WO2015023684A2

WO2015023684A2 - Automated mixing system

Info

Publication number: WO2015023684A2
Application number: PCT/US2014/050758
Authority: WO
Inventors: Wade BARRINEAU, III
Original assignee: Barrineau Wade Iii
Priority date: 2013-08-12
Filing date: 2014-08-12
Publication date: 2015-02-19
Also published as: WO2015023684A3

Abstract

Embodiments of automated mixing systems comprise at least one mixing tank, at least one mixing tank level sensor disposed within the mixing tank, a plurality of inlet pumps configured to deliver at least two different cleaning chemicals to the mixing tank in order to produce a mixed product, at least one product tank comprising at least one product tank level sensor disposed within the product tank, and a control system comprising a processor which executes programmed instructions to determine a level of mixed product in the mixing tank and the level of mixed product in the product tank from the mixing tank level sensor and product tank level sensor, respectively; and trigger the inlet pumps to transport the at least two different cleaning chemicals to the mixing tank to produce mixed product if the level of mixed product in the mixing tank is below a target mixing tank level.

Description

AUTOMATED MIXING SYSTEM

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Serial No. 61 /865,044 filed August 12, 2013, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

[0002] The present disclosure is generally related to automated mixing systems, and specifically related to automated mixing systems for producing detergents onsite in vehicle wash facilities.

BACKGROUND

[0003] Shipping chemical compositions in liquid form is expensive due to the weight of the material. Many liquid materials are aqueous and weigh in excess of eight pounds per gallon, with the vast majority of the weight being represented by water.

[0004] Accordingly, many liquid chemicals, such as materials for cleaning, are shipped in concentrated form, with water and/or other materials added at the point of use. More recently, chemical compositions are shipped in hyper-concentrated form, further reducing water or other liquids to reduce shipping costs. Water, and sometimes other liquid materials, is added at the point of use. A common example is car washes, where liquid cleaning materials are shipped to the car wash location in hyper-concentrated form.

[0005] Accordingly, there is a continual need for improved systems, especially automated systems, which eliminate these shipping and storage costs via onsite detergent production.

SUMMARY

[0006] In light of this continual need, the embodiments of the present disclosure are directed to an automated mixing system, which produce concentrated detergents onsite from raw materials, thereby lowering shipping and storage costs, while also desirably providing the operator with automation and reporting features beneficial to various industries and application, for example, the car wash industry. Additionally, the present embodiments may enable the user to optimize detergent formulations to the specific component in which cleaning is sought. For example, the automated system enables an operator to adjust a cleaning detergent suitable for a vehicle body to a cleaning detergent more suitable for tire cleaning.

[0007] According to one embodiment, an automated mixing system is provided. The automated mixing system comprises at least one mixing unit comprising a mixing tank, and at least one mixing tank level sensor disposed within the mixing tank, wherein the mixing tank level sensor is operable to measure a fluid level inside the mixing tank and convert that measured mixing tank fluid level into an electrical signal. The automated mixing system also comprises a plurality of inlet pumps configured to control transport of at least two different cleaning chemicals to the mixing tank in order to produce a mixed product, wherein the mixed product is an aqueous detergent including the at least two different cleaning chemicals. The system further comprises at least one product tank in fluid communication with the mixing tank and comprising at least one product tank level sensor disposed within the product tank, wherein the product tank level sensor is operable to measure a fluid level inside the product tank and convert that measured product tank fluid level into an electrical signal. Furthermore, the system comprises one or more outlet pumps configured to transport the mixed product from the mixing tank to the product tank, and a control system comprising a processor, and at least one operator interface communicatively coupled to the processor, wherein the processor is communicatively coupled to the mixing tank level sensor, the product tank level sensor, and the inlet pumps. The processor executes programmed instructions to determine a level of mixed product in the mixing tank and the level of mixed product in the product tank based on the electrical signals from the mixing tank level sensor and product tank level sensor, respectively, and trigger the inlet pumps to transport the at least two different cleaning chemicals to the mixing tank to produce mixed product if the level of mixed product in the mixing tank is below a target mixing tank level. [0008] According to another embodiment of the automated mixing system, the processor is communicatively coupled to the mixing tank level sensor, the inlet pumps and a water valve, wherein the processor executes programmed instructions to compute a change in a level of mixed product in the mixing tank based on the electrical signals delivered from the mixing tank level sensor; compare the computed change in mixed product level against an expected change in mixed product level, the expected change in mixed product level being computed from set flow rates of the inlet pumps and a set flow rate of the water valve; and send an alert or message via the operator interface if the difference between the expected change and the computed change exceeds an acceptable threshold.

[0009] According to yet another embodiment of the automated mixing system, the processor is communicatively coupled to the mixing tank level sensor and the product tank level sensor, wherein the processor executes programmed instructions to compute the decrease in level of mixed product in the mixing tank based on the electrical signals from the mixing tank level sensor as well as an increase of level of mixed product in the product tank based on the electrical signals from the product tank level sensor as the outlet pump transfers the mixed product from the mixing tank to the product tank; calculate a transfer rate from the mixing tank to the product tank via a decrease in level of mixed product in the mixing tank and the increase of level of mixed product in the product tank; compare the computed transfer rate against an expected transfer rate, the expected transfer rate being computed from set flow rates of the outlet pumps; and send an alert or message via the operator interface if the difference between the calculated transfer rate and the expected transfer rate exceeds an acceptable threshold.

