VEHICLE WASHING APPARATUS MOTOR CONTROL USING SOFTWARE
AND OPERATOR INTERFACES
CROSS REFERENCE TO RELATED UNITED STATES APPLICATIONS This application claims priority from United States Provisional Application No.
60/295,620, "VEHICLE WASHING APPARATUS MOTOR CONTROL USING SOFTWARE AND OPERATOR INTERFACES" of Malki, et al, filed on June 4, 2001, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to vehicle washing apparatus, and in particular to operator terminals for controlling and monitoring operations in a car wash or other vehicle washing apparatus.
BACKGROUND OF THE INVENTION
In the prior art, car washes and other vehicle washing apparatus are configured with multiple machines such as washers, brushes, blowers, and wax applicators arrayed in a linear direction along a tunnel, with a conveyor moving a car or vehicle along the linear direction for predetermined operation of the machines at predetermined times. Heretofore, the machines have been stand-alone devices, such that malfunctions or other problems in such machines are not readily detected until the washing operations are interrupted. In addition, when a problem with a particular machine occurs, an operator must travel to the machine in order to stop it.
A need exists for a control system for effectively monitoring and controlling each machine in a car wash.
In addition, the machines of a car wash are typically programmed at each machine, with ad hoc adjustment of the timing and operation of the machines on a machine-by-machine basis. Effecting changes in operations of the machines to handle a different type of vehicle or to compensate for a malfunctioning machine must be performed one machine at a time.
A need exists for a control system which can configure all of the machines from a single operator terminal to reconfigure the operation of the entire set of machines in a car wash.
SUMMARY OF THE INVENTION
A computerized control system and method include an operator terminal having an operator interface, using a touch-screen display, to effectively control and monitor the operation of each machine in a car wash, to reconfigure the machines to wash different types of vehicles, and to effectively stop some or all of the machines in alarm conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the disclosed control system connected to a car wash system. FIG. 2 illustrates a schematic of an alternative embodiment of the disclosed control system connected to the car wash system and components thereof. FIG. 3 illustrates a car wash machine length initialization screen.
FIG. 4 illustrates a car wash tunnel control screen. FIG. 5 illustrates a car wash component control screen. FIG. 6 illustrates a statistics reporting screen. FIG. 7 illustrates a report.
FIGS. 8-9 illustrate flowcharts of the operation of the disclosed control system and method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIGS. 1-9 and as described herein, a computerized control system 10 and method of operation are disclosed for operation with a vehicle washing apparatus 12, such as a car wash, using software and operator interfaces. The computerized control system 10 and method includes at least one operator interface including an input terminal 14 and/or other input/output devices, allowing a car wash operator to operate numerous functions in the car wash 12. The functions include providing automatic starting and stopping of the machines/components of the car wash; manual and selective starting and stopping of the machines/components of the car wash; and communicating with other input terminals, with the Internet, or with any given computing device such as a personal computer and/or a hand-held computer such as diagnostic equipment. The functions also include the selective activation and/or control of all machines/components in the car wash, including units which might not be automatically operated, such as vacuum machines, prep guns, etc.
The control system 10 and method also function to control the lighting and other environmental aspects of the car wash, such as ventilation, draining of run-off fluids, etc. In addition, the control system 10 and method can perform accounting and billing functions, such as the capability of generating a number of vehicle tickets for customers to have their vehicles washed. The number of vehicle tickets can be limited to a predetermined number, such as ten tickets, and the control system 10 can coordinate and hack the washing of each vehicle associated with a particular ticket.
