IMPROVEMENT IN AUTOMATIC VEHICLE WASHING MACHINES
Technical Field
The present invention relates to automatic vehicle washing machines.
Generally speaking, the automatic vehicle washers such as vehicle washers in the prior art comprise a carrier frame (bridge), which is set on a track and is capable to perform a back and forth motion parallel to the floor; preferably a horizontal brush, which is coupled so as to move together with this carrier frame and is capable to rotate around its own axis and to perform an upward vertical motion; and preferably two vertical brushes, which are also capable to rotate around their own axes and to move horizontally. In this manner, such vertical brushes and horizontal brushes, respectively, clean the side surfaces and top surface of a car or vehicle placed into such vehicle washer.
In operation, a car to be washed is parked into such vehicle washing machine and the latter is operated either manually or automatically and water, along with a cleaning material is jetted thereto. During these steps, as the bridge part begins to move towards such car, horizontal and vertical brushes initiate to rotate around their own axes. As the bridge is moved further, such brushes coupled with said bridge are positioned according to a car's profile and thereby all surfaces of the vehicle are contacted with said brushes without damaging them while performing a vehicle wash.
Beyond this general approach, once the vehicle washers under the prior art are elaborated, certain significant drawbacks are recognized in their embodiments. Detailed examples towards those embodiments are given hereunder.
The driver mechanisms providing horizontal- and vertical-axis displacements of brushes under current systems given above, are either spring- or pneumatic- based, which can be defined as a rope piston system. A mercury swinging system drives the process, where such brushes are repositioned according to a vehicle while cleaned. Therefore the force applied to a vehicle both by horizontal and
vertical brushes during a vehicle wash is very high so that some parts of cars such as their mirrors, antennas, etc. are exposed to damages sometimes.
Since the piston system, which drives horizontal and vertical brushes, is operated with air in vehicle washers with pneumalic-based driver systems, linear control cannot be ensured and thus it becomes impossible lo clean a vehicle homogenously. And obviously, when pressurized air cannot be supplied to such systems, they fail to operate.
In addition, horizontal brushes used in prior-art systems work in connection with steel ropes and as a result of this, such ropes get abraded and even break after a certain operation time. And it is obvious, what a huge damage a vehicle under wash is exposed to, once such a faulty circumstance happens.
Another drawback in such systems is encountered in mercury keys, which are used to position the brushes (and particularly the horizontal brush) on a vehicle under vehicle wash. In other words, once such a horizontal brush is tilted by a vehicle or for any reasons, one end of the brush is elevated so as to lead to an excessive pressure on the vehicle surface, where the lowered end of this brush is in touch. Such circumstances give rise to certain deformations such as bends, scratches on a car's hood.
Considering the vertical brushes in the prior art, they are repositioned according to a car's profile during vehicle wash. There occurs high restraint, however, between such vehicle surfaces and the vertical brush so as to mechanically tilt the latter and as a result of this, the keys in the tilted field are repositioned and thus the driving motor is operated. Consequently, since the vehicle parts such as antennas, rearview mirrors, etc. cannot exert a pressure on the vertical brush so as to mechanically tilt the latter, the brush does not alter its position and damages such parts.
Considering a car positioning in such vehicle washers in the prior art, since the current systems utilize a mechanical limit llama for this positioning process, it becomes impossible to perform a position arrangement in respect of car dimensions.
Another drawback in prior-art systems is that neither time, nor energy, water, etc. are used optimally in automatic vehicle washers. In other words, since many machines of prior art cannot measure the length of a car, the carrier frame designed for a probable longest vehicle is completely displaced on the displacement track when the operation is started so as to lead to an extravagant water, time, and energy consumption. In addition, since many vehicle washers do not have the device to identify the presence of vehicle for wash, such vehicle washing operation can be started manually even if there is no vehicle within the vehicle washer.
A further drawback in prior-art systems is encountered in displacing-reducing mechanisms currently used to displace the carrier frame on their tracks. These mechanisms are exposed to the entire load of a vehicle washing machine as a result of their functions, and are therefore under the high risk of breakdown. Once a breakdown occurs, the complete machine is stopped and it becomes necessary to remove this mechanism from a narrow opening formed by lifting the entire frame with the aid of jack-like means. This operation requires substantial time and necessitates expertise in many circumstances. Therefore broken-down automatic vehicle washers of prior art are sometimes let out of operation for days long for service and require quite high service fees.
Yet another drawback in prior-art systems is the lack of a pre-warning system to warn the operator of a possible failure. As a natural outcome of this lack, failures are encountered generally as a vehicle is washed so as to damage either the vehicle in vehicle washer or the vehicle washer itself and such service provided for the car's owner is left incomplete.
