Temperature Controller for Infrared Paint Curing December 12, 2001

1. Dec01-11 Team Members Michael Burman, CprE Jonathan Johnson, EE Matthew McMullen, CprE Tom Vedder, EE Mark Wibholm, EE Project Faculty Advisors Dr. John Lamont Dr. Ralph Patterson Project Client H&S Autoshot Centerville, IA Temperature Controller for Infrared Paint CuringDecember 12, 2001

2. H&S Autoshot Profile • Based in Centerville, Iowa • Specialize in devices used in autobody shops • A leader in paint curing systems

3. Problem Statement Design Objectives Operating Environment End-Product Description Assumptions Limitations Project Risks and Concerns Technical Approach Evaluation of Project Success Recommendations for Further Work Human Budget Financial Budget Lessons Learned Closing Summary Questions? Presentation Outline

4. Problem Statement Design a temperature controller to automate paint curing on automobiles using infrared lamps. The lamps must vary the surface temperature throughout the curing process. The temperature sensor must operate without contacting the surface.

5. Design Objectives Functionality of Temperature Controller • Sets infrared lamps to various specified temperatures • Holds temperature of curing surface for specified amount of drying time • Applies two stages of heating • Shuts off lamps when drying cycle is finished Design Constraints • Device must be small enough to mount on lamp stands  • Paint surface cannot be touched • Paint types and surfaces require various curing times and temperatures

6. Design Objectives (cont.) Intended Users • Autobody repair technicians and mechanics Intended Use • Automate paint curing process Intended Advantages • Reduce drying time from 2 days to 15 minutes • Increase production and efficiency of vehicle painting • Increase accuracy of curing process

7. Operating Environment • Temperatures may range from above 150° F to below freezing temperatures when stored • High amounts of dust and other contaminants especially solvents • Device may be knocked around or tipped over

8. End-Product Description A microprocessor-based temperature controller that automates the automobile paint curing process by: • Regulating infrared lamps • Receiving input from a non-contact sensor that reads the surface temperature • Using an internal timer to alter the temperature for various curing stages • Ending the curing process by switching off the lamps

9. End-Product Description (cont.)

10. End-Product Description (cont.) Phase 1: Surface temperature has reached set point of 120° F and is held for approximately 2 minutes Phase 2: Program has changed the set point to 150° F and will hold it for approximately 2 minutes Sample Program Running

11. Assumptions • Temperature controller will display the temperature of the curing surface • Temperature sensor will be accurate within ±2° Fahrenheit • Temperature Controller timer will be accurate within ±5 seconds • Curing surface will be maximum of 4 square feet • Curing lamp will provide uniform temperature coverage over the entire curing surface (maximum 2 feet in one direction) • Curing lamps will not directly affect infrared temperature sensor readings of the paint surface

12. Assumptions (cont.) • Limited electrical technology knowledge of users implies that the device should be simple to operate • No parallel systems will run on the same curing surface • Solid state relay (SSR) will increase power output from temperature controller to curing lamps • Temperature sensor and infrared lamp wires will not interfere with each other

13. Limitations • Paint surface cannot be touched to detect temperature • Device must be mobile • Limited budget of $450 to create system • Temperature sensors range from $75-$200. • Temperature controllers are typically more than $250 • SSRs range from $100-$200 • Project completion time is limited

14. Limitations (Cont.) • Temperature sensor accuracy decreases as distance from the surface increases • Distance between Ames and Centerville • Controller must be able to fit in protective box

15. Project Risks and Concerns • Unfamiliar technology • Loss of a critical person may occur • Testing the finished product may be difficult due to location • Time to complete the project is limited

16. Technical Approach • Utilize infrared temperature sensor to read surface temperature • Utilize the temperature controller to select, set, and control parameters of the process such as surface temperature and curing stage time. • Utilize a Solid State Relay (SSR) to increase the power output from the temperature controller to levels that will power the lamps. • Continue to read and adjust surface temperature until curing is complete

17. Technical Approach (cont.)

18. Evaluation of Project Success 1st Semester Milestones • Project Plan (Fully Met) • Project Poster (Fully Met) • Design Report (Fully Met) • Select temperature controller (Fully Met) • Select non-contact infrared temperature sensor (Fully Met) • Learn how to use temperature controller and how to program it (Fully Met)

19. Evaluation of Project Success (cont.) 2nd Semester Milestones • System Implementation (Fully Met) • Test paint curing system (Fully Met) • Complete all project documentation (Fully Met) • Final Report (Fully Met) • Present project (Fully Met)

20. Recommendations for Future Work • Utilize an advanced temperature controller with large amounts of memory to store curing times for many different paints • Ability to control more than one bank of lights simultaneously

21. Human Budget

22. Financial Budget

23. Lessons Learned • Methods used in the paint curing industry • How to program a temperature controller • How infrared temperature sensors work • Meet at least once a week with group members • Contact advisors and professors for advice and feedback • You can plug wires into the wall and have it work • When someone says “Alright guys stand back,” take them seriously

24. Closing Summary The finished system will: • Automate paint drying process • Increase productivity, efficiency, and accuracy of paint drying process • Decrease drying time from 2 days to 15 minutes

25. Questions