The control system 10 and method can also perform diagnostic functions to locate possible problems in the software and/or the components connect to the control system 10, and to assist in resolving such problems to minimize and/or avoid impairment of operation of the car wash. As shown in FIGS. 1-2, the disclosed control system and method include a computerized control system 10, which could be a computer terminal 14 associated with memory 16 and an operator interface 18 through which an operator controls the entire car wash 12 using the disclosed software and the operator interface features described herein. The computerized control system 10 operating using the software and the operator interface 18 can be embodied in a stand-alone computer such as a personal computer acting as an operator terminal located at the site of the car wash 12, for example, at the entrance of the car wash where the cars to be washed initially enter and their owners communicate with the car wash operator personnel to select the services to be performed by the car wash 12. The operator interface 18 provided by the operator terminal 14 can include a touch-screen and/or a graphic user interface (GUI) for facilitating efficient entry of commands by the car wash operator personnel. For example, any known and commercially available touch-screen technology can be used for the operator interface 18.
In a preferred embodiment, the computerized control system 10 could employ an
"INTEL 486" or "INTEL PENTIUM'-based processor operating with, for example, 66 MHz clock speed, with 30 MB hard disk memory capacity, and 8 MB random access memory (RAM) capacity. Other implementations could use different system configurations, for example, different processors with faster processing speeds and multimedia capabilities, and can use different memory capacities for efficient operation. In the preferred embodiment, the operator interface 18 generated at the operator terminal 14 is implemented by the "MAGELIS" operator terminal software, commercially
available from "SCHNEIDER ELECTRIC", which is configured to run in the computerized control system 10 operating the "WINDOWS 95", the "WINDOWS NT", and/or other "WINDOWS"-based operating systems, commercially available from "MICROSOFT CORPORATION". The "MAGELIS" operator terminal software can be programmed and configured using the "XBTL1003/L1004" development software, commercially available from "SCHNEIDER ELECTRIC", to create interlinked application pages, alarm pages, help pages, form pages, etc., for supporting touch-screen functions and function keys, for what-you-see-is-what-you-get (WYSIWYG) functionality and ease of use, as shown and described herein. The computerized control system 10 and method can also employ one or more communications protocols to connect to the machines of the car wash and to other devices. For example, the UNI-TELWAY, FIPIO, FIPWAY, MODBUS, JBUS, MODBUS PLUS, KS, TCP/IP, and other known protocols and industry standards can be used to establish communications between the computerized control system 10 and method with the machines of the car wash 12, to other computers, and/or to the Internet for remote operations of the car wash.
In alternative embodiments, the memory 16 and the software can be positioned remote from the terminal 14 and operator interface 18, for example, in a server connected to the terminal 14 via a network, such that the software operates in a processor of the server, generates the operator interface 18 at the remote terminal 14 located at the site of the car wash, and responds to operator-input commands to generate the operator interface screens and the various control signals for controlling the machines of the car wash, as described herein.
The computerized control system 10 is operatively connected to the car wash 12 and its various components/machines via communication channels and/or a
communications interface 30, such as wires and cables, for transmitting control signals and/or data signals between the computerized control system 10 and the various machines/components 34, 36, 38 of the car wash 12, such as the conveyor 34, washers, brushes 36, waxers, dryers, etc. Alternatively or in addition, the communications channels could be wireless connections and/or waveguides between wireless transmitters and receivers associated with the computerized control system 10 and the various machines/components.
Referring to FIG. 2, the components of the disclosed computerized control system 10 and method are shown in greater detail with an alternative embodiment of the car wash and its machines/components, shown in a top view. The computerized control system 10 includes a processor 20 connected to the operator interface 18 and the memory 16. The operator interface 18 includes input and/or output devices 22, for example, a touch-screen display 24 for displaying the screens shown in FIGS. 3-7. Screen-displayed alphanumeric keys can be shown on the touch-screen display 24 to permit alphanumeric data entry, for example, customer names or other data. Referring to FIG. 1, a keyboard 26 can be optionally included, for example, to enter customer names or other alphanumeric data, with the optional keyboard supplementing the touch-screen display 24.