There are also PLC controlled automatic vehicle washing machines in the prior art. Under this system, a PLC displaces the brushes and carrier frame according to signals it receives from the sensors positioned in relevant places of a vehicle washing machine. Therefore, in cases that said sensors fail to work or work incorrectly -which is a highly probable case in this type of environments where water and materials such as detergents and soaps are always used: e.g.
calcification; the PLC will not perceive the presence of car and finally the brushes will lead to serious damages on a car in the vehicle washer.
Brief Description of Invention
The present invention relates to a novel automatic-brush vehicle washing machine designed to overcome the aforementioned drawbacks.
The objective of the present invention is to provide a vehicle washing machine, which is full automatic, which has a minimized breakdown probability, which determines and warns probable electrical and mechanical failures beforehand and not during a vehicle wash, which washes a vehicle completely and does not leave behind any unwashed vehicle surfaces, which is used easily by full automation, which does not damage a vehicle during vehicle wash, which does not use insensitive equipments such as cylinders, pistons, ropes, mercury keys, etc, which requires minimum service and service periods, and which operates noiselessly and has decorative brushes.
In order to realize these objectives, the present invention comprises in its broadest sense a carrier frame with two supportive legs and a bridge part connecting together such legs from top; at least one vertical brush, which rotates around its own axis and is coupled to the bridging part of said carrier frame and at least one horizontal brush, which is positioned between said supportive legs; at least one displacing group including a reducer and a motor to cause said carrier frame to move on the horizontal axis; rotating motors, which are coupled to said brushes in order to cause them to rotate around their own axes; driving motors to cause said horizontal brush to move on the vertical axis and said vertical brush to move on the horizontal axis; a drive transmission mechanism to transmit the drive of said driving motors to said horizontal and vertical brushes; speed control circuits driving said rotating and driving motors; a microprocessor control unit, which communicates with said rotating and driving motors through said speed control circuits; and finally a novel driving mechanism, a novel automatic washing machine control method and a novel automatic washing machine control system to control said novel driving mechanism in order to realize this method.
Accordingly, up and down movements of the horizontal brush on the vertical axis are carried out with an extremely sensitively controlled motor-reducer-chain mechanism, in place of pressurized air mechanisms of prior art, of which the linear control is accomplished very difficultly. According to a general description of this mechanism, a horizontal brush chain vertically positioned on each supportive leg of the carrier frame is coupled to the end of this brush by one of its ends and causes said brush to move with the drive it receives from the horizontal brush driving motor. Preferably a weight is hung on the opposite end of this chain in order to both keep it strained and to reduce the weight on the driving motor and reducer.
In compliance with this mechanism, the coupling of the horizontal brush and supportive legs are provided as following. A vertical displacement channel is embodied on each supportive leg of the carrier frame and at least one coupling pulley is attached to both ends of the horizontal brush and by placing these pulleys in said channels during assembly, the vertical-axis movement of said horizontal brush is facilitated.
A trigger belted vehicle driving mechanism ensures the horizontal-axis movement of each vertical brush. According to a general description, this mechanism comprises a trigger belt, which extends along the bridge part of carrier frame, and a coupling piece, which is coupled with this belt and couples the vertical brush to the bridge part. This coupling piece accommodates a gear, which is coupled with said trigger belt, a vertical brush driving motor, which drives this gear, and wheels positioned into vertical displacement channels formed on the bridge part in order to have this coupling piece easily move on said bridge part. Thanks to this embodiment, the vertical brush is easily moved on the bridge part with the rotation of the driving motor and this motion is extremely sensitively controlled by a control system to be described hereunder.
In an alternative embodiment of the present invention, a horizontal drying means is employed as well. This drying means is coupled to said supportive legs as in the case of horizontal brush and is moved upwardly with a mechanism similar to the one that provides the drive of said horizontal brush.
An objective of the present invention, as indicated above, is to produce an embodiment necessitating a minimum service and minimum service period. In order to realize this advantage, the displacing reducer group, which is one of the most failing parts of these machines, is provided with an ease of assembly/disassembly and thus in breakdown positions particularly, a defected reducer group is replaced with the reserve one without having to stop the machine for a long period. In order to realize this feature, the motor and reducer, which make up the displacing reducer group mentioned under the present invention, are assembled to an assembly plate and this plate is fastened to the base of the supportive leg of carrier frame by a detent mechanism formed on this base and by at least one fixation screw, whereas access to this site is highly facilitated by a cover formed on said supportive leg. Thanks to this configuration, a service person gains easily access to the displacing group by opening said cover in a breakdown position and by removing the screw fastening the assembly plate to the base, he frees the assembly plate from the detent mechanism and becomes able to remove the displacing group and thus to rapidly replace it with a reserve one.