[0010] According another embodiment, a vehicle washing system is provided. The vehicle washing system comprises a vehicle washing apparatus and the above automated mixing system in fluid communication with the vehicle washing apparatus. The automated mixing system comprises a processor communicatively coupled to the mixing tank level sensor, wherein the vehicle washing apparatus receives mixed product from the mixed product for use in one or more vehicle wash cycles, and wherein the processor executes programmed instructions to calculate a usage of mixed product per vehicle wash cycle by computing the decrease in level of mixed product in the product tank as the mixed product is transferred from the product tank to the vehicle washing apparatus based on the electrical signals from the product tank level sensor during one or more wash cycles; and send an alert or message via the operator interface regarding the usage of mixed product per wash cycle.

[0011] These and other advantages and features of the invention disclosed herein, will be made more apparent from the description, drawings and claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The following detailed description can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals.

[0013] FIG. 1 is a diagram depicting an automated mixing system in accordance with one or more embodiments of the present disclosure.

[0014] FIG. 2 is a front view depicting a mixing unit of the automated mixing system of FIG. 1 , wherein the mixing unit is in communication with chemical feed sources, in accordance with one or more embodiments of the present disclosure.

[0015] FIG. 3A is another front view depicting a mixing unit of the automated mixing system of FIG. 1 without depicting the plurality of chemical feed sources in accordance with one or more embodiments of the present disclosure.

[0016] FIG. 3B is a side view depicting the mixing unit of FIG. 3A from a side perspective in accordance with one or more embodiments of the present disclosure.

[0017] FIG. 3C is an opposite side view depicting the mixing unit of FIG. 3A from an opposite side in accordance with one or more embodiments of the present disclosure.

[0018] FIG. 4 is a perspective cutaway view of a mixing tank of the automated mixing system of FIG. 1 , wherein the side walls are cut away to depict the internal components of the mixing tank in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION [0019] The following discusses various illustrative embodiments. Those skilled in the art will appreciate that the concepts and features or the present disclosure may be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments depicted herein. Referring to the embodiment of FIG. 1 , an automated mixing system 1 of mixing at least two different cleaning chemicals into a mixed product is regulated by a control system 70.

[0020] As used herein, "two different cleaning chemicals" are raw materials, optionally, aqueous raw materials used in making chemical cleaning detergents. While one or both of the at least two different cleaning chemicals may be aqueous solutions, these aqueous solutions still require an additional component, such as an alkaline or acidic composition. In one or more embodiments, the two different cleaning chemicals may include alkaline compositions, acidic compositions, or both. As used herein, "mixed product" is an aqueous detergent including at least these two different cleaning chemicals and optionally water and other ingredients. For example, the mixed product is a mixture of at least Chemical A and Chemical B, with chemical A and B being different compositionally. In some embodiments, the mixed product yielded may be considered concentrated or hyper-concentrated with the major difference being that hyper-concentrated detergents require further dilution than concentrated detergent. As concentrated or super concentrated detergents generally must be diluted prior to application, it is also contemplated that the present mixed product may be formulated to perform as a ready-to-apply cleaner without requiring additional dilution.

[0021] The mixed product, which is yielded by the raw materials (i.e., the two different cleaning chemicals) onsite, may be optimized to achieve the cleaning performance of various cleaning detergents. For example, the mixed product produced in accordance with the present disclosure may be a high pH alkaline detergent similar to Ryko®'s High Pressure detergents, and the Armor All®

Professional Heavy Duty Alkaline Presoak (H416) composition. Alternatively, the present mixed product may be optimized to perform as a tire and wheel cleaner similar to Ryko®'s Tire Cleaner, and the Armor All® Professional Super

Concentrated Wheel & Tire Cleaner (H401 ) composition. [0022] The automated mixing system 1 comprises a mixing unit 10. Referring to FIGS 1 -4, the mixing unit 10 may comprise at least one mixing tank 12, and at least one mixing tank level sensor 16 disposed within the mixing tank 12. While one mixing tank 12 is depicted in the figures, the use of multiple mixing tanks is also considered within the scope of this disclosure. Various tanks and containers are contemplated for the mixing tank 12 as long as these tanks or containers have suitable strength for mixing of at least two different cleaning chemicals. Additionally, while the figures depict the shape of the mixing tank 12 as a cone, various other shapes are also contemplated herein. As shown in FIG. 1 , the cone shaped mixing tank 12 may facilitate the mixed product being outputted via a bottom portion of the mixing tank; however, other locations for the inlet and outlet are considered suitable.

[0023] Referring again to FIG. 1 , the mixing tank level sensor 16 is operable to measure one or more fluid levels inside the mixing tank 12 and convert that measured mixing tank fluid level into an electrical signal. The mixing tank level sensor 16 detects when the at least two different cleaning chemicals, and optionally water, is being added to the mixing tank 12 by detecting the fluid level and/or the change in fluid level inside the mixing tank 12. The mixing tank level sensor 18 is communicatively coupled to the control system 70. As used herein, "communicatively coupled" means a wireless connection or a wired connection.

