RU2813652C1 - Method of operation of car wash - Google Patents

Abstract

FIELD: car wash.

SUBSTANCE: invention relates to methods for washing vehicles. To reduce energy costs when operating a car wash, the car is placed in the portal, detergent is applied and time is waited, the pump is turned on to supply water to the nozzles, the body is rinsed, the pump is turned off, the fan is turned on, the body is blown, then the car is removed. A pneumatic hydraulic accumulator and a proportional valve are placed on the water supply line, before (a) and (c) the pump performance is calculated, the pump is turned on, the gas valve between the hydraulic accumulator and the gas cylinder is opened, water is pumped into the hydraulic accumulator, accumulating water energy during (a) or (c)). At stage (b), the gas valve and water supply to the nozzles are opened, energy is discharged from the pneumatic accumulator in the form of a stream of water, the pump directs water to the nozzles in the form of jets of increased power, the nozzles oscillate and approach the body. They continuously transmit information from the sensors to the control unit and regulate the pump performance.

EFFECT: reduction in the power consumption of the complex and increase in the efficiency of mechanisms while increasing environmental friendliness.

4 cl, 1 dwg

Description

The present invention relates to methods for washing vehicles at car wash complexes, namely at non-contact automatic wash complexes.

The modern rhythm of life does not allow the car owner to devote much time to regular car washing procedures. From practical experience in operating a car wash, it has been established that the acceptable time for washing a car is 3-5 minutes, which reduces the waiting time in line before the car wash and increases the efficiency of using the space of the car wash complex, reducing the resources spent.

For countries with harsh climatic conditions, contactless washing technology is relevant, the advantage of which compared to the brush washing method is expressed in its gentle effect on the car’s paintwork. However, with contactless washing, in order to effectively overcome the adhesion of the contaminating film to the surface of the car body, high water pressure is required to be supplied to the washing nozzles. In addition, in the process of contactless car washing, aggressive detergents are used, as a result of which car wash personnel are exposed to increased stress on the respiratory system due to fumes in the car wash area.

A method of contactless automatic washing of automotive items is known from the prior art (RF patent for invention No. 2751257, published on July 12, 2021), which includes: 1) sending at least one a manipulator, including an L-shaped rod with spray nozzles, movable, located on the frame and connected to a control unit for the movement of the manipulator, which is connected to a central control unit connected to a water supply unit, a washing solution mixing unit, and a car drying unit ; 2) applying a cleaning solution to automobile objects placed and fixed in the specified area, and leaving it for a specified time; 3) washing off the cleaning solution from automobile objects; 4) return the manipulator to its original position. The disadvantage of this technical solution is the low washing speed. In addition, there is no possibility of using rotary or oscillating nozzles, which leads to the need to use a larger number of nozzles, as a result of which the cleaning ability of machines with complex terrain deteriorates. Also, an unregulated, excessively large distance from the horizontal nozzles to the horizontal surfaces of the car reduces the quality of washing. At the same time, the implementation of this method requires high power connection to the power supply. In addition, it is not possible to wash two sides of the car and one horizontal surface at the same time.

There is a known method for washing a vehicle (patent CN 110217205, published on September 10, 2019), based on image recognition, which includes the following steps: determining the level of cleanliness of the surface of the vehicle body being cleaned; processing of the vehicle being cleaned in accordance with the cleaning program depending on the cleanliness of the body surface. The method allows you to save resources spent on washing (detergents, water, electricity). However, the disadvantages of this method are the complexity and high cost of the software required to implement the method, as well as the need to use aggressive detergents.

The closest technical solution to the claimed one is the automatic contactless car wash portal Christ Aquatus of the German concern “Otto Christ AG” (see. The applied Scan-X technology determines the contours of vehicles and ensures washing of the entire surface of the car body without gaps. A significant disadvantage of this wash is the low water pressure 120 bar with an instantaneous power consumption of 16 kW. Obviously, the designer’s choice of such a low pressure was due to the permissible instantaneous power consumption of electricity. To compensate for the lack of high-pressure washing quality, the manufacturer recommends the use of more aggressive chemical detergents, and also uses slower oscillation of the nozzles and the movement of the portal along the car at low speed.However, the use of aggressive chemical detergents negatively affects the paintwork of the car body.