In an embodiment of the present invention, a horizontal drying means is realized in order to further perform a drying operation after a washing operation. As it is the case with the horizontal brush, this drying means is coupled through wheels with separate vertical displacement channels formed on each supportive leg of carrier frame and is moved up- and downwards in this channel. A motor-reducer-chain mechanism is employed to realize such up- and downward motions of said drying means with a structure identical with the one that is used with the horizontal brush.
The method under the present invention is realized through a microprocessor control unit, comprising the steps of determining the idle working power rate intervals consumed by horizontal and vertical brushes' rotating motors when they do not have any contacts and saving such rates in the memory of said microprocessor control unit; determining the power rates of horizontal and vertical brushes' rotating motors when they have an ideal contact with a vehicle and recording such rates in the memory of said microprocessor control unit;
continuously monitoring the power consumed by said horizontal and vertical brushes' rotating motors during operation and comparing them with the corresponding rate in memory;
If a measured value in at least one rotating motor falls within the idle working power rate interval that corresponds to itself, stopping the displacing group motor and thus the progress of the carrier frame in order to avoid any unwashed surface on such car; and
If a measured value from at least one rotating motor falls out of the ideal working power rate interval that corresponds to itself, adjusting the pressure intensity of the related brush so that it is kept within the ideal working power rate interval by taking control of the related driving motor in order to avoid any damage on such vehicle during a vehicle wash.
The relevant pressure intensity can be determined very sensitively. It is because said control unit has a structure to perceive even a very slight power change in said rotating motors.
As can be understood from above, however, since each vertical brush driving motor is controlled separately, such vehicle wash operation is performed with utmost accuracy, even if a vehicle is not parked properly for a wash, in other words, independent from the position a vehicle is entered into such automatic vehicle washing machine.
In a preferred embodiment of the present method, moment and voltage rates are also used as parameters, in addition power rates consumed by rotating motors.
In another preferred embodiment of the present invention, a profile determined by the horizontal rotating brush on a vehicle during vehicle wash is taken to the memory of said control unit and during the drying operation after such vehicle wash, the control unit sends the required signals to the driving motor of such drying means in order to cause the drying means to move up- and downwards in accordance with said profile. This ensures the most ideal drying operation to be performed.
In a further preferred embodiment of the present method, the height of a vehicle to be cleaned is determined before such cleaning operation and accordingly, said ideal contact power rates are multiplied by a predetermined coefficient.
This matter can be clarified as following. The front faces of vehicles such as buses, trucks etc. are longer when compared to front faces of normal cars. As a result of this, contact surfaces of vertical brushes with such vehicles during a wash operation vary largely in accordance with the types of vehicles. Therefore the powers consumed by a vertical brush with the same contact distance (e.g. when brush hairs enter 5 cm) vary as a bus and car, for example, is washed. If this difference is not taken into account (indeed, such differences are entirely disregarded in current systems), as, for example, a bus is washed, there will be a large pressure rate and thus a large power consumption on the vertical brush so as to lead the control unit to decide that the brush is positioned very close to such vehicle and will cause it to take said brush away from the vehicle. Resultantly, the bus surfaces will not be cleaned efficiently. With this novel system brought forth by the present invention, however, the ideal contact power rates in the control unit's memory shall be multiplied by a predetermined coefficient and be accordingly increased. Resultantly, the aforementioned inefficient cleaning shall be avoided.
In a different preferred embodiment of the present method, said horizontal and vertical brushes are operated idle before a washing operation to determine their power consumptions and the ideal contact power rate intervals are adjusted in accordance with this reference.
This matter can be clarified as following. As a result of deformation occurring after some period in some mobile parts within the motors rotating such brushes, they start to operate more inefficiently and to consume relatively more power. Therefore if this parameter is not taken under control and if there is a rotating motor consuming more power than normal in a washing operation, the control unit will decide that the brush contacts the vehicle surface more than necessary and will take the brush a certain amount away from a vehicle to cause to an inefficient cleaning operation. This feature is employed in order to avoid such circumstances.
Yet in a further preferred embodiment of the present method, the contact force value of a horizontal and/or vertical brush against a vehicle is determined by the user on a user interface according to the dirtiness of a vehicle or the cleaning it requires. Thanks to this, if, for instance, a vehicle is very dirty, the user will be able to increase this parameter to pull above the ideal cleaning power rate interval of rotating motors and the control unit will take control of relevant driving motors, once a relatively higher brush pressure value is met. The control unit, however, will not permit a user to enter a pressure rate likely to damage a predetermined vehicle.
Still in a further preferred embodiment of the present method, thermics of displacing and driving motors, the entire sensors, security keys, communication lines and cables between said control unit and speed control units are continually controlled and in case a failure occurs, the operation is stopped and the error type displayed on said user interface.
Yet in another preferred embodiment of the present invention, the machine's current condition is continually compared with the data received from sensors in the machine and in case a conflict happens, the operation is stopped and the error type monitored by said user interface. As an example for this can be given the circumstance when such horizontal brush makes a downward movement, but no data is received accordingly from the encoder of said horizontal brush's driving motor.