[0024] Many level sensors are contemplated as suitable for use in the present embodiments. In one embodiment, the mixing tank level sensor 16 is a float sensor 16. As show, the float sensor 16 comprises a float ball probe 18 connected to a float transmitter 17. In an exemplary embodiment, the float transmitter 17 is an analog level transmitter. As shown in FIG. 1 , the mixing tank level sensor 16, specifically, the float transmitter 17 may be in wired or wireless communication with the processor 72.

[0025] In addition or as an alternative to level sensors, it is contemplated that the system may also include other sensors such as flow meters inside the mixing tank 12 or elsewhere in the system. In some embodiments, it is contemplated that some or all of the level sensors may be replaced or supplemented with the use of flow meters. Referring to FIG. 1 , the system 1 may include at least one flow meter 120, or a plurality of flow meters 120 that are communicatively coupled with the processor 72 and thereby may also in communication with the level sensors via the processor 72. While not shown in FIG. 1 , the flow meter 120 may be coupled to any of the various tubing, piping, or feed lines. In specific embodiments, the flow meters 120 may be incorporated into the vehicle washing apparatus 100 or other equipment in the vehicle washing facility. In this instance, the flow meters 120 may measure the flow rates of the mixed product delivered to the vehicle washing apparatus 100, or may measure the flow rates of other car washing components. For example, the flow meters may be coupled to a car wax delivery apparatus to determine, for example, the flow rate of the car wax entering a car wax drum or exiting a car wax drum via a nozzle or spray delivery device.

[0026] Additionally as shown in FIGS. 1 and 4, the mixing unit 10 may also include an agitator 14 disposed within the mixing tank 12. The agitator comprises a mixing rod 15 coupled to a motor 13 that drive the mixing rod 15. As will be explained below, the motor 13 may, in some embodiments, be communicatively coupled to the processor and responsive to the processor 72 of the control system 70.

[0027] Referring to FIGS. 1 -4, the system 1 may also include a plurality of inlet pumps 30 which control transport of at least two different cleaning chemicals to the mixing tank 12. As shown in the embodiment of FIGS. 1 , 2 and 3A, three inlet pumps 32, 34, 36 are included; however, more or less pumps are contemplated depending on the desired detergent formulation to be produced in the mixing tank 12. As shown in the embodiments of FIG. 2 and 3A, the inlet pumps 32, 34, 36 may be arranged proximate the mixing unit 10. Specifically, the mixing unit 10 may include a mounting plate 31 used for attaching the inlet pumps 32, 34, 36 to the mixing unit 10. That being said, it is also suitable for the inlet pumps 32, 34, 36 to be oriented separate from the mixing unit 10 in other embodiments. Various pumps are considered suitable for use in the present system, for example, positive

displacement pumps. Commercially available pumps may include a duplex pump provided by FloJet®. The depicted embodiments herein focus on inlet pumps delivering the cleaning chemicals to the mixing tank; however, a single product may also be manually poured into the mixing tank 12.

[0028] Referring to the embodiments of FIGS. 1 and 2, the inlet pumps 30 are connected to chemical feed sources 20. The chemical feed sources 20 may be chemical drums as shown; however, other chemical containers are suitable. As shown, the inlet pumps 32, 34, and 36 are coupled respectively to chemical feed sources 22, 24, and 26.

[0029] As would be familiar to one or ordinary skill in the art, the inlet pumps 30 and chemical feed sources 20 may be coupled via various components such as tubing, valves, nozzles, etc. In FIG. 1 , the inlet pumps 32, 34, and 36 are coupled to chemical feed sources 22, 24, and 26 via tubing or piping 33, 35, and 37,

respectively.

[0030] As shown in the embodiment of FIG. 1 , the system 1 may also include one water source 40 in fluid communication with the mixing tank 12. This water source is not required in all embodiments, specifically in embodiments where the mixed product can achieve its desired concentration by mixing the at least two different cleaning chemicals without adding water. That being said, in this depiction of FIG. 1 , the water source 40 includes a line upstream of water valve 42, which indicates its connection to a water line. Further as shown, the water source 40 may include a valve 42, which regulates a flow rate of water into the mixing tank 12. As described below, the valve 42 may be communicatively coupled and responsive to the processor 72 of control system 70. In one or more embodiments, the valve 42 may be an automatic water valve, which may turn on and shut off the flow of water automatically. Specifically, as shown in the embodiments of FIGS 3B-3C and 4, the valve 42 may include a solenoid valve with a garden hose fitting which may connect to a water line 40. Additionally, the system 1 may include tubing 43 to deliver the water to the mixing tank 12.

