A Project Report On “Automatic Car Washing System” By Mr. Vaibhav M. Kulkarni (2011BIN021) Mr. Ankush J. Gavhane (2011BIN022) Miss. Puja N. Garad (2011BIN030) Under the guidance of Prof. R. G. Jamkar DEPARTMENT OF INSTRUMENTATION ENGINEERING SHRI GURU GOBIND SINGHJI INSTITUTE OF ENGINEERING & TECHNOLOGY, NANDED [431606].
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A Project Report
On
“Automatic Car Washing System”
By
Mr. Vaibhav M. Kulkarni (2011BIN021)
Mr. Ankush J. Gavhane (2011BIN022)
Miss. Puja N. Garad (2011BIN030)
Under the guidance of
Prof. R. G. Jamkar
DEPARTMENT OF INSTRUMENTATION ENGINEERING
SHRI GURU GOBIND SINGHJI INSTITUTE OF ENGINEERING &
TECHNOLOGY, NANDED [431606].
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
CERTIFICATE
This is to certify that Mr. Vaibhav Kulkarni, Mr. Ankush Gavhane,
Miss. Puja Garad are students of Instrumentation Engineering has successfully
completed the project work for VIIIth semester during academic year 2014-2015.
They have completed the project work on
Automatic Car Washing System
Dr. S.T. Hambde Prof. R. G. Jamkar Mr. Tushar Bhaskarwar
Project Head Project Guide Project Mentor
(Instrumentation Department)
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
ABSTRACT
Automatic car washing system is very common in developed countries.
Car washing system is usually associated with fuel filling stations. It consists of large
machines with automated brushes controlled by program logical controllers. Automatic
car washing system is fully automated with different stages of foaming, washing, drying
and brushing. Different types of car washing systems are discussed in this report. This
system uses large quantity of water, thus water recycling plant is also an integral part
of the automatic car washing system but at this level we are only presented the car
washing only. We studied some of the car washing systems from Internet and decided
to do this project.
As compared to the foreign countries this system is used in very less no of
cities in India because of its cost and complexity. But we have tried to minimise it
according to the device list which will be definitely helpful for our project.
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ACKNOWLEDGEMENT
Firstly we would like to thanks our sir for his invaluable Guidance in our
topic. He took interest in checking all minute bugs in our project report and guided us
throughout the project duration.
Our deepest and most sincere feeling of gratitude to our H.O.D Dr. V. G.
Asutkar, who has kindly allowed us to work on this topic and for his valuable guideline
to us. We are also thankful to Prof. R. G. Jamkar for his valuable suggestion.
We also want to thank our classmates for their motivation. Finally we would
like to express our cordially thanks to all of those who helped us directly or indirectly
in this project work. We dedicated our project to the institution of our life that is our
parents.
Mr. Vaibhav M. Kulkarni
Mr. Ankush J. Gavhane
Miss. Puja N. Garad
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INDEX
Sr. No. TOPIC Page No.
1. Introduction 07
1.1 Introduction
2. PLC 13
2.1 Introduction
2.2What is a PLC?
2.3 Central Processing Unit
2.4 Input/output interface system
2.5 PLC specification
3. Hybrid Distributed Control System 17
4. SCADA 21
4.1 Introduction
4.2 Project Development Steps
5. Stages of Car Washing System 23
6. Components of System 26
6.1 List of Components
1) IR Sensor
2) DC Motor
3) Solenoid Valve
4) Dryer
5) Conveyor
6) Small Car
7) Relay
8) Transformer
9) Block Diagram
10) Input interfacing Diagram
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11) Output interfacing Diagram
7. Working of System 38
7.1 Entry -Car Detection
7.2 Foam Wash
7.3 Brushing
7.4 Clean Wash
7.5 Drying
7.6 Exit
8. Ladder Diagram 39
9. SCADA MIMIC of Project 45
10. Documentation 47
10.1 Digital Input-Output Datasheet
10.2 Advantages
10.3 Cost Analysis
10.4 Result
11. Conclusion & References 49
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Chapter 1
System
1.1 Introduction:
The first automatic car washes appeared in the late 1930s. Automatic car washes
consist of tunnel-like buildings into which customers (or attendants) drive. Some car
washes have their customers pay through a computerized POS (point of sale unit), also
known as an "automatic cashier". The mechanism inputs the wash PLU into a master
computer or a tunnel controller automatically. When the sale is automated, after paying
the car is put into a line-up often called the stack or queue. The stack moves sequentially,
so the wash knows what each car purchased. After pulling up to the tunnel entrance, an
attendant usually guides the customer onto the track or conveyor. At some washes, both
tires will pass over a tire sensor, and the system will send several rollers. The tire sensor
lets the wash know where the wheels are and how far apart they are. On other systems
the employee may guide the customer on and hit a 'Send Car' button on the tunnel
controller, to manually send the rollers which push the car through. When the customer
is on the conveyor, the attendant will instruct the customer to put the vehicle into
neutral, release all brakes, and refrain from steering. Failure to do so can cause an
accident on the conveyor. The rollers come up behind the tires, pushing the car through
a detector, which measures vehicle length, allowing the controller to tailor the wash to
each individual vehicle. The equipment frame, or arches, vary in number and type. A
good car wash makes use of many different pieces of equipment and stages of chemical
application to thoroughly clean the vehicle.
