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INDUSTRIAL ENGINEERING

IVA1 TECHNOLOGY AND INDUSTRIAL AUTOMATION

Members Paredes Casado, Miguel Angel Peralta Negreiros, Cristian Renato Silva Rivera, Sandro Eisen Umasi Barahona, Katherine Mariela

Professor Mirko Mirko Klusmann

Topic In-bay automatic car wash with brushes

2017-02

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ABSTRACT Automatic car washing system is very common in developed countries. Car washing system is usually associated with fuel filling stations. It consists of large machines with automated brushes. Automatic car washing system is fully automated with different stages of rinsing, shampooing, washing, drying, and waxing. Different types of car washing systems are discussed in this report. This system uses large quantity of water; thus, water recycling plant is also an integral part of the automatic car washing system. In this project we talk about In-bay automatic car wash with brushes, which it is designed to be friendly and simple as well as to be combined into savings in supplies making it a cost-effective system. The electrical and mechanical systems have been simplified with the intention of reducing downtime and reducing operating costs for self-cleaning.

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TABLA DE CONTENIDO INTRODUCTION .......................................................................................................... 5 1. BACKGROUND AND OBJECTIVES ......................................................................... 6 1.1.

Background .................................................................................................... 6

1.2.

Objectives ....................................................................................................... 7

2. PROCESS DESCRIPTION, ADVANTAGES AND DISADVANTAGES...................... 8 2.1. Automated carwash facilities: In-bay automatic car wash with brushes .............. 8 2.2. Support system: Compressed air and blowers.................................................. 10 3. CONTROL LOOPS, MEASURED AND MANIPULATED VARIABLES .................... 12 3.1. Control loops: ................................................................................................... 12 3.2. Measured and manipulated variables: .............................................................. 12 4. DIAGRAMS (PNEUMATIC, ELECTRIC, PIPING & INSTRUMENTATION, PLC PROGRAMMING, WHERE APPLICABLE) ................................................................. 13 4.1. Pneumatic diagram .......................................................................................... 13 4.2. Electric diagram................................................................................................ 14 4.3. PLC programming ............................................................................................ 15 4.4. Piping & instrumentation ................................................................................... 18 5. INSTRUMENT SELECTION (SENSORT, CONDITIONERS, DRIVES AND ACTUATORS) ............................................................................................................ 19 5.1. Electric system ................................................................................................. 19 5.2. Pneumatic System ........................................................................................... 19 5.3. Hydraulic system .............................................................................................. 20 5.4. Controller.......................................................................................................... 21 6. CAPITAL AND OPERATING COSTS ..................................................................... 22 7. CONCLUSIONS AND RECOMMENDATIONS ....................................................... 24 7.1. Conclusions ...................................................................................................... 24 7.2.

Recommendations ........................................................................................ 24

LIST OF REFERENCES ............................................................................................. 25

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LIST OF FIGURES AND TABLES LIST OF FIGURES Figure 1 ………………………………………………………………………… Figure 2 ………………………………………………………………………… Figure 3 ………………………………………………………………………… Figure 4 ………………………………………………………………………… Figure 5 ………………………………………………………………………… Figure 6 ………………………………………………………………………… Figure 7 …………………………………………………………………………

8 10 13 14 15 18 21

LIST OF TABLES Table 1 ………………………………………………………………………… Table 2 ………………………………………………………………………… Table 3 ………………………………………………………………………… Table 4 …………………………………………………………………………

20 22 23 23

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INTRODUCTION A car wash (also written as carwash) or auto wash is a facility used to clean the exterior and, in some cases, the interior of motor vehicles. Car washes can be self-serve, fully automated, or full service with attendants who wash the vehicle. Automated car wash facilities, like in-bay or tunnel. The tunnel type washing consists of different substations through which the car is moved. With this type of system can be washed more cars because the car can go to the other phases of the washing process. Mostly this type of selfcleaning consists of: entry, prewash, active foam, brushing, cold wax and drying. It should be noted that this type of system has a higher cost than the bridge or bay type. As well as the space needed to install it and its correct operation. The In Bay type washing needs less space of implementation since all its components are in the same place. The disadvantage of this is that it only washes one car at a time. This wash basically consists of the following steps: active foam, washing and rinsing the car, washing wheels, cold wax and drying. In Peru, this business is growing due to the increase of cars in the city that exist today, which generates a great demand for this service. In some countries, this business adds some services such as maintenance, oil change, etc., making this more complete In the present report, the points mentioned in the Background will be developed, which also shows the objectives of this investigation. This research will show the process of a type of automatic car wash, which is called In-bay type with brushes. In addition, the advantages and disadvantages of this car wash and its support system will be indicated. On the other hand, this system has Control loops, measured and manipulated variables, which will be mentioned in this report. As also, the Diagrams (pneumatic, electric, piping & instrumentation, PLC programming, where applicable), which will help us to understand its operation and its composition with their respective sensors, conditioners, controllers, drives and actuators of this. Finally, the Capital and operating costs of this automatic car wash will be analyzed.