[0031] Referring again to FIG. 1 , the system 1 also includes at least one product tank 60 in fluid communication with the mixing tank 12 and also in fluid

communication with the vehicle washing apparatus 100. As shown, there may be two product tanks 61 and 62; however, one or more than two product tanks may be used in other embodiments. Like the mixing tank 12, the product tank 61 or product tank 62 may include product tank level sensors 63 and 66, respectively, disposed therein. The product tank level sensor 63 and 66 measure a fluid level inside the product tank and converts that measured product tank fluid level into an electrical signal. Like the mixing tank level sensor, various options are considered suitable for the product tank level sensors 63 and 66. In one exemplary embodiment, the product tank level sensors 63 and 66 may include float ball probes 64 and 68, respectively. Moreover, the product tank level sensors 63 and 66 may also include level transmitters 65 and 67 communicatively coupled with the processor 72. Like the mixing level tank sensor, the product tank level sensor may be an analog level transmitter or another suitable transmitter type. As shown in the embodiment of FIG. 1 , the level

transmitters 65 and 67 may wirelessly communicate with the processor 72. While not shown, it is also contemplated in further embodiments to include an agitator to induce further mixing of the mixed product in the product tank 60.

[0032] Referring to the embodiment of FIGS. 2, 3A-3C and 4, the mixing tank 12, the product tank 61 , the inlet pumps 30, the outlet pumps 50 (as described below), the water valve 42, and components of the control system 70 (e.g., the processor 72 and operator interface 78) may all be part of an integral mixing unit 10. As shown, the mixing tank 12 may be vertically disposed between the processor 72 and one or more product tanks 61 and 62. Without being bound by theory, this integrated mixing unit 10 may be portable and thus can be easily incorporated into various industrial applications and facilities, such as a vehicle washing facility.

[0033] Additionally as shown in FIG. 1 , 3B, 3C and 4, the system 1 also comprises one or more outlet pumps 50 configured to transport mixed product from the mixing tank 12 to the product tank 61 and/or 62. As shown, there are two outlet pumps 52 and 54 corresponding to the two product tanks 61 and 62, respectively; however, more or less pumps may be utilized. Like the inlet pumps 30, the outlet pumps 50 may also be communicatively coupled to the processor 72. In addition to the outlet pumps 52 and 54 transferring mixed product from the mixing tank 12 to the product tanks 61 and 62, there may be additional tubing or piping 1 1 and 19 upstream of the outlet pumps 52 and 54 and additional tubing or piping 53 and 55 downstream of the outlet pumps 52 and 54 Like the inlet pumps 30, various pump types are considered suitable for the outlet pumps, for example, a positive displacement pump.

[0034] Referring again to FIG. 1 , the control system 70 may comprise a processor 72, and at least one operator interface 74 and 78 communicatively coupled to the processor 72. Various hardware as familiar to one of ordinary skill in the art is contemplated for use in the processor 72, for example and not by way of limitation, an input/ output module, a programmable logic controller, an antenna, power supply, etc. As described below, many of the decision-making and controlling features described in the embodiments below are performed by the programmable logic controller. That being said, alternatives to programmable logic controller are also contemplated, for example, microprocessor controller units. As shown in the embodiment of FIG. 1 , the processor 72 may receive data from the mixing tank level sensor 16 and the product tank level sensors 63 and 66. Based on these data readings, the processor 72 is programmed with instructions to automatically adjust the operation of the inlet pumps 32, 34, and 36, the water valve 42, and/ or the outlet pumps 52 and 54.

[0035] Further as shown in FIG 1 , the control system 70 may also include a transmitter 76 communicatively coupled to the processor 72 and the operator interface 74 or 78. In one embodiment, the transmitter 76 is a wireless modem. Here, the data readings provided by the level sensors may trigger the processor 72 to send an alert or message to the operator via the operator interfaces 74 and 78. The operator interface 78 may be wired to the processor 72, and thus delivery of the alert or message occurs via that wired route. However, the aforementioned wireless modem transmitter 76 may also send an alert or message to a remote electronic device 74 regarding the data readings obtained from the level sensors.

[0036] As mentioned, the operator interfaces 74 and 78 receives an alert or message and therefore includes a display component to show that alert or message. As shown in FIGS. 3A and 3B, the operator interface 78 may be a control panel wired proximate the processor 72, whereas operator interface 74 as depicted in FIG. 1 is a remote device wirelessly coupled to the processor 72. As shown in FIG. 2, the integrated operator interface 78 may be a control panel attached to the mixing unit. The operator interface 78 may include indicators 79 having some indicia (e.g., color or icon) which alert the operator of a specific event or the present status of the system. For example, the indicator 79 may be red, and when lit, it may indicate and issue, for example, the transfer rate of mixed product from the mixing tank 12 to the product tank 61 or 62 is not optimal. Alternatively, a green indicator may inform the operator that the system 1 is performing properly. In a further alternative, an alert may be sent via an alarm. In addition to the lights or button indicators 79, it is also contemplated that the operator interface 78 may have other communication components such as a monitor or other suitable graphical user interface. In that case, a message may be sent to the operator via the monitor.

[0037] Additionally, the operator interface 78 may have a user actuation

component. For example, one or more of the buttons 79 could be buttons used to adjust or shut down specific system components or override alerts. The operator interface 74, which is a remote electronic device, may be a mobile electronic device such as a mobile phone, a smartphone, a radiophone, a tablet, a laptop computer, or combinations thereof. In a specific embodiment, the mobile electronic device is a smartphone. The remote electronic device may also be a desktop computer, or the like. In the embodiments of FIGS. 1 and 2, operator interface 74 may include multiple devices: 1 ) a control unit 78 attached to the mixing unit; and 2) a mobile phone 74 (e.g., a smartphone) for communication with the system 1 . The operator interface 74 also includes a display (e.g., a monitor or screen) to receive messages or alerts, and also includes a user input component (e.g., a keyboard or keypad) to provide instructions to the processor 72. The operator may instruct the processor 72 to adjust or shut down specific system components, such as the inlet pumps 30.