The objective of the claimed invention is to reduce energy costs during the operation of a car wash complex.

The technical result to be achieved by the invention is to reduce the instantaneous power consumption of the complex, as well as increase the efficiency of the mechanisms while simultaneously increasing the environmental friendliness of the entire process.

The technical result is achieved by using a method of operating a car wash for vehicles, which includes stages in which: a) the car is placed inside the portal of the car wash complex, a detergent is applied to the surface of the body and the time required for the said product to act is waited, b) the detergent is applied via an electronic control unit a signal to supply water to the nozzles installed on the inside of the portal and rinse the car body, after which a signal is sent through the electronic control unit to turn off the high-pressure pump, c) through the electronic control unit a signal is sent to turn on the fan and the car body is blown, after after which the car is removed from the portal. A pneumatic-hydraulic accumulator and a controlled proportional valve are installed on the high-pressure water supply line. Before steps (a) and (c), the required performance of the high-pressure pump is calculated using the electronic control unit, the high-pressure pump is turned on, a signal is sent from the electronic control unit to open the gas valve connecting the hydraulic accumulator and the gas cylinder, and high-pressure water is pumped into the hydraulic accumulator, carrying out the accumulation of potential energy of water during stage (a) or (c). At stage (b), signals are sent from the electronic control unit to open the gas valve and supply water to the nozzles, discharge potential energy from the pneumatic accumulator in the form of a high-pressure water flow, maintaining the required water pressure on the nozzles by controlling the gas valve and the proportional water valve on the high-pressure line pressure, while the high-pressure pump continues to operate, also directing the flow of water to the nozzles to form jets of water of increased power. At the same time, they change the direction of the jets, oscillating the nozzles at angles calculated using an electronic control unit based on information about the dimensions of the car received from sensors installed on the portal, and bring these nozzles closer to the surface of the car body, extending them using a drive. During all these stages, information from the sensors is transmitted to the electronic control unit and the performance of the high-pressure pump is regulated using a frequency converter.

Excess water can be discharged into the buffer tank through a safety valve opened by a signal from the electronic control unit.

In step (b), the movement of the portal can be slowed down as it approaches the area of the car's wheels and their arches, creating more vibrations of the injectors in this area.

The pulsation of consumed electrical power can be reduced using a buffer battery, charging it when the car wash complex is idle.

The essence of the proposed technical solution is illustrated by a drawing, which shows a functional diagram of the implementation of the method.

The numbers indicate the following:

1 - payment terminal;

2 - battery charger;

3 - electronic control unit (hereinafter - ECU);

4 - sensors for vehicle position, water pressure, gas pressure, temperature;

5 - rechargeable battery (hereinafter - battery);

6 - frequency converter (hereinafter referred to as the frequency converter);

7 - high pressure pump;

8 - pneumatic hydraulic accumulator (hereinafter referred to as PHA);

9 - buffer tank with water;

10 - controlled gas valve;

11, 12 - controlled water valves;

13 - expansion cylinder for gas;

14-proportional water valve;

15 - controlled nozzles.

The device that implements the proposed method consists of a U-shaped portal, on the inside of which there are many movable nozzles 15 for supplying water and sensors 4 for vehicle position, water pressure, gas and temperature. A high-pressure pump 7 with an electric motor is installed on the water supply line to the nozzles 15. After the high pressure pump 7, a PGA 8 is installed on the water supply line, containing water and gas pressure sensors. PGA 8 is combined with an expansion gas cylinder 13 through the gas supply valve 10. The device includes a battery 5, an inverter 6, a power supply motor for the high-pressure pump 7, as well as an air supply system. The high pressure line valve 14, the sensor unit 4, the air supply system, the high pressure pump 7, the inverter 6 and the gas supply valve 10 are connected to the ECU 3 via a communication channel.

The implementation of the method of operation of a car wash for vehicles includes alternating phases: applying detergents to the car body and waiting time for their action (F1), high-pressure washing (F2) and air drying (AF).

The time of phase F1 is 2-3 minutes and depends on the selected washing mode, the density of the car’s contamination, the temperature of the car body, and the type of detergent (alkaline or acidic solution, rinse aid, wax, hydrovarnish or similar product).