The control system of the automatic vehicle washing machine realizing the foresaid method under the present invention comprises speed control units, which drive each driving and rotating motor and which communicate with peripheral units; a microprocessor control unit, which is electrically connected through said driving and rotating motors and said speed control unit; sensors, which inform such microprocessor control unit about starting and ending points of a vehicle entered into the present machine and determine the height of such vehicle in order to let said microprocessor control unit
determine the presence of vehicle entered therein and to let such vehicle be positioned accurately; encoders, each in connection with the relevant driving motor of brushes in order to determine the amount of motion necessitated by said horizontal and vertical brushes and by the displacing group; and a user interface, in order to let said microprocessor incorporated control device be programmed and to monitor the messages it gives.
In a preferred embodiment of the system under the present invention, sensors are employed, which report said control unit if a vertical brush is at the start or end, if a horizontal brush is in its highest or lowest position, if a drying means is in its highest or lowest position.
In another preferred embodiment of the system under the present invention, a presence sensor is positioned on the vehicle-facing surface of carrier frame's supportive legs in order to determine and report to said control unit the presence of a vehicle to be washed.
In a further preferred embodiment of the system under the present invention, two sensors are positioned with a certain interval on a same height on the vehicle- facing surface of carrier frame's supportive legs. First of these sensors function to determine if a vehicle is positioned as desired within the machine and report it to the control unit and the other sensor functions to report the control unit if a vehicle is excessively entered into the machine. Said control unit receiving such signals informs the user accordingly.
In a different embodiment of the preferred system under the present invention, another sensor is positioned on a height higher than both of said sensors and even higher than the height of a normal vehicle to determine the height of such vehicle. Thanks to this sensor, the microprocessor control unit can determine, for example, that a vehicle to be washed is not an automobile, instead a larger transportation vehicle, and accordingly can increase the power reference rates.
Yet in another preferred embodiment of the system under the present invention, a horizontal drying means, a driving motor to move this drying means on the vertical
axis, and a speed control unit to drive this motor are also incorporated, whereas said control unit records the profile that a horizontal rotating brush acquires from a vehicle under vehicle wash, and during a drying operation after such vehicle wash, said control unit determines the up- and downward motions of said drying means by making reference to such saved profile.
The structural and characteristic features of the present invention shall be made clear with annexed figures and with a detailed description referring to said figures hereunder and thus, the present invention must be considered by taking into account said figures and the detailed description.
Brief Description of Figures
Figure 1 gives a general view of the automatic vehicle washing machine under the present invention.
Figure 2 gives a representative view of the novel drive transmission mechanism employed in the present invention.
Figure 3 gives a top view of the novel drive transmission mechanism of the horizontal brush.
Figure 4a gives a front view of the horizontal brush assembled to the carrier frame.
Figure 4b gives a close view of the points where the horizontal brush is assembled to the carrier frame.
Figure 5a gives a close view of the points where the vertical brush is assembled to the carrier frame.
Figure 5b gives a cross-sectional view of the vertical brush coupled to the bridge's surface.
Figure 5c gives a top view of the vertical brush coupled to the bridge's surface.
Figure 6 gives a perspective view of the novel displacing reducer group cassette mechanism embodied under the present invention.
Reference Numbers
1. Carrier frame;
1.1 supportive leg of carrier;
1.2 bridge part of carrier frame; 1.3 base of supportive leg;
2. displacement track;
3. vertical brushes;
4. horizontal brush;
5. chain of horizontal brush; 6. driving motor of horizontal brush;
7. chain gear of horizontal brush;
8. drive transmission shaft of horizontal brush;
9. rotating motor of horizontal brush;
10. coupling piece of horizontal brush; 10.1 conical coupling pulleys;
10.2 chain coupling extension;
11. drying means;
12. chain of drying means;
13. driving motor of drying means; 14. chain gear of drying means;
15. drive transmission shaft of drying means;
16. weights;
16.1 weight supportive pulleys;
17. driving motor of vertical brush; 18. rotating motor of vertical brush;
19. joint of vertical brush;
20. coupling head;
20.1 conical coupling pulley;
20.2 horizontal displacement channel; 20.3 plastic bumper;
20.4 trigger belt;
20.5 gear;
21. assembly plate;
22. displacing motor of carrier frame;
23. reducer;
24.1 3-detent group;
24.2 2-detent group; 25. fixation screws.