Additionally, the operator may also adjust the algorithms or source code

programmed into the processor 72. As described further below, the operator may input instructions to adjust the concentration or mix ratio of the mixed product, thereby altering the instructions programmed into the processor 72. Moreover, the operator may, via the operator interface 74, read the mixer usage, silence alarms, turn of the system 1 , etc.

[0038] In light of the system framework described above, the following

embodiments illustrate numerous, but by no means exhaustive, operational features achieved by the present system 1 .

[0039] For example, the mixing tank level sensor 16 may determine a level of mixed product in the mixing tank 12 and send an electrical signal corresponding to this level to the processor 72. If there is volume available for mixing inside the mixing tank 12 and/or the mixing tank 12 is substantially empty or merely below a target fill level, the processor 72 may trigger the inlet pumps 30 to deliver cleaning chemicals to the mixing tank to produce further mixing product. That being said, the processor 72 may also obtain the level of mixed product in the product tank 60 based on the electrical signals from the product tank level sensor 63 and 66. If there is no available volume in the process tank 60, the processor 72 may be programmed to shut down or not trigger the inlet pumps 30 to start production of mixed product or additional mixed product. Furthermore, in both these instances, the processor 72 may inform the operator via one or more of the operator interfaces 74 and 78 regarding the mixed product levels in the mixing tank 12 and product tank 60. At which point, it is contemplated that the processor 72 may query the operator to approve the next step, and it is further contemplated that the operator may then confirm, override and/or modify that proposed procedure via the user input component.

[0040] Additionally, if the mixed product in the product tank 60 drops below a predetermined level, an alert such as a flashing light or audible alarm may notify the operator. If the mixture in the product tank 60 drops to an even lower predetermined level, the control system 70 may send a message, such as a text message by smart phone, or an automated message by e-mail, which indicates the even lower mixture level. This kind of tiered messaging protocol (i.e., first an alarm for an initial concern, then another form of alert or message for a greater concern) is one of many conceivable ways in which the control system 70 may communicate with the operator.

[0041] The control system 70 may automate various other steps of the mixing process conducted in the mixing tank 12. For example, the processor 72 may trigger the water valve 42 to provide water used to rinse the mixing tank 12 before or after mixing steps. As the water valve 42 may be an automatic valve, the processor 72 may automatically trigger the water valve 42 to rinse the mixing tank for a predefined interval when the mixing tank level sensor 16 detects a substantially empty mixing tank 12. Moreover, water may automatically be added to the mixing tank 12 when the mixing tank level sensor 16 measures a sub-optimal fill level inside the mixing tank 12.

[0042] Moreover, the control system 70 may regulate the agitation of the mixture inside the mixing tank 12. Specifically, the processor 72 may trigger the motor 13 of the agitator 14 to drive the mixing rod 15 upon determining that the fluid level in the mixing tank 12 is at a desired fill level. In specific embodiments, the processor 72 may deactivate the agitator 14 upon completion of a predefined stirring cycle. This predefined stirring cycle may vary depending on various factors, such as the detergent formulation desired. For example, the predefined stirring cycle may be from 10 seconds to several hours. Upon completion of the predefined stirring cycle, the processor 72 may trigger the outlet pumps 50 to begin the transfer from the mixing tank 12 to the product tank 60. That being said, the control system 70 still considers whether volume is available in the product tank 60 before beginning the transfer of the mixed product.

[0043] The control system 70 may then automate the transfer from the mixing tank 12 to the product tank 60. After the mixed product is transferred to the product tank 60, an indicator on the operator interface 78, such as a light, indicates that an operator may add more concentrate to the mixing tank 12. In one embodiment, the restart of mixing is automatic. In another embodiment, the two or more chemicals may be manually added, and a signal, such as a visual signal or light, indicates that it is OK to add chemicals and the mixing starts after the chemicals are added.

[0044] Additionally, the control system 70 is effective at troubleshooting potential issues in the system 1 , for example, issues in feed rates into the mixing tank 12, or issues with the transfer rate from the mixing tank 12 to the product tank 60. In one embodiment, the processor 72 may execute programmed instructions to compute the change in the level of mixed product in the mixing tank 12, and compare the computed change in mixed product level against an expected change in mixed product level. The expected change value may be preset or computed from set flow rates of the inlet pumps 30 and a set flow rate of the water valve 42. The processor 72 may send an alert or message via the operator interface if the difference between the expected change and the computed change exceeds an acceptable threshold. The processor 72 may pause the inlet pumps 30, the water valve 42, or both if the difference between the expected change and the computed change exceeds an acceptable threshold. Then, the processor 72 may trigger the inlet pumps 30, the water valve 42, or both to resume operation upon actuation of a user input component of the operator interface 74 and/or 78. [0045] Moreover, the processor 72 may compute the time required to add the proper amount of chemical to the mixing tank 12. If the computed time is exceeded, an alarm is set. The processor 72 computes the time based on the product ratios that are programmed into the processor 72. If ratios are changed remotely, such as by a smartphone connection, the processor 72 re-computes the time based on the new ratio. The transfer of mixed product to the product tank 60 is similarly computed. The processor 60 can also measure the fill rates of the pumps to their respective tanks with the level sensor in each tank. The processor 72 may sends a wireless text/email report if the fill rate in the respective tank is less than that calculated by the processor 72.

