Transcript Temperature Controller for Infrared Paint Curing

Temperature Controller for Infrared Paint
Curing
September 13, 2001
Dec01-11 Team Members
Project Faculty Advisors
Michael Burman, CprE
Dr. John Lamont
Jonathan Johnson, EE
Matthew McMullen, CprE
Dr. Ralph Patterson
Project Client
Tom Vedder, EE
Mark Wibholm, EE
H&S Autoshot
Centerville, IA
Presentation Outline
• 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?
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
sensor must operate without contacting the surface.
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 require various curing times and temperatures
Design Objectives (cont.)
Intended Users
• Auto body 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
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
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
End-Product Description (cont.)
Temperature sensor detects room temperature
Upper level temperature has been reached
Upper level temperature is set to 90 degrees Fahrenheit
Assumptions
• Temperature controller will display the temperature of the
surface
• Temperature sensor will be accurate within ±2° Fahrenheit
• 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
• Limited electrical technology knowledge of users implies that the
device should be simple to operate
Limitations
• Paint surface cannot be touched to detect temperature
• Device must be mobile
• Temperature sensors and controllers may be very expensive
• Project completion time is limited
• Temperature sensor accuracy decreases as distance from the
surface increases
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
Technical Approach
• Utilize infrared temperature sensor to read surface temperature
• Utilize the temperature controller to select, set, and control
parameters of the process
• Utilize temperature controller to regulate lamp temperature
• Continue to read and adjust surface temperature until curing is
complete
Technical Approach (cont.)
Evaluation of Project Success
1st Semester Milestones
• Project Plan (Fully Met)
• Project Poster (Fully Met)
• Design Report (Fully Met)
• Select temperature controller (Partially Met)
• Select non-contact infrared temperature sensor (Fully Met)
• Learn how to use temperature controller and how to program it
(Fully Met)
Evaluation of Project Success (cont.)
2nd Semester Milestones
• System Implementation (Partially Met)
• Test paint curing system (Partially Met)
• Complete all project documentation (Partially Met)
• Final Report (Not Started)
• Present project (Not Started)
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
Human Budget
Human Budget (to date)
Estimated
Actual
0
100
200
Hours
300
400
Financial Budget
Item
Estimated Cost
Actual Cost
Microprocessor temperature controller
$ 250
$0
Temperature sensor
$ 90
$0
Poster
$ 50
$50
Wiring and other connection materials
$ 50
$0
Total estimated cost
$ 440
$50
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
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
Questions