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Design of Automatic Car Washing System and Construct Prototype
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1. INTRODUCTION:
Currently necessity of man is to live life in automatic way so as to perform tasks at higher speed.
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Technology is best interconnecting channel in each part of world with the means of transportation or communication or business which led to a highly increase in the number of cars. So how to maintain or clean those? Using automated washing system? All peoples face big issue called as Time i.e. time consumption essential for cleaning these vehicles or cars etc. Time management is directly proportional to reduction of cost for maintenance. Project helps us to use a conveyor belt on which customer stop the car. After it switch detector is used for detecting the car then conveyor belt start moving. Sensor plays vital role on conveyor belt for car detection. As soon as car is sensed functioning of conveyor assembly invokes. After specified delay for all activities to perform conveyor get stops. The main objective of this project is to perform exterior car washing automatically using Programmable Logic Controller integrated with PLC sends information like arrival or departure of vehicle. Car washing technique is collection of various things as spraying solution of detergent, cleaning with water and brushes, & then completing task with forced air drying fans.
Fig.1.1 Rotating brushes [3]
The first automatic car washes appeared in the late 1930s. Automatic car washes consist of tunnel-like buildings into which customers (or attendants) drive. Some car washes have their customers pay through a computerized point of sale unit (POS), also known as an "automatic cashier". The mechanism inputs the wash Programming Logic Controller (PLC) into a master computer or a tunnel controller automatically. When the sale is automated, after paying the car is put into a line-up often called the stack or queue. The stack moves sequentially, so the wash knows what each car purchased. After pulling up to the tunnel entrance, an attendant usually guides the customer onto the track or conveyor. At some washes, both tires will pass over a tire sensor, and the system will send several rollers. The tire sensor lets the wash know where the wheels are and how far apart they are. On other systems the employee may guide the customer on and hit a 'Send Car' button on the tunnel controller, to manually send the rollers which push the car through. When the customer is on the conveyor, the attendant will instruct the customer to put the vehicle into neutral, release all brakes, and refrain from steering. Failure to do so can cause an accident on the conveyor. The rollers come up behind the tires, pushing the car through a detector, which measures vehicle length, allowing the controller to tailor the wash to each
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individual vehicle. The equipment frame, or arches, vary in number and type. [1]
Fig.1.2 A vehicle in the high pressure rinse stage of the wash. [2]
A good car wash makes use of many different pieces of equipment and stages of chemical application to thoroughly clean the vehicle. Also visible is the conveyor. The carwash will generally start cleaning with pre-soaks applied through special arches. They may apply a lower pH (mild acid) followed by a higher pH (mild alkali), or the order may be reversed depending on chemical suppliers and formula used. Chemical formulas and concentrations will also vary based upon seasonal dirt and film on vehicles, as well as exterior temperature, and other factors. Chemical dilution and application works in combination with removal systems based on either high pressure water, friction, or a combination of both. Chemical substances, while they are industrial strength, are not used in harmful concentrations since car washes are designed not to harm a vehicle's components or finish. The customer next encounters tire and wheel nozzles, which the industry calls Chemical Tire Applicators (CTA). These will apply specialized formulations, which remove brake dust and build up from the surface of the wheels and tires. The next arch will often be wraparounds, usually made of a soft cloth, or closed cell foam material. These wraparounds should rub the front bumper and, after washing the sides, will follow across the rear of the vehicle cleaning the rear including the license plate area. [1] Past the first wraps or entrance wraps may be a tire brush that will scrub the tires and wheels. This low piece is often located beneath a mitten (the hanging ribbon-like curtains of cloth that move front to back or side to side) or top wheels. There may also be rocker panel washers