[0046] In specific embodiments as shown in FIG. 1 , the automated system 1 may be incorporated into a vehicle washing system wherein the vehicle washing apparatus 100 receives mixed product from the mixed product for use in one or more vehicle wash cycles. The processor 72 may calculate a usage of mixed product per vehicle wash cycle by computing the decrease in level of mixed product in the product tank 60 as mixed product is transferred from the product tank 60 to the vehicle washing apparatus 100 based on the electrical signals from the product tank level sensor 63, 66 during one or more wash cycles, The processor 72 may then send an alert or message via the operator interface 74 regarding the usage of mixed product per wash cycle. Specifically, operator interface 74 e.g., the smartphone may receive a report by text and/or e-mail providing the number of mix cycles in a specific period, or additionally, or alternatively, the total volume of each product used. The reporting cycle may be at a predetermined time each day or week, or after a predetermined number of mix cycles. Alternatively, the report may include

information about how many vehicles were cleaned, how many gallons of chemical were used, and/or how much raw material is left.

[0047] In addition to computing the wash usage of mixed product, the present system 1 may also be useful in systems wherein the product is premade and is not being produced in the mixing tank 12 as described above. For example, it is possible to load premade detergent product in the mixing tank 12 or product tank 60 and have the processor 72 calculate the usage per wash cycle or the number of vehicles cleaned by the premade detergent, etc. Moreover, other car wash components, such as car wax, can also be measured either by using the tanks and level sensors described above or by using flow meters as also described above. Without being bound by theory, the present system 1 is a comprehensive system that may provide information and control to operators regarding various pieces of equipment within the vehicle wash facility in addition to just the soap/detergent sections.

[0048] EXEMPLARY PROCESS

[0049] An exemplary process for using a device according to the disclosure. While these steps have been discussed individually above, the following examples illustrate the processor driven automated system 1 sequentially performing many of those steps.

[0050] If the level in the mixing tank 12 as reported by the mixing tank level sensor 16 to the processor 72 shows that the mixing tank 12 is empty, or below a required level, and if the level in the product tank 60 as reported by the product tank level sensor 63 or 66 in product tank 60 shows enough available capacity to add another batch of mix, the processor 72 initiates an automatic blending cycle.

[0051] The database for the processor 72 has a preloaded recipe for the amount of water to be added to the mixing tank 12. The database for the processor 72 has a preloaded length of time of stirring the blend. The volume of water added is calculated by the processor 72, which multiplies the level changes in the tank by the known volume per increment of height of the tank, thereby converting the height changes in the mixing tank 12, as reported by the mixing tank level sensor 16 to the processor 72, to volume measurements such as gallons or liters.

[0052] The recipe for the blends can be altered by, for example, dialing into a wireless communication device such as a smart phone, entering a password, and changing the individual ingredient volumes to be added.

[0053] Since the inlet pumps 30 and the water valve 42 for adding products to the mixing tank 12 have known flow rates, the performance of these devices may be determined by the processor 72, which divides the volumes to be added to the mixing tank 12 by the known fill rates, and determines an estimated the time for each product addition. If the estimated times are exceeded by a preset amount, the processor 72 issues an alarm, such as an audible and/or visual alarm on the control panel 78 of the mixing unit 10, and may send a text message reporting the anomaly to preselected communications devices 74 such as smartphones. The audible alarm or other signal may be terminated or silenced by actuating a switch such as a silencing button on the control panel.

[0054] The processor 72 is preferred to enter a pause mode if an anomaly occurs. When the situation is rectified, a resume button on the operator interface 78, which may be connected as a digital input to the processor 72, may be pressed and the cycle resumes from where it was interrupted. An example of an anomaly is where the water valve 42 is in the off position.

[0055] When all required fill levels are reached, the processor actuates a stirring device for the period required by the recipe.

[0056] Upon completion of the stirring cycle, the processor 72 actuates an outlet pump 50 that transfers the completed blend to the product tank 60. When the mixing tank is completely empty, the processor 72 may terminate actuation of the outlet pump 50, reset the recipe for the blend, and restart the automatic blending cycle in the mixing tank 12 when the level in the product tank 60 shows adequate capacity.

[0057] If the pump transfer time exceeds an estimated time calculated by the processor 72 and reported by the level sensors in both tanks, an alarm condition may be set and a message alarm, such as a text message, describing the situation may be communicated to preselected parties.

[0058] The product tank level sensor in the product tank 60 may report to the processor 72 when a liquid level drops below a preset low level point. The processor 72 then actuates an alarm, such as a visual alarm or alarm light on the control panel 78. If the level drops further to an even lower level point, the processor 72 may send a communication, such as an alarm text message, to preselected parties, and/or engage a local audible alarm.