The cyclic operating mode with the operating time of the washing phases known in advance allows potential energy to be accumulated at a time when high water pressure is not required, and spent during the water washing cycle - phase F2. For this purpose, the proposed method proposes to use a potential energy storage device on the water supply line of a car wash complex.

The accumulation of potential energy can occur in hydraulic, PGA, electrochemical batteries and their combinations. The optimal price/performance ratio is energy storage in PGAs, which can be membrane, balloon or piston type. In a PGA, the working volume and the compressible gas are separated, depending on the type, by a stretchable membrane, a balloon or a piston. Inexpensive industrial nitrogen is usually used as the compressed gas. PGA allows you to accumulate high-pressure water and quickly release it at the right time, providing the necessary water flow to a large number of nozzles, while simultaneously reducing the requirements for high-pressure pump performance, noise levels and pressure pulsations. PHA allows you to use both clean tap water and recycled (already used) water after it has been purified from solid particles.

In high-pressure pumps, the piston moves using a crank mechanism, the speed of which varies according to the sine law of the angle of rotation of the pump shaft. The water supply from the pump will also change in accordance with the movement of the piston, also unevenly and intermittently. Triplex pumps, due to the displacement of the three pistons by 120 degrees, produce a more uniform flow, however, they also produce significant pressure pulsations, which leads to significant noise and vibration, reducing the reliability of high-pressure hoses. The use of PHA 8 in the inventive method makes it possible to protect equipment from hydraulic shocks that form in the system when the solenoid valves are activated, and to reduce the level of pressure pulsations.

In traditional washing, the high-pressure pumps only operate during the F2 phase, which lasts about 40 seconds. During the process of washing the washing complex, in accordance with the claimed method, the high pressure pump 7 operates continuously most of the time. In phases F1, F3, when there is no water flow, PHA 8 is filled with high-pressure water. As PHA 8 is filled with water, the gas is compressed, decreasing in volume, and water, on the contrary, occupies the released volume.

The electric motor drive of the pump 7 is powered from the inverter 6, which allows you to smoothly regulate the speed of an asynchronous or synchronous motor by creating an electrical voltage of a given frequency at the output of the inverter 6. ECU 3, with the help of inverter 6, adjusts the speed of the electric motor of pump 7 and, accordingly, its performance in such a way as to complete filling of PHA 8 with high-pressure water by the beginning of phase F2. Due to the incompressibility of water, the pressure generated by a high-pressure piston pump is a constant value, independent of the pump capacity.

ECU 3 continuously makes calculations based on information from input sensors 4 of water and gas pressure in PGA 8, temperature, selected washing mode and adjusts the performance of pump 7 with minimum instantaneous power consumption for timely complete filling of PGA 8 with water, which eliminates unnecessary starts/stops of the electric motor pump 7, reduces energy costs and increases the service life of the entire complex. Electric motors have high efficiency in the power range of 0.4-1.0 from the rated power, according to the design and parameters of the most common types of electric motors, therefore ECU 3, receiving information from IF 6 about the current operating modes of the electric motor, maintains optimal speed of the electric motor in the high efficiency zone. For the most complete use of the volume of PHA 8, pump 7 pumps water into PHA 8 with a pressure exceeding the required 1.3-2 times for the operation of nozzles 15. However, in the washing phase F2, ECU 3 maintains the optimal water pressure in nozzles 15, controlling the proportional valve 14 in the high pressure line of injectors 15.

For more precise control of the discharge pressure of PHA 8, an additional storage gas cylinder 13 was introduced into the complex, into which gas is displaced from PHA 8 when it is charged. In phase F2, when PGA 8 is discharged, gas flows through the controlled valve 10 from the storage cylinder 13 back to PGA 8, while ECU 3 controls the gas valve 10 to maintain constant water pressure from PGA 8.