which are shorter in size (ranging in size from 18 inches [45 cm] up to 63 inches [160 cm] tall) that clean the lower parts of the vehicle. Most rocker brushes house the motor below the brush hub so they don't inhibit cloth movement and allow the brush to be mounted under a support frame or below a mitten. Some car washes have multiple mittens, or a combination of mittens and top brushes after the mutter or top brushes the car may pass through a second set of wraparounds. This may also be where high pressure water streams are used to clean difficult to reach parts of the vehicle. The car generally passes over an under carriage wash and/or has high pressure nozzles pointed at it from various positions. Next may be a tire spinner, High pressure nozzles angled specifically to clean wheels and tires. [1]
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After the several wash stations the vehicle may go through triple foamers, usually red, blue, and yellow, although colours can be customized with higher end chemical suppliers. The triple foam process includes special cleaners as well as some protective paint sealant. Protectants vary by manufacturer. Near the rinse is where a tire shining machine is often installed, which is designed to apply silicone tire dressing to the tires. This application makes the tires look good (new, and glossy) and preserves the rubber. Next the vehicle is treated with a drying agent and a final rinse. Many carwashes utilize a "spot free" rinse of soft water that has been filtered of chlorine and sent through semi permeable membranes to produce highly purified water that will not leave spots. After using spot free water, the vehicle is finished with forced air drying, in some cases utilizing heat to produce a very dry car. [1]
Fig.1.3 Interior view [3]
Older automatic washes-a majority of which were built prior to 1980-used to use brushes with soft nylon bristles, which tended to leave a nylon deposit in the shape of a bristle, called brush marks, on the vehicle's paint. Many brushes in the US are now either cloth (which is not harmful to a car's finish, as long as it is flushed with plenty of water to remove the grit from previous washes), or a closed cell foam brush, which does not hold dirt or water, thus is far less likely to harm any painted finish, and can, in fact, provide a gentle polishing effect to leave the paint much shinier. In order to avoid paint marking issues, "touch less" or "no-touch" car washes were developed. This means the car is washed with high water pressure instead of brushes. There is no contact with friction so the chance of any damage is less, however the actual cleaning, or removal of film from the paint, is nearly impossible with no touch systems. At "full-service" car washes, the exterior of the car is washed mechanically with conveyor equipment, or in some cases by hand, with attendants available to dry the car manually, and to clean the interior (normally consisting of cleaning the windows, wiping the front and side dashes, and vacuuming the carpet and upholstery). Many full service car washes also provide "detailing" services, which may include polishing and waxing the car's exterior by hand or machine, shampooing and steaming interiors, and other services to provide thorough cleaning and protection to the car. [2]
2. LITERATURE SURVEY:
2.1 Introduction:
· Mr. Abhishek Pansare, Ms. Priyanka Yadav, Ms. Vrushali Thigale, Mr. S.C.Rajgade, “PLC Based Automatic Car Washing System”, The main objective of this research is to perform exterior car washing automatically using Programmable Logic Controller integrated with PLC sends information like arrival or departure of vehicle. Car washing technique is collection of various things as spraying solution of detergent, cleaning with water and brushes, & then completing task with forced air drying fans.
· Mr. sreenivasa reddy, ch. vidya, ch. hinduja, d soumith, k pavankumar, “Automatic car washing system with is module using conveyor belt”, In this project we are using AT mega 16 Microcontroller, motor drivers IC’s and relay motor drivers to drive the DC motors with the regulated power supply to run the respective motors to fulfil the output requirement.
· P.B.Patel, S.V.Rokade, P.S.Tujare, “Automatic car washing system”, the main aim of our project is use less water, more efficient washing. Practically at home we use 150 gallons of water but using this process 35 gallons of water gets used up. By using this process we can clean up the car up to 95.
· Nidhi Bhatia, jayana rana, (International journal of innovative research in technology) Our car washing system has three main processes namely washing, cleaning & drying, hence the exterior of the car will be washed by detecting the car on conveyor belt & further controlled by PLC & SCADA.