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1. BACKGROUND AND OBJECTIVES 1.1.

Background

The growth of the automatic car wash coincided with the rapid expansion of the automobile’s presence in the United States and Europe after World War II. It is estimated that the USA went from about 50 million cars in 1950 to more than 250 million today. The exuberant increase created a steady rise in demand for automatic car washes. The in-bay automatic wash concept was designed to operate without supervision and offer its customers a quick and economical exterior wash. In many cases, the automatic bay was complementary to existing businesses, such as a self-serve wash or a gasoline station. The first washes, manufactured in the 1960s, were typically very basic noncontact portals or friction washes with simple brush control systems, using polyethylene brush materials that were reliable, provided reasonable cleaning, and operated functioned efficiently. After the oil crisis of the early 1970s, oil companies began to buy automatics in quantity, in many cases providing the automatic wash as a “free service” for their customers who bought their fuel and automotive services. The concept was successful, and, in many cases, operators were able to develop premiums such as spot-free rinse and conditioners to provide a means of upgrading customers to generate washout revenue. One consistent negative was the damage of the car: the vehicles changed, accessories were added and, in an effort to be more efficient in fuel consumption, they were built with lighter materials. This, coupled with primitive brush technology, resulted in damage. The major oil companies began to consider at the car wash as a paradox: a relatively cheap opportunity to gain market share and build customer loyalty, but a possible cause of losing customers as a result of vehicle damage. This led to further development of the touch-free automatic: same operating criteria, runs unattended, works safely, and drastically reduces the chances of customer damages. Major oil began buying touch-free automatics on a high-volume basis, gaining market share and even creating market share for automatics. Professional operators jumped on the automatic bandwagon too. Improvements in technology, POS systems, and touch-free cleaning-quality improvements allow them to be owners and operate without necessarily being hands on. The in-bay automatics reached their all-time high in 2006 with, approximately, 42,000 units in operation in the United States alone.

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1.2.

Objectives

The objectives of this research are: 

Understand, analyze and proposed industrial automation solutions in each type of automatic washing and its support units



In addition.it focuses on the design, planning and application of automation technology.



Analyze the amount of Capital and operating costs of this type of car wash

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2. PROCESS DESCRIPTION, ADVANTAGES AND DISADVANTAGES 2.1. Automated carwash facilities: In-bay automatic car wash with brushes 2.1.1. Process description First, the PLC activates the motors that move the structure and the foam sprinklers. Then, the washing is carried out, first, the vertical brushes move linearly to wash the back of the car, at the same time that the sprinklers of the 3 rollers begin to throw water. At the same time, the horizontal roller lowers and the beginning of the turn, when it starts to raise the motors that move towards the machine are activated and the sprinklers that spray the car begin to work throwing water. Upon reaching the center of the car, the horizontal rotation of the brush is reversed to stop at the machine, while this process is carried out, when reaching the front of the car, the vertical rollers move linearly. At the end of the use of the vertical brushes, the wheels are washed, the motors move the machine and the sensors detect the movement of the wheel causing the machine and the pistons that have the brushes that wash the wheel, these detect the wheels Through force transducers and the motors that rotate the brushes begin to rotate, then these reverse the turn and retract to detect the rear wheel and repeat the operation. In the fourth and last route, the fans go down and detect that the car begins to delineate it. This is done by means of inductive sensors, making the same path opposite to the direction.