During the duration of phase F2, the flow of high-pressure water to the nozzles 15 consists of the productivity of the operating pump 7 and the discharge of the PHA 8. Thus, the total flow of high-pressure water exceeds the productivity of the high-pressure pump 7 several times, which allows speeding up the operation of the washing complex without exceeding the instantaneous power consumption by high-pressure pump 7. When discharging, PHA 8 is capable of quickly delivering a large flow of accumulated water, which makes it possible to feed a larger number of nozzles 15 located on the U-shaped portal (3-4 times more than with a traditional wash) with high pressure. The U-shaped portal allows you to wash two sides of the car and one horizontal surface at the same time. The transverse horizontal beam of the portal with nozzles 15 moves along a vertical axis, bending around the car body with optimal clearance and making maximum use of the energy of the water jet. PGA 8 allows you to produce a flow of water sufficient to supply high pressure nozzles 15 in two or more portals simultaneously.

High water pressure in the nozzle 15 is necessary to create an initial high speed and energy of the water, since with increasing distance from the nozzle 15 to the surface of the body, the energy of the water jet quickly decreases. Typically, the water pressure is 170-200 bar, which requires the allocation of significant power to drive the high-pressure pump 7 at the rate of 4-5 kW for each washing nozzle 15 at a flow rate of 10-12 l/min. To increase the washing speed, the simultaneous operation of many nozzles 15 is necessary, but the use of a large number of nozzles is extremely energy-consuming, since the power of the high-pressure pump is directly proportional to its performance. The required drive power of a high-pressure piston pump can be approximately calculated from the relationship:

where 530 is a dimensionless constant, and water pressure and water flow l/min are calculated based on the selected operating points of the nozzles.

The design of the car wash portal used according to the claimed method contains movable controlled nozzles 15. As the portal of the car wash complex moves along the car, each of the controlled nozzles 15 oscillates, sequentially processing its own section of the surface of the car body. ECU 3 receives information from sensors 4 (ultrasonic, radio wave and optical), determines the shape of the car body and adjusts the angles of oscillation of injectors 15. When the portal approaches the places of greatest contamination, which, as a rule, are wheels and wheel arches, the longitudinal movement of the portal slows down, jets of water make more passes over the same place, thoroughly cleaning the surface. Using a mechanical drive, the nozzles 15, controlled by the ECU 3, are brought closer to the surface of the body to conserve water energy when the distance from the nozzles 15 to the surface of the body is too large.

For example, when operating a traditional touchless car wash portal with eight nozzles and a water flow rate of 90 l/min, the pump motor consumes more than 32 kW of instantaneous power. A further increase in the speed of car washing leads to an increase in the number of washing nozzles and a proportional increase in the instantaneous power consumption of the washing pump, which creates difficulties with connection to distribution networks capable of allocating the necessary power taking into account starting currents, and also leads to undesirable high cyclic loads of the electrical network, increasing losses in cables, reduces the reliability and efficiency of the car wash complex as a whole. In the case of using an internal combustion engine as a pump drive, high engine power is required and, accordingly, high fuel consumption, low efficiency due to the variable load capacity of the engine in different washing operating modes, which leads to a decrease in engine life. The present invention reduces the instantaneous power consumption of the complex several times, evenly distributing power consumption over time, minimizes the number of start/stop cycles of motors, increases efficiency and increases the reliability and service life of pumps and motors in general.

Next, we compare the instantaneous power consumption in the case of the traditional and proposed solutions.

Example 1: Traditional washing scheme.

An electric pump motor with a power of 32 kW is used.

The duration of the F2 washing phase is 40 seconds.

The instantaneous power consumption of the pump electric motor is 32 kW, excluding starting currents, which can exceed the rated current by 4-7 times.

The consumed electrical power in the washing phase F2 is equal to:

32 kW * 40 sec = 0.356 kW/h.

As a result, in the traditional circuit there is a higher instantaneous power consumption of 32 kW, a high starting current, and the mode of frequent starts/stops negatively affects the service life of high-pressure units.

Example 2: Proposed scheme.

An 8 kW electric pump motor is used.

Accumulation of high pressure water in the PHA for 120 seconds in phase F1.

Electrical power consumed: 8 kW * 120 sec = 0.267 kW/h

The duration of the F2 washing phase is 40 seconds.

The high pressure pump continues to operate, the pump performance and the water flow from the PHA add up.

Electric power consumption of the pump: 8 kW * 40 sec = 0.089 kW/h

Total power consumption during the high pressure washing phase:

0.267+0.089=0.356 kW/h. In practice, the consumed power will be slightly higher, taking into account the efficiency of the PGA.