· Akilandeswari.k, Haripriya.j, Sangavi Nirmala.v, (International journal of innovative research in science, engineering & technology), The main objective of this paper is to perform exterior car washing automatically used in PLC Integrated with GSM modem. GSM-PLC sends information like entry, exit of entry, emergency conditions to the customer or operator through SMS. After acquiring the information from PLC, the operator can able to act upon it.
2.2 Market Survey:
Car washing systems are the systems that are being used for cleaning the exteriors and interiors of the cars. It facilitates easy washing and cleaning of the automobile. The growth in automotive industry leads to an increase in demand for the car wash systems. The other factors driving the growth of the car wash systems market are the increase in production and sales of vehicles, reduced instances domestic car washing, and high disposable income. Also, the growth of the market is driven by features such as improved efficiency, higher safety, easy management, reliability and time efficiency.
Car washing systems are very common in developed countries. These systems are fully automated with different stages of rinsing, shampooing, washing, and drying. Consumers are becoming more aware of the benefits of car wash services such as improved efficiency and safety. Also, the increasing environmental awareness among people is driving the growth of car wash services, which ensures optimal deployment of water resources and proper dumping of solid waste, thus helping the growth of market for car wash systems. Using an automatic car wash service, is a good way to be environmentally conscious and protect the resale value of the car. Automatic car washes also save water, reduce groundwater pollution, and retain the car’s paint and finish. Technological advancement and heavy investments in car wash systems also add to the car wash system market. There is an increase in the need for professional car cleaning organizations, which are capable of providing flawless car cleaning. So, there is high demand for a professional and reliable cleaning brand over the forecast period. Other factors contributing growth of the market are continuous rise in industrialization, increasing new car registrations, decline in gasoline prices and lower interest rates on loans. Increase in the installation of mechanized and automated car wash systems is further propelling the growth of the market. Consumers have become smarter and machine savvy. Hence, there will be growth in the car washing system market during the forecast period. However, the growth of the market is expected to be restrained by the high cost associated with manufacturers along with the low degree of awareness among consumers. Owing to this, the global car wash systems market is expected to expand with a CAGR of approx. 3% over the forecast period.
2.3. Regional Analysis:
Asia Pacific is dominating the market of car wash system due to the growth of the automotive industry. With the global economy undergoing an unprecedented level shift, major developing countries in Asia Pacific region such as China, India, Thailand, and Indonesia have become manufacturing hubs for global automotive players. The income levels of individuals have been steadily increasing, resulting in a rise in their disposable income. The currently booming automotive industry, combined with steadily increasing disposable income, is expected to contribute significantly in the growth of the market. The automotive repair shops and dealers are focusing on the installation of car wash systems for easy washing and cleaning of cars on a large scale.
Car washing systems are the systems that are being used for cleaning the exteriors and interiors of the cars. It facilitates easy washing and cleaning of the automobile. The growth in automotive industry leads to an increase in demand for the car wash systems. The other factors driving the growth of the car wash systems market are the increase in production and sales of vehicles, reduced instances domestic car washing, and high disposable income. Also, the growth of the market is driven by features such as improved efficiency, higher safety, easy management, reliability and time efficiency.
Car washing systems are very common in developed countries. These systems are fully automated with different stages of rinsing, shampooing, washing, and drying. Consumers are becoming more aware of the benefits of car wash services such as improved efficiency and safety. Also, the increasing environmental awareness among people is driving the growth of car wash services, which ensures optimal deployment of water resources and proper dumping of solid waste, thus helping the growth of market for car wash systems. Using an automatic car wash service, is a good way to be environmentally conscious and protect the resale value of the car. Automatic car washes also save water, reduce groundwater pollution, and retain the car’s paint and finish. Technological advancement and heavy investments in car wash systems also add to the car wash system market. There is an increase in the need for professional car cleaning organizations, which are capable of providing flawless car cleaning. So, there is high demand for a professional and reliable cleaning brand over the forecast period. Other factors contributing growth of the market are continuous rise in industrialization, increasing new car registrations, decline in gasoline prices and lower interest rates on loans. Increase in the installation of mechanized and automated car wash systems is further propelling the growth of the market. Consumers have become smarter and machine savvy. Hence, there will be growth in the car washing system market during the forecast period. However, the growth of the market is expected to be restrained by the high cost associated with manufacturers along with the low degree of awareness among consumers. Owing to this, the global car wash systems market is expected to expand with a CAGR of approx. 3% over the forecast period.