Detailed Description of Invention
As seen from Figure 1 , an automatic vehicle washing machine basically comprises a reverse-U-shaped carrier frame (1 ) made up of two vertical supportive legs (1.1 ) and a bridge part (1.2) connecting these legs (1.1 ) together from top; two vertical brushes (3) hung mutually vertically from two ends of said bridge part (1.2); and a horizontal brush (4) coupled from both of its ends to said supportive legs (1.1 ). As can be further seen from this Figure, the carrier frame (1 ) and thus the brushes coupled thereto are moved forth and back on a displacement track (2) when a vehicle is cleaned. A displacing mechanism with a motor-reducer structure positioned on supportive legs provides the displacement of carrier frame (1 ) on such displacement tracks.
A water-dosing system is further embodied under the present invention to mix water, shampoo, polisher, and other chemicals in a desired ratio and to apply such material timely to a vehicle for cleaning purposes. More elaborately, this complete system comprises nozzles, pipes, and hoses to apply washing and rinsing water to a vehicle's top and sides and to brushes in desired angles, amounts, and pressures; electro-valves to automatically open and close the feed of purifying and clean water; and a dosing system to automatically inject chemicals such as shampoo, polisher, emollient into the washing water via dosing pumps and ventury systems in desired amounts.
As mentioned above, one of the most significant features of the present invention are the driving mechanisms enabling the horizontal brush (1 ) to displace on the vertical axis. A sketch is given under Figure 2 to illustrate the working principle of this mechanism. Accordingly, two components, namely a horizontal brush (4) to move up- and downward on a vertical axis and a drying means (11) are employed in the present system. Both of these components are coupled from both of their
ends to said supportive legs. One apiece chain gear (7, 14) are coupled preferably to the shafts of driving motors (6, 13) of drying means and of horizontal brush positioned at the top part of said supportive leg, while one horizontal brush chain (5) with one end connected to the horizontal brush (4) and one drying means chain (12) with one end connected to the drying means are hung to such chain gears (7, 14). One apiece weight (16) are hung to free ends of such chains (5, 12) through weight support pulleys (16.1) in order to provide the required tension. Accordingly, when the driving motors (6, 16) of horizontal brush and horizontal drying means commence to rotate, the resultant drive is transmitted to the horizontal brush (4) and to the drying means (11 ) through their own gears and own chains and the horizontal brush and drying means are moved up- or downward according to the direction of rotation of such driving motor.
In a preferred embodiment of the present invention, a drive transmission mechanism referred to in the above paragraph is embodied on both sides of the supportive leg in order to apply force from both ends of the drying means and the horizontal brush (4) coupled to supportive legs. The driving motor, however, is provided merely on one side and the drive created by such motor is transmitted to other ends of horizontal brush and driving means through a horizontal brush drive transmission shaft (8) and a drying means drive transmission shaft (15) extending between two supportive legs along the carrier frame's bridge part (1.2).
Figure 4a gives an idea as to how the horizontal brush (4) is coupled with the supportive legs (1.1 ) of carrier frame. As can be seen from this front view, said horizontal brush (4) is coupled by both of its end with vertical displacement channels formed upwardly along mutual supportive legs (1.1) through a horizontal brush coupling piece (10) and an roller-bearing-like element coupled to this piece. In a preferred embodiment of the present invention, conical coupling pulleys (10.1 ) are employed as roller-bearing-like elements. A horizontal brush rotating motor (9) is positioned on one of these coupling points in order to let the horizontal brush (4) to rotate around its own axis.
The horizontal drying means (11 ), not given in figures though, is coupled to supportive legs (1.2) in the manner described in the above paragraph, and it
comprises left and right spiral fans, a drying brim towards vehicle surfaces, and groups of gears, chains, motors, and reducers, as indicated above to move up and down this mechanism. In a preferred embodiment, resistances are employed to provide hot air for vehicles.
In an alternative embodiment of the present invention, vertical drying means are also employed -besides said horizontal drying means (11 )- on supportive legs (1.1 ) to control air flow by means of flaps.
Figure 4b gives the detail of said coupling piece (10) and coupling manner. Accordingly, this coupling piece (10) comprises three parts: a central part, whereto the horizontal brush (4) is coupled, and extremities, which extends downwardly from both sides of the central part in a form resembling a stepped structure. Conical pulleys (10.1 ) jointed to such extremity parts and thus the horizontal brush (4) is placed in the channel formed on the supportive leg (1.1 ) by means of these conical pulleys (10.1 ). A horizontal brush chain (5) is connected to a chain coupling extension (10.2) formed on the top end of the coupling piece (10) and thus it is easily moved with a received drive up and down in said vertical displacement channels by being pulled by the chain (5) through conical pulleys (10.1 ) of the horizontal brush (4).