Figure 1. Process of In-bay automatic car wash with brushes

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2.1.2. Advantages     

Investment in equipment is lower and are less expensive to construct, since they fit in smaller spaces than the automatic washing of tunnels. They typically require less maintenance and have fewer damage claims than tunnel washes. In-bay automatic washes can be operated without full time attendants, allowing for 24-hour operation. In-Bay automatic car washes don't require much staff and are very cheap to operate. It can be located in different places, since it requires less space than other types of automatic car wash. This adds value to standard services.

2.1.3. Disadvantages 

  

These car washes are slow, which means that the amount of washed vehicles is reduced, generating less income than automatic tunnel car wash. Unlike a tunnel wash, in-bay automatic washes can only wash one vehicle at a time. The general perception of in-bay automatic washes is that their wash quality is lower than that of a tunnel wash. These in-bay washes are everywhere and many of them are increasingly ignored in favor of better options.

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2.2. Support system: Compressed air and blowers 2.2.1. Process description We start the plant operation by turning the ON-OFF main switch. The first thing the PLC controller is going to do is verify the minimum water level required to start to operate if the liquid level is the minimum required what you do is open the valve to allow the air to enter and turn on the pump, otherwise the electro-vent air valve will turn on and then the pump and it will return to test the minimum level. It is constantly checking the air pressure and the water level, to determine if they are the minimum required by the system (these are compared with previously determined reference values by means of tests), if these are correct, proceed to open the water outlet valve. Always, also, the values are being measured the air pressure at the entrance of the lung, to know if its operation is correct. If these values were not the operating minima will be corrected at the output of each of them to try to maintain a constant water flow at the output, which would cause a constant pressure and will be given a warning to see that it is malfunctioning inside the part that is failing.

Figure 2. Process of support system 2.2.2. Advantages ● Air tools are easier to use Air tools generally contain far fewer moving parts than electrically powered tools which means that there is less to go wrong with them and they require minimal maintenance. Air tools are safer the absence of an electrically powered motor in air tools means that the risk of the operator receiving an electrical shock from a malfunctioning tool is eliminated.

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

Air tools are more reliable Air tools are safer than electric tools. Using them eliminates the risk of electric shock from any defective parts.

● Easy transport and storage Air is available everywhere. Since outlet air escapes into the open, there is no need for return lines. Electrical and hydraulic systems need a return line to the source. Compressed air can be transported over great distances in pipelines. The energy stored in compressed air can be widely distributed in this way. Storage of compressed air is easy in tanks that are built specifically for this use. ● Air tools increase productivity The flow rates are very high allowing short times in their passage and with it fast conversion of energy into work. This is able to perform complex tasks in a shorter time. 2.2.3. Disadvantages ● Filters should be inspected periodically. A clogged filter will increase pressure drop, which can either reduce pressure at the point of use, or increase the pressure required from the compressor. Both of these situations can result in excessive energy consumption. ● The air compressor can also have problems, due to the system overheating. Elevated compressor temperature can cause many problems. 

Air powered tools and valves that are not lubricated properly can fail prematurely. Valves that are not properly lubricated can stick, causing the chemical pump to stay on and wasting chemical. That can be costly.

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3. CONTROL LOOPS, MEASURED AND MANIPULATED VARIABLES 3.1. Control loops:   

Level Controller Pressure Controller Temperature Controller

3.2. Measured and manipulated variables:    

Operating Pressure Feed Flow Rate Operating Temperature Liquid Level

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4. DIAGRAMS (PNEUMATIC, ELECTRIC, PIPING & INSTRUMENTATION, PLC PROGRAMMING, WHERE APPLICABLE) 4.1. Pneumatic diagram

Figure 3. Pneumatic diagram

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4.2. Electric diagram

Figure 4. Electric diagram

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4.3. PLC programming

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Figure 5. Flowchart

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4.4. Piping & instrumentation 

Support System P&ID

Figure 6. Compressed air and blowers P&ID

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5. INSTRUMENT SELECTION (SENSORT, CONDITIONERS, DRIVES AND ACTUATORS) 5.1. Electric system The automatic washing machine has seven motors that work with three-phase power (200/230 volts at 60 Hz.). 