3. MOTIVATION
The car wash industry has been in an upward trend for the past few years and many are asking the question “where is the car wash industry heading?” There have been a number of articles and conversations about this subject, however I believe that most of them just reiterate what is actually happening in the industry right now. I believe the car wash industry is headed to an exciting place in the next in the next 5 to 10 years, but it will look a lot different. Focusing, understanding and marketing towards millennials is the key to the next generation of successful car washing businesses. Millennials have exponential purchasing power and influence in their social networks. Their influence can already be seen in other industries like the toy, beauty and restaurant industries. These industries are already altering their business models to compete in this new arena. I believe that the car wash industry will continue to grow and change at an extreme pace and will weed out the businesses that fail to keep up with the times. Below is a list of changes that I feel will really speak to the next generation of car wash industry leaders [2]
3.1 Speed of Service:
The tunnels are already pretty efficient in this regard but the name of the game is speed of service and Intermediate Bus Architecture (IBA) will get faster and faster, time is money in all regards. This type of equipment will need to stand the test of time and be able of washing 30 plus cars per hour. Do not be fooled with perceived value, we as a society, are so strapped for time and people will pay more for less time. 30 second wash in the future? I wouldn’t bet against it. [2]
3.2 Automation:
Automation will continue to increase at a spectacular pace and we will have systems in place to monitor our doors, chemicals, temperatures, rails and other pieces of equipment. These systems will notify us even better and faster of problems or preventative maintenance issues making the owners more and more passive. [2]
4. METHODS OF CAR WASHING
4.1 Manual car washing:
The manual car washing is widely used method. This system required less space and it is economical. Washing of car is done by hand wash .the device required for this system are water spray gun, water treatment system, Submersible Pumps hand Cuffs. The main disadvantage of that process is time consuming. [1]
Washing the Car Body:-
In order to avoid dips scratches the vehicle must be rinsed before sponge is applied. Make sure that the section of the vehicle that is being washed is wet, dip the sponge into water and wet for it absorbs soap water. Squeeze sponge repeatedly. And apply it on the roof of the vehicle in straight method. [1]
Washing the wheel:-
Wheel are clean by the soap solution and wheel brush. Rinsing all the soap off of the vehicle being at the top and spread downward. To avoid splashing soap back upto the top of vehicle. As much as possible dry the vehicle throughout to prevent water spot and corrosion. Car dry by the cloth. [1]
Procedure:
· Clean wheels and tires:-
Fig.4.1.1 Clean wheels and tires
· Exterior Prewash:-
Fig.4.1.2 Exterior Prewash
· Foaming:-
Fig.4.1.3 Foaming
· Post wash:-
Fig.4.1.4 Post wash
· Drying:-
Fig.4.1.5 Drying
4.2 Semi-Automatic Car washing System:
In semi-automatic car washing system it is a combination of automatic and semi-automatic car washing system.it performs reliable operatons.in this system we use bulgers rollers for the purpose of washing wheels and car body it takes less time as compared to manual car washing system. It enhance fine quality of car washing.
Procedure:
· Manual wheels & exterior washing:-
Fig.4.2.1 Manual wheels & exterior washing
· Automatic pre Exterior washing:-
Fig.4.2.2 Automatic pre Exterior washing
· Foaming:-
Fig.4.2.3 Foaming
· Post Washing:-
Fig.4.2.4 Post Washing
· Drying:-
Fig.4.2.5 Drying
4.3 Automatic Car Washing System:
Mainly the car wash system works on the principal, that the water and solution is release with pressure of the nozzle and water can release either individually or with the solution. This device discloses a power driven rotary brush mounted in a handle with water and detergent, or soap inlet means and means to discharge the water, with or without the soap, on to the brush.