The use of PGA 8 with control of ECU 3 made it possible to reduce the instantaneous power consumption of the washing machine by 4 times. The service life of the PGA is hundreds of thousands of charge/discharge cycles with a service life of more than 15 years. Maintenance of the PGA is simple and comes down to monitoring the gas pressure, which is automatically carried out by the ECU using electronic pressure sensors. In the event of a decrease in gas pressure or significant wear of the PHA, the ECU calculates by analyzing data from sensors, and the information is automatically sent to the service department. PHA repair comes down to replacing components, while the cost of consumables and replacement work is not high.

The ripple of consumed electrical power from the network is further reduced using small-capacity buffer batteries 5. Through the control and protection unit, battery 5 is connected to the DC bus of the inverter 6 after the AC rectifier of the supply network. At a time when the complex consumes instantaneous power below the maximum permissible, the battery 5 is constantly charged through the charger 2, controlled by the ECU 3 with balancing of the elements of the battery 5 for an equal charge of all elements in the battery. ECU 3 adjusts the charging current so that the maximum power consumption from the network is not exceeded. Battery 5 can be charged more intensively when the car wash is idle, during vehicle entry/exit, when powerful energy consumers are turned off. When starting or at maximum operating modes of powerful electric motors of the high-pressure pump 7 or drying fans in phase F3, part of the energy comes from the buffer battery 5, reducing the ripple of power consumption from the network. Due to the short period of use of batteries 5, their large capacity is not required. Modern batteries have a service life of about 15 years and are designed for a large number of cycles in the event of partial charge-discharge in buffer mode.

The method is carried out as follows. After selecting the mode for washing the car body and paying for the service in payment terminal 1, place the car inside the portal of the car wash complex and start the washing process by sending a signal from ECU 3. ECU 3 continuously receives signals from sensors 4 and updates information about the current operating mode of the complex, spatial position car in the washing room, values of sensors 4 for water pressure, gas, temperature, network voltage, state of charge of battery 5 and PGA 8. ECU 3 continuously calculates the required power of pump 7 to minimize energy consumption, taking into account the degree of filling of PGA 8 with water and the remaining operating time of the pump 7 in phase F2 or accumulation of water in PHA 8 in other phases. In phase F1, detergents are applied to the car body and the recommended amount of time for exposure to contaminants is maintained. ECU 3 sends a signal to open controlled valve 11. Valve 14 remains closed in this mode. The starting currents of turning on the high-pressure pump 7, transient processes that occur when changing the modes of the inverter 6, voltage fluctuations in the network are smoothed out by the energy coming from a small buffer battery 5 connected to the DC bus of the inverter 6. The ECU 3 sends a signal to open the valve 10. When When the PGA 8 is charged with water, the compressed gas passes through the open valve 10 into the expansion gas cylinder 13. For the fullest use of the volume of the PGA 8, the high-pressure pump 7 pumps water into the PGA 8 with a pressure exceeding the optimal one for the operation of the injectors 15. In emergency cases, if it is exceeded the pressure in the high-pressure line or in the PGA 8 is higher than the set one, the ECU 3 sends a signal to open the safety valve 12, while excess water is discharged into the buffer tank 9, and the pressure in the system is reduced to a safe one. The moment of completion of charging of PHA 8 is determined by ECU 3 using information received from gas pressure, water and temperature sensors 4.

With the beginning of phase F2 of washing with high pressure water, PHA 8 is fully charged with water with a pressure exceeding that required for the operation of injectors 15. Controlled valves 10 and 12 are closed, and ECU 3 sends a signal to open valves 11 and 14. High pressure water flow to injectors 15 consists of the productivity of the operating high-pressure pump 7 and the discharge of the PHA 8, while the total flow of high-pressure water exceeds the productivity of the high-pressure pump 7 several times. To maintain optimal water pressure in injectors 15, ECU 3 in real time, controlling the opening of gas valve 10 and proportional valve 14 in the high-pressure water line, maintains the required pressure in the high-pressure line of injectors 15. As PGA 8 discharges, the water pressure gradually decreases to a minimum, while the pressure at the end of discharge of PHA 8 remains sufficient to ensure high-quality washing. While the portal moves along the car body, the controlled nozzles 15 oscillate at the angles specified by the ECU 3 to wash each section of the body surface. The ability of PGA 8 to quickly release a large flow of water allows you to use two portals with a large number of 15 nozzles simultaneously to wash one car, which allows you to reduce the washing time by half.