 

Motor M1 - Horizontal brush motor: Power motor 1 HP mounted on the right end of the horizontal brush through a speed reducer that provides an angular speed of 115 RPM approx. Motor M2 - Left vertical brush motor. Power motor 1 HP mounted on top of left vertical brush, which works in combination with a right-angle speed reducer that provides an angular speed of 115 RPM approx. Motor M3 - Right vertical brush motor. Power motor 1 HP mounted on top of the right vertical brush, which works in combination with a right-angle speed reducer that provides an angular speed of 115 RPM approx. Motor M4 - Left wheel-washer motor: Motor of 1 HP of power combined with a reducer of speed, is used for the operation in both directions of the lava wheels left at a speed of approx. of 115 RPM. Motor M5 - Motor of lava-wheels right: Motor of 1 HP of power combined with a reducer of speed, is used for the operation in both directions of the lava wheels right at a speed of approx. of 115 RPM. Motor M6 - Motor for left wheel drive: 1/2 HP motor connected by means of a speed reducer to the transmission of the left trailer wheel. Motor M7 - Motor for right wheel drive: 1/2 HP motor connected by means of a speed reducer to the transmission of the right towing wheel.

5.2. Pneumatic System This system works at a maximum pressure of 10 Bar and a minimum pressure of 7 Bar. The compressed air goes through a maintenance unit, which filters the air, regulates the pressure and lubricates the air, then reaches a lock out valve, and it passes to the bifurcation module, from which the power lines will exit. 5.2.1. Actuators   

Actuator A01: Linear actuator, which will move a mass of 10 kg corresponding to the brush with motor lava wheels right. Actuator A02: Linear actuator, which will move a mass of 10 kg corresponding to the brush with motor washes left wheels. Actuator A03: Double acting actuator, which will move a mass of 60 kg corresponding to the sum of the masses of the vertical brushes. 19

 

Actuator A04: Double acting actuator, which will move a mass of 15 kg corresponding to the mass of the horizontal brush. Actuator A05: Double acting actuator, which will move a mass of 50 kg corresponding to the sum of the masses of the fans.

5.2.2. Pressure regulators 

 





The pneumatic system uses 6 pressure regulators, which are responsible for reducing the pressure that reaches the cylinder, these are positioned after valves and before the flow regulator. The regulators of cylinders A01 and A02 work at a maximum pressure of 2 Bar. The cylinder regulator A03 works at a maximum pressure of 1.5 Bar. Excessive pressure can cause the vertical brushes to forcefully hit the car damaging it. The regulators for cylinder A04 regulate the pressure of the piston that controls the horizontal brush. Here the valve is normally open to keep the brush in the raised part until the signal it receives is different or changes. The regulator for cylinder A05 controls the pressure of the cylinder that holds the fans. This works at a maximum pressure of 1 Bar and at a very low speed opening and closing according to the signals it receives, and this regulator scans the shape of the automobile to direct the air of the fans. Table 1: List of components Components Quantity Linear actuator 3 Standardized cylinder 2 Solenoid valve 4 Ball valve actuator unit 3 Throttle valve and non-return valve 10 Maintenance unit 1 Pressure regulator 5

5.3. Hydraulic system Water is the basic element for the action of the automatic washing system. To increase the action of water, chemical elements are used, such as active foam to remove dirt particles on the brushes. To ensure the quality of the wash, it is necessary to use and properly administer the water. The water must be supplied at 20 L / m at a pressure of 2 Bar minimum and maximum 10 Bar. 20

The system for the distribution of shampoo and cold wax, are designed to dilute these with water and disperse them on the autmobile. The nozzles located on the interior walls of the machine will carry out the application of these solutions. The shampoo and wax are added to the hydraulic system with a 115v pump. A check valve prevents the return of shampoo and wax to the tank. 5.4. Controller Motor Control Center (MCC): “brain” of the car wash operation, and considered “finger safe” the system controls the car wash equipment to maximize cleaning performance at optimum chemical consumption. The MCC houses the starters, switching, and overload protection devices for electric motors that are used in the car wash system. The MCC operates a variety of motors on different devices and machines. It contains motor starters, circuit breakers and manual on/off controls for all three-phase motors on equipment without automatic controls.

Figure 7: Motor Control Center (MCC)

PLC (Programmable Logic Control): term relating to knowledge base to adjust and or repair MCC.