The main invention in this system is that the sponge type brush is rotated with the help of an electric motor which is fitted into the handle or the nozzle. Another criteria used in this system is that the pressure and the speed of the water flowing or coming out through the nozzle can be control during washing and rinsing of the vehicle. Also the solution and the water is separated with to different pipes which comes in nozzle or handle through the pump. After the vehicle is wash with soap or detergent suds the vehicle may be rins by cutting of the supply of soap or detergent.
· Procedure:
1. Entry of car
2. Pre-wash
3. Foam Wash Section
4. Brushing
5. Clean Wash Section
6. Drying Section
7. Exit
5. TIME STUDY:
5.1 Manual car washing system:
Fig.5.1.1 Manual Car wash [1]
The manual car washing is widely used method. This system required less space and it is economical. Washing of car is done by hand wash .the device required for this system are water spray gun, water treatment system, Submersible Pumps hand Cuffs. In Comparison of semi-automatic and automatic car washing time required for manual car washing is more. There are many chances of human error.
· Procedure:
1. Clean wheels and tires.
2. Wash exterior.
3. Foaming
4. Washing
5. Drying
Table No. 5.1.1 Manual Car Wash Time Study
Sr. No. | Procedure | Process Time | Idle Time(Between Two Process In Min) | Total time required (in and out, in Min.) |
(In Min) | ||||
1 | Clean Wheel And Tire | 13 | - | 13 |
2 | Prewash | 12 | 1 | 26 |
3 | Foaming | 7 | 2 | 35 |
4 | Post wash | 10 | 1.5 | 46.5 |
5 | Drying | 10 | 1 | 58.5 |
| Total | 52 | 5.5 | 58.5 |
5.2 Semi-automatic:
Fig.5.2.1 Semi-Automatic Car Washing System
In semi-automatic car washing system it is a combination of automatic and semi-automatic car washing system.it performs reliable operatons.in this system we use bulgers rollers for the purpose of washing wheels and car body it takes less time as compared to manual car washing system. It enhance fine quality of car washing.
· Procedure:
1. Manual wheels & exterior washing
2. Automatic Exterior washing
3. Foaming
4. Washing
5. Drying
Manual operations:
Table No. 5.2.1 Semi-Automatic: Manual Operation
Sr. No. | Procedure | Process Time | Ideal Time(Between Two Process In Min) | Total time required (in Min.) |
(In Min) | ||||
1 | Manual Wheel And Tire Cleaning | 10 | - | 10 |
Automatic Operation:
Table No.5.2.2 Semi-Automatic: Automatic Operation
Sr. No. | Procedure | Process Time | Idle Time(Between Two Process in Min) | Total time required (in and out, in Min.) |
(In Min) | ||||
1 | Pre Wash Exterior | 1 | - | 1 |
2 | Foaming | 1 | 0.5 | 2.5 |
3 | Washing | 2 | 0.5 | 5 |
4 | Drying | 2 | 1 | 8 |
| Total | 6 | 2 | 8 |
5.3 Automatic Car Washing:
Fig.5.3.1 Exterior washing [3]
· Procedure:
1. Entry of car
2. Pre-wash
3. Foam Wash Section
4. Brushing
5. Clean Wash Section
6. Drying Section
7. Exit
Table No. 5.3.1 Automatic Car Washing Time Study
Sr. No. | Station | Process Time | Idle Time(Between Two Process In Sec) | Total time required (in and out, in sec.) |
(In Sec) | ||||
1 | Entry Of Car | - | - | - |
2 | Pre-Wash | 30 | 10 | 40 |
3 | Foam Wash Section | 40 | 10 | 90 |
4 | Brushing | 70 | 10 | 170 |
5 | Clean Wash Section | 30 | 10 | 210 |
6 | Drying Section | 60 | 10 | 280 |
7 | Exit | 0 | 10 | 290 |
