used for this project. Figure 2 lists the personnel efforts of each team member. The estimated costs for all items to be used in the project are shown in Figure 3. Finally, the total estimated costs for the items used and labor resources consumed are shown in Figure 4. Schedule Shown below is a gantt chart for the project schedule. Different phases and tasks are drawn with different time bars. Closing Summary This project will determine the different ways of expanding the area to be cured and list the positive and negative aspects of every discovered method. H&S Autoshot will use the group’s findings to produce a curing system that has an increase of surface area while still being relatively economical for its customers.