Design and Implementation of an ImprovedControl Algorithm for CompactEngineering’s Infrared Paper Dryers(Mid-Project Report)May 11, 2005Team Members: Michael R. FrostMatthew R. HarveyKellin M. Lang-GillmingProject Sponsor: Dr. Joe LawProject Advisor: Dr. Joe LawiTable of ContentsTable of Contents......................................................................................... iAbstract...................................................................................................... iii1. Project Description ..................................................................................11.1 Background................................................................................11.2 Problem Statement.....................................................................21.3 Objectives ..................................................................................21.4 Solution Method ........................................................................22. Design Procedures ...................................................................................32.1 Demonstration of Concept .........................................................32.2 Lamp Characterization...............................................................42.3 Scaled Model Dryer ...................................................................53. Scaled Dryer Model Subsystems .............................................................63.1 Firing Controller / Firing Algorithm..........................................63.1.1 Purpose / Function ......................................................63.1.2 Specifications..............................................................73.1.3 Methods ......................................................................73.1.4 Status...........................................................................93.2 Power Supply.............................................................................93.2.1 Purpose / Function ......................................................93.2.2 Specifications..............................................................93.2.3 Methods ......................................................................93.2.4 Status.........................................................................103.3 Zero Cross Detector .................................................................103.3.1 Purpose / Function ....................................................103.3.2 Specifications............................................................103.3.3 Methods ....................................................................103.3.4 Status.........................................................................113.4 Switching Hardware.................................................................113.4.1 Purpose / Function ....................................................113.4.2 Specifications............................................................113.4.3 Methods ....................................................................123.4.4 Status.........................................................................133.5 Power Computer Simulator......................................................133.5.1 Purpose / Function ....................................................133.5.2 Specifications............................................................133.5.3 Methods ....................................................................143.5.4 Status.........................................................................143.6 Serial-Parallel Logic ................................................................143.6.1 Purpose / Function ....................................................143.6.2 Specifications............................................................143.6.3 Methods ....................................................................153.6.4 Status.........................................................................15ii4. Test Procedure .......................................................................................154.1 SDM Hardware Test Procedure...............................................154.2 SDM Control Algorithm Test Procedure.................................165. Results....................................................................................................175.1 Operating Procedures...............................................................175.1.1 Demonstration of Concept ........................................175.1.2 Lamp Characterization Models.................................175.2 Validation Results....................................................................185.3 Cost Analysis ...........................................................................196. Acknowledgements................................................................................20Appendix A: Lamp CharacterizationA.0 Overview................................................................................A1A.1 Bulb Dimensions....................................................................A1A.2 Bulb Resistance and Temperature..........................................A3A.3 Bulb Specific Heat .................................................................A9A.4 Bulb Conduction Losses and Emissivity .............................A11A.5 Steady State Model ..............................................................A13A.6 Transient Model ...................................................................A18A.7 Transient Experimental Setup and Results ..........................A18Appendix B: Project SpecificationsB.1 Design Specifications for the SDM........................................B1B.2 Design Specifications for the DOC........................................B2B.3 Environmental Specifications ................................................B3Appendix C: DOC DocumentationC.0 Schematics..............................................................................C1C.1 Bill of Materials .....................................................................C3C.2 Assembler Code .....................................................................C4Appendix D: Individual ReportsD.1 Michael Frost .........................................................................D1D.2 Matthew Harvey.....................................................................D2D.3 Kellin Lang-Gillming.............................................................D4iiiAbstractThe infrared
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