Figures 5a and 5b are given to elaborate the vertical brush (3) embodiment employed under the present invention. As can be seen further from Figure 5a, the vertical brush (3) is coupled to the supportive leg's bridge part (1.2) via a coupling head (20). A novelty is brought forth here on the connection point between said coupling head (20) and vertical brush (3). More detailed, the vertical brush (3) is jointed to said coupling head by means of a vertical brush joint (19) and besides, at least one plastic bumper (20.3) or alternatively, another plastic-based or impact- absorbing material is positioned in the free site between said coupling piece and the upper face of vertical brush. Thanks to this, if the vertical brush (3) swings during operation, noises likely to occur when this brush hits the lower surface of said coupling head (20) are avoided in order to provide a noiseless operation.
Another novelty is brought forth here on the connection point between the coupling piece and the carrier frame's bridge part (1.2). As can be seen accordingly in
Figure 5b with a top view of this embodiment, preferably two horizontal displacement channels (20.2) are realized on the upper surface of said bridge part (1.2). In addition, preferably four roller-bearing-formed coupling pulleys (20.1) are jointed on mutual sides of such coupling heads (20) of each vertical brush and these coupling pulleys (20.1) are placed into said horizontal displacement channels (20.2) during assembly.
As can be seen in Figure 5c, a trigger belt (20.4) is embodied, which is fixed on the carrier frame (1 ) so as to extent between two supportive legs (1.1 ) on the upper part of said coupling head (20), whereas a driving motor of vertical brush is placed on this coupling head (20), and this motor (17) is connected with said trigger belt (20.4) by means of a gear (20.5) coupled to the shaft of said motor (17). The resultant structure looks like a car when viewed from top and when the driving motor (17) of vertical brush starts rotating, this entire group moves under the guide of horizontal displacement channels (20.2) and the trigger belt (20.4).
Figure 6 shows the displacing reducer group, as mentioned shortly under the Brief Description of Invention. This easily assembled/disassembled reducer group ensures the displacement of the carrier frame (1) on the tracks it is placed to. Accordingly, the displacement reducer group is preferably positioned on the base (1.3) of at least one of supportive legs of the carrier frame and comprises a carrier frame displacing motor providing the necessary drive to this carrier frame to move on said displacement tracks (2), a reducer (22.1 ), as a drive transmission element, which is coupled to this motor (22), and an encoder (23), which is in connection with the shaft of said displacing motor (22) in order to report the control unit the position of said carrier frame. This mechanism further comprises limit switches, though not shown under this Figure, to report the control unit if said carrier frame (1) has moved to the start or end of said displacement track (2). This group is assembled on a plate-like assembly plate (21 ), whereas this assembly plate (21 ) is placed to the carrier frame's supportive leg's base (1.3) so as to first contact with a number of protruding detents formed on this base and then fixed to said base (1.3) by means of fixation screws (25). In this preferred embodiment of the present invention, said assembly plate (21) has the form of a rectangular plate, which has extensions on its mutual sides to produce a T-like form. Accordingly, a three-
detent group (24.1 ), which is formed to contact externally to the flat lower side of this assembly plate (21 ), and a two-detent group (24.2), which is formed to contact the inward of extending or protruding parts at the opposite side of said assembly plate (21), are embodied on the base of such supportive leg (1.1). Though illustrated so, this placement and the number of detents can be altered as desired in alternative embodiments of the present invention.
As an alternative to this structure, the carrier frame can be designed immobile, and not on displacement tracks (2), and a vehicle entered into the present machine can be moved by means of a conveyor. As a result, it is obvious that the present novelties can be applied to such an embodiment as well.
In another alternative embodiment, a cassette like structure, whereby wheels are assembled, is formed and fixed by means of screws on the front of supportive leg base (1.3) to provide an easy access to such wheels in the displacement track (2) on the front of such carrier frame (1) without removing the entire frame. A user can take out such wheels by removing said screws and pulling such cassette-like embodiment towards to him/her.
The automatic vehicle washing machine under the present invention is fully enclosed like a tunnel and covered preferably with a transparent decorative dress, whereas incorporated photocells can automatically illuminate its interior in dark.
This preferred embodiment of the present invention further employs brushes with polyethylene-made brush hairs in horizontal and vertical brushes. More elaborately, such brushes incorporate water-conveying channels made from 100% polyethylene material with an X cross-section and with specifically haired tips, and are particularly manufactured for vehicle wash with different colors and with UV resistance.
Besides the foregoing disclosures, the control of some elements such as brushes and drying means of the present automatic vehicle washing machine are realized by means of a microprocessor control unit, as mentioned before. This unit further detects beforehand any failures likely to occur in the automatic vehicle washing machine.
In a preferred embodiment of the present invention, said control unit employs a PLC (Programmable Logical Controller) as such microprocessor unit, and speed control circuits, which communicates with such PLC and which drives system's displacing and driving motors so as to provide them with a soft start in accordance with the signals it receives from said PLC. A driving motor within this disclosure means a motor, which -depending on the type- provides motion on a vertical or horizontal axis, and a rotating motor means a motor that causes a brush, which it is connected to, to rotate around its own axis, whereas all such motors are electric motors. The operation manner of the present system is illustrated hereunder with references to the foregoing disclosures.