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6. CAPITAL AND OPERATING COSTS Car Wash and support system components costs Table 2: Capital Costs Component type

Electric

Pneumatic

Hydraulic

Structure

Electronic

Components Motors Speed reducers Drivers PLC Electrical accessories Linear actuator Normalized cylinder Solenoid valve Ball valve actuator unit Choke and non-return valve Maintenance unit Precision pressure regulator Hoses Pneumatic accessories Air compressor 0.5 HP pump Sheet galvanized sheet Steel cable Ventilator Rails Brushes Wheel washer Proximity sensor Electronic accessories Total Total

Cost $ 31,724.50 $ 24,173.20 $ 25,000.00 $ 20,000.00 $ 21,000.00 $ 6,550.00 $ 5,500.00 $ 5,400.00 $ 2,725.00 $ 7,750.00 $ 1,915.00 $ 6,025.00 $ 11,000.00 $ 18,900.00 $ 5,000.00 $ 3,500.00 $ 1,677.00 $ 200.00 $ 15,000.00 $ 2,800.00 $ 54,000.00 $ 15,000.00 $ 9,885.66 $ 20,000.00 $ 314,725.36 S/. 1,021,598.52

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Operating costs Table 3: Energy consumption, Kw/day Equipment

Number of Consumption Consumption Consumption Hr/day engines Kw/hr/engine Kw/hr Kw/day

Motion action sensors 4Hp engine Flow distributor 2Hp action engine 3 Hp pump Step pump Ventilator

2 1 1 1 1 1 1

1 3 3 6 8 3 2

2 3 3 6 8 3 2

3.4 10 10 10 0.5 3 0.8

6.8 30 30 60 4 9 1.6 141.4

Total Operation days annually: 300 days It is considered an additional 5% of unforeseen

Table 4: Energy Costs, S/. / year Consumption Consumption Consumption S/. / Kw S/. / year Kw/year Kw/year Kw/year 141.4

42,420

44,541

1

26,725

Workforce Cost: S/. 144,000 Water Cost: S/. 35,000

Total Cost: S/. 1,227,323,12

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7. CONCLUSIONS AND RECOMMENDATIONS 7.1. Conclusions 

 

7.2.

With this research it is concluded that when designing and implementing a car wash in bay with brushes an efficient process is obtained. Optimizing times either machine or operator, improving the quality of service It shows a mechanical, electrical and electronic system focused on the self-cleaning process. The result of this research complies with the development objectives, which generate and apply scientific and technological knowledge. Recommendations

On the other hand, some recommendations that can be indicated are: 



It is recommended that another type of material be used on the brushes for gentle washing. All this in order to better car care and a longer duration of equipment. Leave the operator free to use the machine programs that are convenient for the operation of this

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LIST OF REFERENCES 

ICS Innovative control systems (2017). Defining the world of car wash technology. Recuperado de: https://www.icscarwashsystems.com/index.php?product=27#article/2063. Consulta: 29 de setiembre del 2017.

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Coleman Hanna Carwash systems LLC (2016) efushion Friction. Recuperado de: https://colemanhanna.com/equipment/in-bayautomatics/efusion-friction/. Consulta: 29 de setiembre del 2017.



Evaluation of Potential Best Management Practices (2006) Vehicle Wash Systems. Recuperado de: https://www.cuwcc.org/Portals/0/Document%20Library/Resources/Water %20Efficient%20Product%20Information/Vehicle%20Washing/PBMPDRAFT-Vehicle-Wash.pdf Consulta: 29 de setiembre del 2017

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Carwash Equipment 101. A basic overview of the major components that make your business operate. (2017) Recuperado de:https://www.carwash.com/carwash-equipment-101/ Consulta: : 29 de setiembre del 2017

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Ojeda Manzano, Mauricio Xavier y Ortega Salazar, Leonardo Pabel (2015). Automatización e implementación de lavado express de autos Car wash con aplicación de agua, agente limpiador (shampoo) y agente abrillantador (rinse) de un equipo Polisher reciclado. Carrera de Ingeniería Mecánica. Universidad de las Fuerzas Armadas ESPE. Matriz Sangolquí.

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BOCANEGRA VILLAGOMEZ, D. S., MARTINEZ CARBAJAL, G. U. I. L. L. E. R. M. O., PLANCARTE SALAS, M. A. R. I. A., & SANCHEZ AVILA, M. E. (2009). MAQUINA DE AUTOLAVADO AUTOMÁTICO

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