Rotating brushes inside a conveyor car-wash.
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Also visible is the conveyor. The carwash will generally start cleaning with pre-
soaks applied through special arches. They may apply a lower pH (mild acid) followed
by a higher pH (mild alkali), or the order may be reversed depending on chemical
suppliers and formula used. Chemical formulas and concentrations will also vary based
upon seasonal dirt and film on vehicles, as well
as exterior temperature, and other factors. Chemical dilution and application works in
combination with removal systems based on either high pressure water, friction, or a
combination of both. Chemical substances, while they are industrial strength, are not
used in harmful concentrations since car washes are designed not to harm a vehicle's
components or finish. The customer next encounters tire and wheel nozzles, which the
industry calls CTAs (Chemical Tire Applicators). These will apply specialized
formulations, which remove brake dust and build up from the surface of the wheels and
tires. The next arch will often be wraparounds, usually made of a soft cloth, or closed
cell foam material. These wraparounds should rub the front bumper and, after washing
the sides, will follow across the rear of the vehicle cleaning the rear including the license
plate area. Past the first wraps or entrance wraps may be a tire brush that will scrub the
tires and wheels. This low piece is often located beneath a mitter (the hanging ribbon-
like curtains of cloth that move front to back or side to side) or top wheels. There may
also be rocker panel washers which are shorter in size (ranging in size from 18 inches
[45 cm] up to 63 inches [160 cm] tall) that clean the lower parts of the vehicle. Most
rocker brushes house the motor below the brush hub so they don't inhibit cloth
movement and allow the brush to be mounted under a support frame or below a mitter.
Some car washes have multiple mitters, or a combination of mitters and top brushes.
A vehicle in the high pressure rinse stage of the wash.
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After the mutter or top brushes the car may pass through a second set of
wraparounds. This may also be where high pressure water streams are used to clean
difficult to reach parts of the vehicle. The car generally passes over an under carriage
wash and/or has high pressure nozzles pointed at it from various positions. Next may
be a tire spinner, high pressure nozzles angled specifically to clean wheels and tires.
After the several wash stations the vehicle may go through triple foamers, usually red,
blue, and yellow, although colors can be customized with higher end chemical suppliers.
The triple foam process includes special cleaners as well as some protective paint
sealant. Protectants vary by manufacturer. Near the rinse is where a tire shining machine
is often installed, which is designed to apply silicone tire dressing to the tires. This
application makes the tires look good (new, and glossy) and preserves the rubber. Next
the vehicle is treated with a drying agent and a final rinse. Many carwashes utilize a
"spot free" rinse of soft water that has been filtered of chlorine and sent through semi
permeable membranes to produce highly purified water that will not leave spots. After
using spot free water, the vehicle is finished with forced air drying, in some cases
utilizing heat to produce a very dry car.