In alternative embodiments, a mouse and/or the keyboard 26 can be provided for use with a GUI, such as a "WINDOWS"-based application implemented, for example, using "MICROSOFT VISUAL BASIC" and/or "MICROSOFT ACTIVEX" software, and/or "JAVA" technology available from "SUN MICROSYSTEMS", and can include web-based operator interfaces using browsers such as "MICROSOFT INTERNET EXPLORER" or "NETSCAPE NAVIGATOR", to enter commands and to display the operator screens described and shown herein.
Referring to FIG. 2, other input and/or output devices 22 such as styluses or light pens for user selections through the operator interface, and liquid crystal displays or plasma-based flat panel screens can be used to implement the operator interface 18 described herein. The memory 16 in FIG. 2 stores the data settings input by the operator, for example, the lengths of time of operation of each machines, input into the screen shown in FIG. 3, as well as other configuration data such as the speed of the conveyor 34, the duration for applying wax, the times when the brushes and the wax are activated, etc.
Referring to FIG. 2, the memory 16 also stores stored programs 28, such as the software which operates the computerized control system 10 to generate the screens displayed through the operator interface 18.
The computerized control system 10 is connected to a communications interface 30, which can include wires and/or wireless connections 32 as described herein, to convey control signals and data signals between the computerized control system 10 and the various components/machines 34, 36, 38 of the car wash 12 as well as secondary devices associated with the car wash, and external devices 40 such as networks and telephone equipment for connection to, for example, the Internet.
Such secondary devices can include video cameras 42, audio devices 44 such as alarm klaxons and/or loudspeakers, emergency warning lights 46 such as rotating red lights, lighting 48 such as fluorescent lights throughout the car wash, electronic marquees 50 or other message display devices, and other devices and control systems such as ventilation controllers, fluid run-off pumps, and other useful devices known in the art for use in a car wash 12.
For example, video cameras 42 can be used to convey images to the operator at the terminal 14 to view the machines 34, 38, 38 and their operation in the car wash, to
view the progress of any selected car through the car wash 12, and to view any safety or emergency situations involving the machines 34, 36, 38 in the car wash 12, for example, to assist the operator in identifying an emergency involving a customer and to quickly shut down a particular machine or all of the machines of the car wash to avert accidents or injury. Such video can be generated in video windows overlaying the screens in FIGS.
4-7 using windowing and multimedia techniques known in the art, for example, by activation of a function key through the operator interface 18.
The audio devices 44 can be klaxons for emitting loud warning noises or signals, for example, with sufficient volume to be heard over the sounds of the machines of the car wash 12. Alternatively or in addition, the audio devices 44 can be loudspeakers through which an operator can provide messages to employees via a microphone optionally provided as an input device 22 of the operator terminal 14 of the computerized control system 10.
The emergency warning lights 46 such as rotating red lights can be used in conjunction with audio klaxons to indicate a warning condition; for example, during initial startup before the machines 34, 36, 38 of the car wash 12 are activated at the beginning of the operating day, to warn employees that the machines, such as the conveyor 34 and brushes 36, are about to be activated.
The lighting 48 and other environmental conditions described herein such as ventilation can be controlled tlirough the computerized control system 10, for example, during a start-up procedure at the beginning of the operating day and throughout the day as desired by the operator.
The marquee 50 or other message devices can be positioned throughout the car wash as well as outside the car wash, for example, near the entrance of the car wash, with such message devices controlled through the control terminal of the computerized control
system 10; for example, an input screen can be displayed to the operator to enter prices for services such as wax, and to indicate price specials or sales.
In this manner, using the touch screen 24 of the operator terminal 14 as well as the various screens shown in FIGS. 4-5, the entire operation of the car wash can be automated, such that a single operator at the operator terminal 14 can monitor and control operation of the entire car wash facility, inside and out, with single and/or simple touches and mode selections.
In further embodiments, the operator can be able to generate statistics screens and reports, as shown in FIGS. 6-7, and also able to generate vehicle tickets and bills for customers, which can be displayed on the touch screen and can also be printed or otherwise transmitted to other devices. For example, the output device 22 shown in FIG.