At first, a user programs such PLC by selecting the desired washing mode via a user interface to direct said PLC to operate so. Many alternatives can be produced for the cleaning mode with the following examples: wash with drying; wash without drying; wash at entry plus drying at exit; wash at one entry-exit and drying at next entry-exit; pre-wash mode with only water and detergent flush at entry (without brush) and with brush application at exit; dance wash mode with vertical brushes moving jointly to left and right on only a vehicle's front and rear to clean particularly dirty license plates, for instance.
Thanks to such user interface, a user can also adjust the maximum pressure amount to be applied on a vehicle according to a vehicle's dirtiness.
Under the assumption that a user selects the mode "wash at entry plus drying at exit," a vehicle is brought to the entry of a washing machine, a presence sensor newly employed under the present automatic vehicle washing machine activates and communicates the vehicle's presence to such PLC and the latter causes the traffic light on the machine to illuminate green accordingly. A driver seeing this position moves further the vehicle some small distance and when the vehicle's front comes to a photocell, which is formed on a point of said supportive leg to determine the most ideal position for a vehicle wash, such PLC receives this signal and immediately causes the traffic light to light red in order to avoid such driver to move further, since the vehicle is in its ideal position already. Another sensor is positioned a little further from said first sensor on said supportive leg (1.1) for
circumstances when a driver fails to see this sign and tries to move further. This sensor causes the traffic light to flash in yellow and leads to an acoustic signal in order to warn such driver, once he/she drives in such vehicle more than required.
As a result, once the vehicle is perfectly positioned, the PLC causes the carrier frame's driving motor (22) to activate and to move it backwards on displacement tracks (2) until it exceeds the starting point of said vehicle. Immediately after this, the rotating motors (9, 18) of vertical and horizontal brushes start to rotate said brushes (3, 4). Whilst the carrier frame (1) and thus the connected brushes (3, 4) move towards the vehicle, there naturally occurs a certain constrain, though little, on the motor rotating a vertical and/or horizontal brush (3, 4), when the hairs of the relevant brush contacts the vehicle. Thus the power consumed by the relevant motor increases. This constrain is immediately sensed by PLC so that it immediately activates the driving motor (6, 17) of the relevant motor through its analog output and causes it to displace on the vertical axis if it is a vertical brush and on the horizontal axis, if it is a horizontal brush.
To clarify this operation logic, the entire action of brushes is adjusted based on the power alterations of relevant driving motors (9, 18) occurring due to contacts. An ideal pressure power interval is kept in the PLC's memory corresponding to the power of a rotating motor to consume for cleaning at a desired pressure. The PLC continuously controls the power rates consumed by connected rotating motors (8, 9) of horizontal and vertical brushes during operation and continuously compares such rates with predetermined power rate intervals kept in its memory. Thus if a/some power rate(s) measured from a/some rotating motor(s) falls out of such predetermined power interval while operating, the PLC immediately detects such circumstance and controls the relevant driving motor until the power consumed by the relevant driving motor is brought back to such determined power interval and then stops such motor.
The logic of how a PLC controls a driving motor can de described as following. If the power of the rotating motor (9) of the horizontal brush exceeds said ideal pressure power rate interval, it activates the driving motor (6) of the horizontal brush (4) and moves it upwards, and if the power is below a predetermined
interval, it moves downwards said horizontal brush and this process is continued until the PLC deactivates the driving motor (6) of horizontal brush after said predetermined interval is achieved.
Regarding the vertical brushes, if the power consumed by the rotating motor (18) of vertical brush is a rate exceeding said rate interval, it moves the vertical brush (3) towards the supportive leg (1.1 ) it is connected to or it takes away the vertical brush from the vehicle; and if the power consumed by the rotating motor of said vertical brush is a rate below said interval, it moves it downwards to bring it close to the vehicle. Once the desired ideal pressure power rate interval is achieved, it stops the driving motor (17) of the vertical brush (3) to maintain its position.
The PLC's control on horizontal (4) and vertical brushes (3) during a cleaning operation is exemplified in order to make clear the aforesaid operation logic.
With the assumption that a car is entered into the present washing machine, the horizontal brush (4) will naturally contact with the car's front once the carrier frame (1) starts moving and the power consumed by the rotating motor of this horizontal brush (9) will increase. If such consumed power exceeds a determined rate interval, the PLC will detect this and activate the driving motor (6) of said horizontal brush. When this motor (6) starts rotating, the horizontal brush chain gear (7) coupled with this driving motor (6) will start rotating as well and drive the horizontal brush chain (5) it is connected to. Thanks to this, the horizontal brush chain (5) of the horizontal brush (4) will be moved upwards.