Typical "tunnel" car wash view from the inside
Clean Water Washing
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Older automatic washes-a majority of which were built prior to 1980-used to use
brushes with soft nylon bristles, which tended to leave a nylon deposit in the shape of a
bristle, called brush marks, on the vehicle's paint. Many brushes in the US are now
either cloth (which is not harmful to a car's finish, as long as it is flushed with plenty of
water to remove the grit from previous washes), or a closed cell foam brush, which does
not hold dirt or water, thus is far less likely to harm any painted finish, and can, in fact,
provide a gentle polishing effect to leave the paint much shinier. In order to avoid paint
marking issues, "touch less" or "no-touch" car washes were developed. This means the
car is washed with high water pressure instead of brushes. There is no contact with
friction so the chance of any damage is less, however the actual cleaning, or removal of
film from the paint, is nearly impossible with no touch systems. At "full-service" car
washes, the exterior of the car is washed mechanically with conveyor equipment, or in
some cases by hand, with attendants available to dry the car manually, and to clean the
interior (normally consisting of cleaning the windows, wiping the front and side dashes,
and vacuuming the carpet and upholstery). Many full service car washes also provide
"detailing" services, which may include polishing and waxing the car's exterior by hand
or machine, shampooing and steaming interiors, and other services to provide thorough
cleaning and protection to the car.
1.2 Stages of car washing system:
I. Pre-wash/foam wash:
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II. Brushing for side of car:
III. Brushing for the top of car:-
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IV. Brushing for wheel/tires:
V. Clean wash
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
Chapter 2
PLC
2.1 Introduction:
A PLC (Programmable Logic Controller) is usually called as Programmable
controller. It is a solid-state, digital, Industrial Computer. Upon first look, a PLC may
seem to be no more than a black box with wires bringing signals in and other wires
sending signals out. It might also appear there is some magic being done inside that
somehow decides when field devices should be turned on. In actuality, there is no
magic. The PLC is a computer, and someone had to tell it what to do. The PLC knows
what to do through a program that was developed and then entered into its memory. The
PLC is a computer, however without a set of instructions telling it what to do, it is
nothing more than a full of electronic components. Without instructions, the black box
that we call a PLC can do nothing. The user program is the list of instructions that tells
the PLC what to do.
Computers such as PLC can be wonderful tools, however it might appear. They
only do exactly what the human programmer told them to do.
2.2 What is a PLC?
The PLC can be classified as a solid-state member of the computer family. A
programmable controller is an Industrial Computer in which control devices such as
limit switches, push buttons, proximity or photoelectric sensors, float switches or
pressure switches and few incoming control signals called Input.
Input interact with instructions specified in the user ladder program, which tells
the PLC how to react to the incoming signals. The user program also directs the PLC
on how to control field devices like motors, solenoids etc.
A programmable controller, as illustrated in Figure, consists of two basic
sections:
• CPU (Central Processing Unit)
• Input/output interface system
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
2.3 Central Processing Unit:
The central processing unit (CPU) is the heart of PLC. The CPU reads signals
and follows the instructions that a programmer has stored in memory. As a result of
solved program, the PLC turns outputs or field controlled devices turn on-off.
The CPU consists of following three parts:
• Processor
• Memory System
• Power Supply
2.4 Input/output interface system:
It consist of following parts
The sensing section:
Sensing section is made up of limit switches, photoelectric sensors, push
buttons and so far. These incoming hardware devices provides input signals
and are known as field inputs.
Input section: The input sec0tion of PLC contains two major areas. First the
physical screw terminals where incoming signals from field input devices. The
second section is PLC internal conversion electronics. The function of the
input section electronic component is to convert and isolate the high voltage
input levels from the field devices.
Controller: The controller is commonly known the central processing unit or
simply the processor .This is the brain or microprocessor that controls or
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supervises the entire process. The CPU solves the user program and updates
the status of the output.
Programmer: The programmer is a device where by the programmer or
operator can enter and edit programs, instructions or data. The programmer
can be a handheld unit, personal computer or an industrial computer
programming terminal.
Output section :The result of looking at or reading the ON/OFF status of the
inputs and using the information to solve the user ladder program is to send,
updated signals to the output section is simply a series of switches, one of each
output point, that are controlled by CPU and are used to turn output devices
ON/OFF.
Field hardware devices: They will stop the conveyor motor by de-energizing
the motor starter coil, when the products are sensed. The motor starter is a
device control by PLC. The devices that are controlled by PLC output section
screw terminals are the field hardware devices.
2.5 PLC specification:
Input Power Supply: 230 V AC
Number of digital inputs: 14
Number of digital outputs: 10
IF2-OF2 Module: 1 (for analog inputs and outputs)
Analog Input Indicator Module: 2
Analog Output Indicator Module: 1
PLC PC Communication: RS-232 Cable (1761-CBL-PM02)
Cable Length (1761-CBL-PM02): 2 meters (6.5 ft.)