2 can include a printer for printing such vehicle tickets, bills, and reports. Alternatively, the operator could be able to transmit such vehicle tickets, bills, and reports to external devices through the communications interface 30 of FIG. 2; for example, to credit card companies or banks to charge or to debit the costs of the car wash. Such billing and payment systems can be automatic, such as the commercially available "E-Z PASS" system, to permit "drive-thru" car washes without stopping and/or without passenger disembarkation.
In other embodiments, the car wash 12 could be part of a group of associated merchants, such as franchises in a chain of car washes, and the bills, statistics, and reports can be transmitted via telephone connection and/or the Internet as the external devices 40, for data collection in a central tracking database.
In this manner, billing and operational reporting of the business of the car wash can be automated and facilitated for improved operation at the customer level as well as at the business administrative level,
In further embodiments, the diagnostics functions of the computerized control system 10 can also generate status reports, such as diagnosed conditions of the machines and/or of the software, with such status reports also capable of being transmitted via the communications interface to external devices, such as a remote diagnostic facility which, upon receiving such status reports, can assist the car wash operator to identify machine and/or software problems and to remedy them remotely. CONTROL SYSTEM INITIALIZATION
When the operator configures the control system 10 to select the operating settings of the car wash and its machines, the operator could be presented with screens which identify the machines by type and by index number, and which identify their current settings. For example, as shown in FIG. 3, multiple blowers can be numbered "1", "2", "3", and can be indexed as machines "10", "11", "12", respectively, along the path of the tunnel formed by the car wash and its machines, as shown in FIGS. 1-2. Using the touch screen displaying the screen of FIG. 3, the operator can select and change the length of operation of each blower. For example, the lengths of operation can be measured in minutes ranging from "0" to "99".
The screen in FIG. 3 can represent one page of multiple selectable "pages" of screens through which the operator can step, for example, using a page icon in the lower right hand corner of the screen. Each screen controls a set of machines, such that the operator can select and configure the entire car wash for operation. For example, if one blower is malfunctioning or out of service, the operator can increase the lengths of duration of the other blowers to compensate.
In addition, with such screens, the operator can configure the operator interface to fit with the set of available machines in the car wash. For example, some car washes can be attended soft cloth tunnels, unattended soft cloth tunnels, hand wash tunnels, or touch
drive-thru tunnels, each of which have different configurations of machines. Through the operator interface, the operator can configure the control system 10 to identify the position and type of each machine along the tunnel, to set the duration and timing of each machine for automated operation, and to save or modify such configurations as needed or desired.
CONTROL SYSTEM OPERATION
Referring to FIG. 4, when a vehicle enters the car wash, the operator can activate a tunnel control screen to select a mode of operation. For example, the tunnel control screen displays a plurality of icons simulating buttons to be pressed by the operator. The buttons can simulate up-raised buttons which, upon activation by touching of the icon at the corresponding position on the touch screen, is changed by the control system 10 to display a simulation of a down-pressed button, in a manner known in the art. Alternatively or in addition, the buttons can display a first color and/or texture indicating an OFF position, and can display a second color and/or texture indicating an ON position. In an example embodiment, the button can appear blue in an OFF position, and appear red in an ON position. In other embodiments, described in conjunction with FIG. 5, the button can display a single color and no image in an OFF position, and can display an image of the selected machine in an ON position, indicating that the displayed machine is active and/or to be activated. The buttons can also display words, such as ON or OFF, in any pre-selected language.
Referring to FIG. 4, the automated operation of the car wash can be selected to perform predetermined programs or service modes of specific actions to be performed or not performed, such as ordinary operation by selecting the SILVER button which can leave out the application of wax treatment, wax operation at extra cost by selecting the GOLD button, extra cleaning such as longer soaping and washing by selecting the
SUPER button, full services by selecting FULL-S or FULL-SERVICE, washing with a roller up with selection of the ROLLER UP button, etc.