With the beginning of phase F3 of drying the washed car body, PGA 8 is discharged, and a closing signal is sent to valve 14. ECU 3 calculates the duration of charging time for PHA 8 before the start of the next phase F2 of washing with high pressure water. ECU 3 sends signals: to supply air to the fan for blowing the car body in a known way during the FZ phase, to open the controlled valve 11 and to open valve 10. By analogy with phase F1, using IF 6, ECU 3 adjusts the performance of the high-pressure pump 7 for minimum consumption of instantaneous power consumption. PHA 8 is charged with water, and the compressed gas passes through the open valve 10 into the expansion gas cylinder 13. The moment of completion of charging of PHA 8 is determined by the ECU 3 using information received from sensors 4 of gas pressure, water and temperature 4.

ECU 3 continuously monitors the charging status of battery 5. If battery 5 is not fully charged, then ECU 3, controlling battery charger 2, performs charging and balancing of battery 5, optimized for power consumption, charge current and resource.

After the end of the high-pressure washing (F1 and F2) and drying (FZ) phases, the cycle is repeated, charging and discharging the PHA 8. In the case of a full charge of the PHA and a long period of inactivity, ECU 3 turns off the high-pressure pump 7, closes all valves and goes into Standby mode.

The method of operating a car wash for vehicles can also be used in multi-post self-service car washes, which will significantly reduce the pulsations of instantaneous power consumption.

The way a car wash works for vehicles allows you to get the following advantages:

- reduce the concentration of aggressive alkaline or acid-based detergents,

- reduce the risk of environmental problems,

- reduce wastewater treatment costs.

Claims (8)

1. A method of operating a car wash for vehicles, including the stages in which: a) the car is placed inside the portal of the car wash complex, the detergent is applied to the surface of the body and the time required for the said product to act is waited, b) via the electronic control unit, a signal is sent to turn on the high pressure pump to supply water to the nozzles installed on the inside of the portal and rinse the car body, after which, via the electronic control unit, a signal is sent to turn off the high pressure pump, c) by means of an electronic control unit, a signal is sent to turn on the fan and the car body is blown, after which the car is removed from the portal, characterized in that a pneumatic-hydraulic accumulator and a controlled proportional valve are installed on the high-pressure water supply line; before stages (a) and (c), the required performance of the high-pressure pump is calculated using an electronic control unit, the high-pressure pump is turned on, and a signal is sent from the electronic control unit to open gas valve connecting the pneumatic accumulator and the gas cylinder, and pump high-pressure water into the pneumatic accumulator, accumulating the potential energy of water during stage (a) or (c), at stage (b) signals are sent from the electronic control unit to open the gas and supply valve water to the nozzles, discharge potential energy from the pneumatic accumulator in the form of a high-pressure water flow, maintaining the required water pressure on the nozzles and controlling the gas valve and the proportional water valve on the high-pressure line, while the high-pressure pump continues to operate, also directing the water flow to the nozzles with the formation of jets of water of increased power, while changing the direction of the jets, oscillating the nozzles at angles calculated using an electronic control unit based on information about the dimensions of the car received from sensors installed on the portal, and bringing these nozzles closer to the surface of the car body, extending them using a drive, and during all these stages, information from the sensors is transmitted to the electronic control unit and the performance of the high-pressure pump is regulated using a frequency converter. 2. The method of operating a car wash according to claim 1, characterized in that excess water is discharged into a buffer tank through a safety valve opened by a signal from the electronic control unit. 3. The method of operation of a car wash according to claim 1, characterized in that at stage (b) the movement of the portal is slowed down as it approaches the area of the car wheels and their arches, creating a greater number of vibrations of the nozzles in this area. 4. The method of operating a car wash according to claim 1, characterized in that it reduces the pulsation of consumed electrical power using a buffer battery, charging it when the car wash complex is idle.