Whilst the carrier frame (1) keeps progressing on the car, the horizontal brush (4) shall arrive at the front hood of the car after a while. While it passes from the front to this roof region, the contact between the horizontal brush (4) and the car will quite weaken on the roof region, since said brush shall move upwards due to the vertical surface on the front. Therefore the power consumed by the rotating motor of horizontal brush (9) shall decrease and fall under the determined ideal pressure power rate interval. The PLC shall activate again at this point and change the direction of rotation of the driving motor of said horizontal brush to move said brush downwards, namely, to move it closer to the front roof of said car. As a result of this, the horizontal brush will start to contact with the front roof of such car
after a certain position and the power consumed by the rotating motor (9) and after a certain while, will enter into the determined ideal pressure power rate interval. The PLC will detect this desired condition at this point and will stop the driving motor (6) of such horizontal brush.
As the carrier frame shall progress and come to the driver region of such car, the pressure force and thus the power consumed by the rotating motor (9) will increase during the pass between the roof region and the driver region due to the vertical surface, and the horizontal brush (4) shall be moved upwards as was the case indicated in the former paragraph. When this region is cleaned and the rear trunk region is arrived, the contact of the horizontal brush with the car shall start to decrease and the power rate of the rotating motor (9) shall fall below such determined rate interval. Having detected this fall, the PLC shall immediately take control of the driving motor (6) of horizontal brush in order to move downward said horizontal brush (4) as described above.
The control logic of vertical brushes (3) is as following. When the front of such car is contacted, the powers consumed by both of rotating motors (18) of such vertical brushes shall naturally increase. When such power rates exceed a determined rate interval, the PLC, having detected this, shall activate the vertical brush driving motors (17) coupled to each brush. The rotation action of this motor (6) shall be transmitted to the coupling piece (20) of the vertical brush by means of the vertical brush drive transmission mechanism with a trigger belt (20.4) and thus the vertical brush (4) shall move towards the supportive leg (1.1) it is connected to by means of the horizontal displacement channel (20.2). Since the contact shall reduce as the car's width is left behind, the power consumed by each vertical brush rotating motor (18) and the determined pressure power rate interval shall be departed accordingly. Thus the PLC will change the direction of the vertical brush driving motor (17) and cause the vertical brush to move closer to side surfaces of such car. This operation shall continue under this logic.
The point to be noticed at this position is that said vertical brushes are controlled entirely independently. It is because each vertical brush has its own driving motor and the PLC controls such motors separately depending on such contacts.
Therefore even if a car is not properly positioned within the present machine, there shall be experienced no problems concerning the cleaning thereof.
Another point to be noticed during these operations is that the PLC deactivates the carrier frame driving motor (22), when there is no contact between one of such horizontal and vertical brushes and the car. Thanks to this, the risk of an unwashed spot on such cars is avoided. In order to realize this, a blank power rate interval is maintained for any rotating motor within the memory of PLC in relation to power rates consumed when a brush connected to such rotating motor does not contact with such car surface. Thanks to this, the PLC determines the lack of contact when the power rate consumed by any rotating motors enters into such interval.
After the carrier frame moves the length of such car, the signal outputs of said photocells change, since there is not a car in front of them to perceive. These signal changes are detected by the PLC. Before stopping the entire system, the PLC determines the positioning of the horizontal brush. It is because, if the horizontal brush is not on its lowest position, this means that the car's length is still not completed and therefore the PLC continues to operate the entire system since this brush becomes to its lowest position. As a result, when the horizontal brush comes to its lowest position and said photocells transmits signals indicating the absence of a car, PLC starts the process of drying. During a washing period, the PLC saves the data, which are received from the displacement motor's encoder, as to how much the carrier frame is moved, and from the horizontal brush driving motor's encoder, as to how long and how much the horizontal brush has moved towards which direction, and forms the entire profile of such car by making use of such data. Thanks to this, the drying means (11 ) is moved according to this profile in a drying operation.
Another function of the PLC employed under the present invention is to detect any failures, which are occurring during an automatic vehicle washing machine and to report a user with such data. Accordingly, the PLC continuously controls all aforesaid photocells and sensors, limit switches, communication cables between the PLC and speed control unit, security keys, encoders in connection with the
driving motors all employed in the present washing machine, and in a case of malfunctioning or of receipt of a signal indicating an illogical position (for example, if the carrier frame is moving, but the relevant encoder is not transmitting a signal accordingly; this indicates a failure in the relevant encoder), such conditions are immediately displayed by means of a user monitor.
The present invention cannot be restricted with the foregoing. It is obvious that a skilled person in the art can bring forth the present novelty by using similar embodiments and/or can apply this embodiment on other embodiments with similar purposes in the relevant art. Therefore it is obvious that those embodiments shall lack the criteria of novelty and inventive step and that those embodiments shall be covered within the claims of the present application.