Through the tunnel selection screen in FIG. 4, the operator can also select the type of vehicle being handled, such as TAXI, VAN, or MINI- VAN, which causes the automated control system 10 to adjust the timing and duration of operation of the machines, such as the speed of the conveyor and the amount of time for the brushes to operate, for example, longer for vans than for sedan-sized taxis. In addition, the type of service can also be modified to select EXTERIOR for exterior cleaning only, and which, if not selected and so being in the OFF setting, can cause a light or message to be displayed to the car wash personnel to also clean the interior of the car. hi alternative embodiments, the selection of EXTERIOR to the OFF setting can cause automated robots to perform interior cleaning.
The operator can also select FREE to control the billing, for example, for customers with coupons for free washes, and for pre-arranged business agreements with rental car companies and dealerships for washes pre-paid or monthly, such that such washes are paid independent of the arrival of the car to be washed. The control system 10 then does not generate a bill or payment request at the time that the car is being washed.
Referring to FIG. 4, the control system 10 can be configured to display any number of buttons, with each button corresponding to a predetermined program or mode of service having a selected permutation of the operations of the machines. For example, there can be three types of wax, two types of soap, and two types of drying mechanisms such as blowers or infrared heaters, thus forming twelve selectable permutations, each of which can have different price ranges for different types or sizes of vehicles, so multiple buttons for each permutation can be configured and accessed by the operator. In addition, instead of a car wash, the tunnel can be configured to wash trucks, tractor trailers, and
even railroad cars, requiring large numbers of washers, blowers, and brushes in numerous configurations to comprehensively wash such large vehicles, which can require dozens of buttons for different types and sizes of vehicles and different types of service for each vehicle. MANUAL CONTROL
Referring to FIG. 5, the control system 10 can be manually controlled by an operator, as opposed to automated pre-programmed control using a pre-programmed set of procedures described in conjunction with FIG. 4.
As shown in FIG. 5, the operator can selectively activate and deactivate machines from a remote location, such as a single operator terminal at the entrance of the car wash. At the operator's discretion, the operator can press the button adjacent to the label FRONT TO REAR, which causes the control system 10 to change the monotone button to display the image of a front-to-rear machine, and which then activates the front-to-rear machine to operate for a predetermined duration and/or until the operator deactivates the FRONT TO REAR button by pressing that image. Similarly, the operator can press the button adjacent to the label VAN BRUSH, which causes the control system 10 to change the monotone button to display the image of a van brush machine and to activate the van brush machine. If, for example, the foamer was active, when the operator presses the image of a foamer adjacent to the label FOAMER, in the position 52 shown in FIG. 5, in response the control system 10 deactivates the foamer machine and also changes the image of a foamer to a monotone button or alternatively to a button 52 with an index number such as "T7", as shown in FIG. 5.
In this manner, although portions of the operation of each machine can be automated and/or preset, such as the speed of the convey or the respective duration of
operation of the blowers, the activation and deactivation of each machine can be manually controlled by a single operator at the operating terminal.
Using manual control, the operator is thus able to manually and selectively override each individual machine, with the starting and stopping of each machine being accompanied by an exact picture of the machine in question. ALARM SYSTEM
Through the operator terminal, icons and messages can be directly displayed to the operator, for example, to signal operating conditions as well as alarm conditions, such as a low oil condition for each machine using lubricating oil, a low water or low water pressure condition for those machines using water, as well as mechanical and/or electrical conditions for each machine, such as short circuit conditions, malfunctioning solenoids, etc. When such conditions are detected, the operator terminal can generate and display a new screen such as an alarm screen or page, or alternatively can generate an overlaying window with a message pertaining to the detected alarm condition and any diagnosed problem.
The operator is thus informed of the status of the car wash and its machines in order to act accordingly, such as to turn off the faulty machine, or if necessary to shut down the entire car wash until the problem can be addressed and resolved. REPORTS GENERATION Referring to FIGS. 6-7 and as described herein, upon activation of a pre-defined icon or function key, the control system 10 can compile and display the statistics associated with the selected operations of the car wash; for example, the number of cars, taxis, and mini-vans services, and a break-down of the types of services performed for each type of vehicle. Such statistics can be used to project future profits and to analyze the customer base.