[0059] When a digital input to the process 72 device is connected to a device such as a vehicle wash system, the usage per wash cycle may be calculated by the processor 72. The level drop in the product tank 60 during a wash cycle is measured. The calculated per wash usage may be viewed by dialing into with a smartphone or otherwise communicating with the processor 72. Preset parameters may be programmed in the processor 72 that send a text message alarm if the usage falls outside of the predetermined parameters.

[0060] It is further noted that terms like "preferably," "generally," "commonly," and "typically" are not utilized herein to limit the scope or to imply that certain features are critical, essential, or even important to the structure or function of the claimed embodiments. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.

[0061] The above detailed description of embodiments of the disclosure is intended to describe aspects of the disclosure in sufficient detail to enable those skilled in the art to practice the disclosed embodiments. Other embodiments can be utilized and changes can be made without departing from the scope.

[0062] In this description, references to "one embodiment," "an embodiment," or "embodiments" mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to "one embodiment", "an embodiment", or "embodiments" in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, step, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.

[0025] What is claimed is:

Claims

1 . An automated mixing system comprising at least one mixing unit comprising a mixing tank, and at least one mixing tank level sensor disposed within the mixing tank, wherein the mixing tank level sensor is operable to measure a fluid level inside the mixing tank and convert that measured mixing tank fluid level into an electrical signal; a plurality of inlet pumps configured to control transport of at least two different cleaning chemicals to the mixing tank in order to produce a mixed product, wherein the mixed product is an aqueous detergent including the at least two different cleaning chemicals; at least one product tank in fluid communication with the mixing tank and comprising at least one product tank level sensor disposed within the product tank, wherein the product tank level sensor is operable to measure a fluid level inside the product tank and convert that measured product tank fluid level into an electrical signal; one or more outlet pumps configured to transport the mixed product from the mixing tank to the product tank, and a control system comprising a processor, and at least one operator interface communicatively coupled to the processor, wherein the processor is

communicatively coupled to the mixing tank level sensor, the product tank level sensor, and the inlet pumps, wherein the processor executes programmed instructions to determine a level of mixed product in the mixing tank and the level of mixed product in the product tank based on the electrical signals from the mixing tank level sensor and product tank level sensor, respectively; and trigger the inlet pumps to transport the at least two different cleaning chemicals to the mixing tank to produce mixed product if the level of mixed product in the mixing tank is below a target mixing tank level.

2. The automated mixing system of claim 1 wherein the two different cleaning chemicals include alkaline compositions or acidic compositions.

3. The automated mixing system of claim 1 wherein the triggering of inlet pumps also requires the level of mixed product in the product tank to be below a target product tank level.

4. The automated mixing system of claim 1 wherein the mixing tank level sensor, the product tank level sensor, or both is in wireless communication with the processor.

5. The automated mixing system of claim 1 wherein the control system

comprises a transmitter communicatively coupled to the processor and the operator interface.

6. The automated mixing system of claim 5wherein the transmitter is a wireless modem.

7. The automated mixing system of claim 1 wherein the operator interface comprises a display and a user input component.

8. The automated mixing system of claim 7 wherein actuation of the user input component may alter instructions programmed into the processor.

9. The automated mixing system of claim 7 wherein the programmed

instructions, which may be altered, include a formulation of the mixed product.

10. The automated mixing system of claim 7wherein the operator interface is a mobile electronic device, a remote electronic device, a control panel proximate the mixing unit, or combinations thereof.

1 1 . The automated mixing system of claim 10 wherein the mobile electronic device is a mobile phone, a Smartphone, a tablet, or combinations thereof.

12. The automated mixing system of claim 10 wherein the remote electronic device is a laptop computer, a desktop computer, or combinations thereof.

13. The automated mixing system of claim 10 wherein the processor triggers the inlet pumps to transport the at least two different cleaning chemicals to the mixing tank to produce the additional mixed product if the product tank is substantially empty.

14. The automated mixing system of claim 10 wherein the mixing unit comprises at least one agitator component disposed within the mixing tank.

15. The automated mixing system of claim 14 wherein the agitator is

communicatively coupled to the processor, wherein the processor activates the agitator upon determining that the fluid level in the mixing tank is at a desired fill level.

16. The automated mixing system of claim 15 wherein the processor shuts down the agitator upon completion of a predefined stirring cycle.

17. The automated mixing system of claim 14 wherein the one or more outlet pumps are communicatively coupled to the processor, wherein the processor triggers the outlet pump upon completion of the predefined stirring cycle.

18. The automated mixing system of claim 1 wherein the mixing tank level sensor, the product tank level sensor, or both is a float sensor.

19. The automated mixing system of claim 1 wherein the mixing tank, the product tank, and the processor are part of the mixing unit, wherein the mixing tank is vertically disposed between and the processor and the product tank.

20. The automated mixing system of claim 1 wherein the processor comprises a programmable logic controller.

21 . A vehicle washing system comprising a vehicle washing apparatus, and the automated mixing system of claim 1 , wherein the product tank is in fluid

communication with the vehicle washing apparatus.