| Total | 230 | 60 | 290 |
6. COST ANALYSIS:
6.1 Manual car washing:
Fixed Cost:
Table No. 6.1.1 Manual Car Washing: Fixed Cost
Sr. No. | Fixed Cost | In Rs. |
1 | Compressor | 20000 |
2 | Spray Gun | 4500 |
3 | Hose Pipe | 4300 |
4 | Tank | 7750 |
5 | Pump | 6000 |
| Total | 116430 |
Variable cost:
Table No.6.1.2 Manual Car Washing: Automatic Cost
Sr. No. | Variable Cost | In Rs |
1 | Labour | 8000 |
2 | Electricity & Water | 2500 |
3 | Maintenance | 1500 |
| Total | 12000 |
6.2 Semi-Automatic Car Washing:
Fixed Cost:
Table No.6.2.1 Semi-Automatic Car Washing: Fixed Cost
Variable cost:
Table No.6.2.2 Semi-Automatic Car Washing: Variable Cost
Sr. No. | Variable Cost | In Rs |
1 | Labour | 8000 |
2 | Electricity & Water | 2500 |
3 | Maintenance | 1500 |
| Total | 12000 |
6.3 Automatic car washing:
Fixed Cost:
Table No.6.3.1 Automatic Car Washing: Fixed Cost
Variable cost
Table No.6.3.2 Automatic Car Washing: Variable Cost
7. Automatic Car Washing System:
7.1 Block Diagram:
Fig.7.1.1 Sequence of operation
7.2 Construction:
7.2.1Arduino:
It was developed with intent to provide an economical trouble-free way for hobbyists, student and professional to build devices that interact with their situation using sensor and actuators. This make it perfect for newcomer to get started quickly. Arduino is an open sources platform the software is not purchase and only the coast of buying the board or its part is incurred, the make it very cheap. To make an Arduino board function easy and also making it available everywhere these board come with a USB Cable for power requirement as well as functioning as a programmer.
Fig.7.2.1 Arduino UNO 328P
7.2.2 DC Motor:
A dc motor uses electrical energy to produce mechanical Energy. The input of a DC motor is current/voltage and its output is torque (speed) that results in movement. The DC motor has two basic parts: the rotating part that is called the armature and the stationary part that includes some coils of wire which are called as field coils. The stationary part is called as stator.
Fig.7.2.2 DC Motor
7.3.3 Roller conveyor:
A series of roller supported in a frame over which vehicle are advanced manually, by power. These easy to install, low maintenance rollers are built to carry vehicle.
Fig.7.3.3 Roller Conveyor
7.2.4 Nozzles:
Nozzle is a component which work on the instructions given by the microcontroller. It sprays a soap/water mixture under relatively high velocity.
Fig.7.2.4 Nozzle
7.2.5 Sprocket:
It is power transmitting component on which chain has being connected with their outer peripheral mounted. In this system one sprocket is rotate like driver and another one is rotate like driven.
Fig.7.2.5 Sprocket
7.2.6 Chain:
The rollers are connected via sprockets and chain to a drive motor mounted to the side of conveyor. Chain transmits the power from one sprocket to another sprocket.
Fig.7.2.6 Chain
7.2.7 Buffer:
The brushes are provided which enhances the removal of dirt from the car and the cleaning of the car without the use of abrasive cleansers.
Fig.7.2.7 Roller Conveyor
7.2.8 Compressor:
The compressor is a device that converts power (using an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air, (i.e., compressed air).
An air compressor must be differentiated from pump because it works for any gas/air and pump work on liquid.
Fig.7.2.8 Compressor