Using a PRINT button shown on the screen in FIG. 6, the statistics on that screen can be printed or otherwise outputted by an output device in a pre-determined format, such as the format shown in FIG. 7. The report can indicate the time frame in which the data was complied, such as a daily report or a report for operations from dates input by the operator through the touch screen and/or through a keyboard or other input device.
Such statistics and report generation need not require a password for access and generation, so the operator requesting the report could obtain such information in realtime, to view the number of vehicles washed and the various services, as in FIGS. 6-7.
In another embodiment, the control system 10 can provide a secure statistics function which requires a password in order to generate real-time reports of the vehicles washed as well as the various prices charged on such services and the total charges.
The control system 10 can maintain such statistics and vehicle service information for a predetermined time, such as thirty days, and can either delete such information, generate a single report prior to deletion, or archive such information in a specialized database separate from the working memory used in daily operations, in order to optimize the functioning of the computerized control system. METHOD OF USE
As shown in the flowcharts of FIGS. 8-9, the disclosed control system 10 implements a method for controlling the processing of operator settings and the operations of the machines of the car wash 12.
FIG. 8 illustrates the general method of operation in which, upon start-up of the car wash 12, for example, at the start of the operating day, the control system 10 initializes from previously saved settings, such as default settings or a last-saved configuration, in step 60. The control system 10 then waits in step 68 for vehicles such as cars to arrive for servicing.
After cars arrive at the car wash 12, the control system 10 processes the cars in step 70. Referring to FIG. 9, the step 70 of processing the cars includes the steps of detennining the vehicle type in step 71 and selecting a service package at step 72. A vehicle ticket is output in step 73, and the car is counted in step 74 by incrementing a count to be saved in the memory 16 for use in generating the statistics of processed cars. The control system 10 then detects for any new configuration settings for the vehicle type and service package input through the operator interface 18 by the operator in step 75. If new configuration settings have been input, the control system 10 receives the new configuration settings in step 76, reconfigures the control system 10 and in turn the operation of the machines to act as the current configuration settings for operation and saves the new configuration settings in step 77, for example, in the memory 16. However, if in step 75, no new configuration settings are detected, the control system 10 proceeds to step 78 to begin activating the machines to service the vehicle and to operate using the last-saved configuration settings as the current configuration settings. Then, for each car, the method includes the step of controlling each machine in the car wash 12 in step 78 to activate according to the current configuration settings for each car as the car is positioned at the location of each machine by the conveyor 34. The method thus performs and/or applies any selected services for each car, for example, to apply wax or to apply full-service overall if, for example, FULL-SERVICE has been activated by the operator via the tunnel control screen in FIG. 4.
For each car, after the machines are selectively activated in step 78, any flags or variables used in processing a respective car are reset in step 79 for operation with the next car. The control system 10 then waits for a next car in step 80. For each car, steps 71-80 are performed repeatedly until all available cars are serviced by the car wash 12. ADVANTAGES
By providing such flexible and adaptable configurations, the operator is able to service more and different customers to meet all of their demands. The operator has greater control over the car wash to operate and monitor the operations of each machine in the car wash from a single location, such as the entrance of the car wash instead of having to perform manual control at relay boxes associated with each machine or at an office located a distance apart from the entrance and away from customers.
In addition, by using video cameras providing images of the machines to the operator terminal, the operator can more effectively monitor and control the machines, to detect problems and to mitigate or avoid injuries to customers or employees, for example, by manually shutting down malfunctioning machines with a quicker response time.
While the present invention has been described and illustrated in various preferred and alternate embodiments, such descriptions and illustrations are not to be construed to be limitations thereof. Accordingly, the present invention encompasses any variations, modifications and/or alternate embodiments with the scope of the present invention being limited only by the claims which follow.