22. An automated mixing system comprising at least one mixing unit comprising a mixing tank, and at least one mixing tank level sensor disposed within the mixing tank, wherein the mixing tank level sensor is operable to measure a fluid level inside the mixing tank and convert that measured mixing tank fluid level into an electrical signal; at least one water source in fluid communication with the mixing tank and comprising a water valve operable to regulate water flow rate into the mixing tank; a plurality of inlet pumps configured to control transport of at least two different cleaning chemicals into the mixing tank for in order to produce a mixed product, wherein the mixed product is an aqueous detergent including the at least two different cleaning chemicals; at least one product tank in fluid communication with the mixing tank; one or more outlet pumps configured to transport the mixed product from the mixing tank to the product tank; and a control system comprising a processor, and at least one operator interface communicatively coupled to the processor, wherein the processor is

communicatively coupled to the mixing tank level sensor, the inlet pumps and the water valve, wherein the processor executes programmed instructions to compute a change in a level of mixed product in the mixing tank based on the electrical signals delivered from the mixing tank level sensor; compare the computed change in mixed product level against an expected change in mixed product level, the expected change in mixed product level being computed from set flow rates of the inlet pumps and a set flow rate of the water valve; and send an alert or message via the operator interface if the difference between the expected change and the computed change exceeds an acceptable threshold.

23. The automated mixing system of claim 22 wherein the processor pauses the inlet pumps, the water valve, or both if interface if the difference between the expected change and the computed change exceeds the acceptable threshold.

24. The automated mixing system of claim 23 wherein the processor triggers the inlet pumps, the water valve, or both to resume operation upon actuation of a user input component of the operator interface.

25. The automated mixing system of claim 22 wherein the operator interface comprises a display and a user input component, wherein actuation of the user input component can alter instructions programmed into the processor.

26. The automated mixing system of claim 22 wherein the processor triggers the water source to rinse the mixing tank.

27. The automated mixing system of claim 22 wherein the operator interface is a mobile electronic device and the message is a text message.

28. A vehicle washing system comprising a vehicle washing apparatus, and the automated mixing system of claim 22, wherein the product tank is in fluid

communication with the vehicle washing apparatus.

29. An automated mixing system comprising at least one mixing unit comprising a mixing tank, and at least one mixing tank level sensor disposed within the mixing tank, wherein the mixing tank level sensor is operable to measure a fluid level inside the mixing tank and convert that measured mixing tank fluid level into an electrical signal; a plurality of inlet pumps configured to control transport of at least two different cleaning chemicals to the mixing tank in order to produce a mixed product, wherein the mixed product is an aqueous detergent including the at least two different cleaning chemicals; at least one product tank in fluid communication with the mixing tank and comprising at least one product tank level sensor disposed within the product tank, wherein the product tank level sensor is operable to measure a fluid level inside the product tank and convert that measured product tank fluid level into an electrical signal; a control system comprising a processor, and at least one operator interface communicatively coupled to the processor, wherein the processor is

communicatively coupled to the mixing tank level sensor, and the product tank level sensor, wherein the processor executes programmed instructions to compute the decrease in level of mixed product in the mixing tank based on the electrical signals from the mixing tank level sensor as well as an increase of level of mixed product in the product tank based on the electrical signals from the product tank level sensor as the outlet pump transfers the mixed product from the mixing tank to the product tank; calculate a transfer rate from the mixing tank to the product tank via a decrease in level of mixed product in the mixing tank and the increase of level of mixed product in the product tank; compare the computed transfer rate against an expected transfer rate, the expected transfer rate being computed from set flow rates of the outlet pumps; and send an alert or message via the operator interface if the difference between the calculated transfer rate and the expected transfer rate exceeds an acceptable threshold.

30. An automated mixing system of claim 29 wherein the operator interface is a mobile electronic device and the message is a text message.

31 . A vehicle washing system comprising a vehicle washing apparatus, and the automated mixing system of claim 29, wherein the product tank is in fluid

communication with the vehicle washing apparatus.

32. A vehicle washing system comprising a vehicle washing apparatus and an automated mixing system in fluid communication with the vehicle washing apparatus, wherein the automated mixing system comprises: at least one mixing unit comprising a mixing tank; at least one water source in fluid communication with the mixing tank and comprising a water valve operable to regulate water flow rate into the mixing tank; a plurality of inlet pumps configured to control transport of at least two different cleaning chemicals to the mixing tank in order to produce a mixed product, wherein the mixed product is an aqueous detergent including the at least two different cleaning chemicals; at least one product tank in fluid communication with the mixing tank and the vehicle washing apparatus, the at least one product tank comprising at least one product tank level sensor disposed within the product tank, wherein the product tank level sensor is operable to measure a fluid level of mixed product inside the product tank and convert that measured product tank fluid level into an electrical signal; a control system comprising a processor, and at least one operator interface communicatively coupled to the processor, wherein the processor is

communicatively coupled to the mixing tank level sensor, wherein the vehicle washing apparatus receives mixed product from the mixed product for use in one or more vehicle wash cycles, and wherein the processor executes programmed instructions to calculate a usage of mixed product per vehicle wash cycle by computing the decrease in level of mixed product in the product tank as the mixed product is transferred from the product tank to the vehicle washing apparatus based on the electrical signals from the product tank level sensor during one or more wash cycles; and send an alert or message via the operator interface regarding the usage of mixed product per wash cycle.

33. The vehicle washing system of claim 32, wherein the operator interface is a mobile electronic device and the message is a text message.