Paint Heat Lamp Power and Control System

1. Dec 03-03 Paint Heat Lamp Power and Control System December 9, 2003 Client: H & S Autoshot Team Members: Sui Kwan Ng Vincent Ong Raymond Sidharta Joseph L. Vetter Faculty Advisors: Dr. John W. Lamont Prof. Ralph E. Patterson Prof. Glenn G. Hillesland

2. 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 Presentation Outline

3. 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

4. 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

5. 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

6. Operating Environment • 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

7. Intended Users and Uses • Intended users • Auto body repair shop personnel • Intended uses • To cure an automobile’s body paint

8. 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

9. 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

10. 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

11. Present Accomplishments • Defined the Problem • Researched Alternatives • Testing • UV Filter Glass • Transformer Voltage and Current • UV Intensity • Ordered Parts • Documented Research and Testing

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. Research Activities (cont.) Transfer Rate of UV Filter Glass

20. 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

21. 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

22. 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

23. 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

24. Technical Design 8 Lamp Ballast and Control Box

25. Technical Design (cont.) 8 Lamp Curing Arrangement

26. 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

27. 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

28. Intensity Test Results

29. Current and Voltage Testing Results

30. Personnel Efforts

31. Financial Requirements

32. Other Resources

33. Schedules Schedule Gantt Chart

34. Project Evaluation • Research of All Possible Alternatives 100% • Testing of Existing Components 100% • New Parts Ordering 55% • Testing of New System 40% • Final Design Documentation 100%

35. Commercialization

36. 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

37. 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

38. 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

39. 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

40. Questions?