Communication Software (PC-PLC): RS-Linx
Ladder Logic Software: RS-Logix -500
SCADA Software Available: RS-VIEW 32 version 6.30
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
Chapter 3
Hybrid Distributed Control System
Introduction:-
• The importance of DCS systems to increase as global competitive dynamics in
food and beverage, specialty metals, pulp and paper, pharmaceutical and fire
chemical processing.
• The DCS has networking capabilities which are useful for business
management.
• The DCS has capacity for processing large number of I/O points.
TYPES OF DCS:
1) Conventional DCS.
2) PLC based DCS.
3) Hybrid DCS.
4) Open DCS System
CONVENTIONAL DCS
This is a pure “Process only” control system. Usually purchased from one vendor.
This DCS arranged into three categories:
• Small - Less than $ 100,000.
• Medium - Greater than $100,000 & Less than $500,000.
• Large - Greater than $500,000.
PLC Based DCS: - This is a network of PLC’s used to perform the task of
conventional DCS and programmable functionality when required.
Hybrid DCS: - Performs both process and sequential control.
Open DCS System.
This is Field-Bus Control. Advantages are lower wiring cost and less
failure, smaller expansion costs and multi-vendor interoperability DCS and PLC can
be more closely and efficiently interconnected.
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
Hybrid DCS Features:-
• Multitasking.
• Multiprocessing.
• Multilanguage System.
• High performance Instruction set.
• A common Software environment across multiple hardware platforms.
• Flexible network Architecture.
• Operational efficiency and availability.
Languages Supported:-
Ladder Diagram
Functional Block Diagram
Sequential Function Chart
Structured Text
Different Controllers:-
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Compact Logix L43 Hybrid DCS Setup:-
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Specification of Compact Logix L43 Hybrid DCS
Industrial communication protocol such as Ethernet, Control net,
Profinet and Modbus modules.
4 Analog Input and 4 Analog Output (2 AI/AO drive by Controllnet
module and 2 AI/AO drive by Ethernet module )
8 Digital Input and 8 Digital Output (4 DI/DO drive by Controllnet
module and 4 DI/DO drive by Ethernet module )
Variable Frequency Drive for motor speed controlling.
Energy Meter controlled by Modbus
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
Chapter 4
SCADA
4.1 Introduction:
A SCADA system may be regarded as an extension of computer data
logger systems. SCADA system is one of the plant automation process due to its visual
representation and its advance features. As its name suggests that this system not only
a data acquisition but also it gives master supervisory control and able to take decision
regarding the project.
SCADA system is very popular because it gives total plant appearance on a
single screen and its monitoring and control for the user. It made very easy to look into
the plant and study the different controlling parameters with different device making
with their changes continuously. So it gives the interesting and visual plant process
appearance without going into the actual field. In practice, the different SCADA
software are available in market. Everyone is having its different features but the basic
concept is same for all. RS VIEW-works-Rockwell Software: RS VIEW-works is very
popular SCADA software.
The project can be studied using this SCADA alone i.e. without link with PLC,
by using Visual basic languages with by linking with PLC. It gives control over total
PLC program. SCADA is having its own graphic display on which the mimics are
developed. Different mimics can be made as desired or the different structures can be
easily brought from the library of RS view works software itself. After constructing the
total process mimic then we have to assign the tag database for i.e. button, tank, control
valve, light, motor etc.
4.2 Project Development Steps:
1. Working with a project manager:
system configurations
graphic display
library
alarm security
2. Creates and edit projects
3. Defining events and drive tags
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4. System Configuration:
Channel-:
In this, the proper RS232, DF 485 etc. should be select for
channelling between PLC & SCADA. e.g. AB-DFI-1 (Allen-
Bradley)
Node:
Node is to be assign of PLC i.e. for Allen-Bradley
Micrologix/SLC I-DH-485.(communication)
Station link gateway:
AB-DFI-1
OK
Accept
Scan class:
Generally this is kept as default setting.
Tag data base
It creates and edit tag data base. Tag data base consists of records
called Tags. Tags are organizing tags in to group using folders.
Three types of tags can creates.
5. To setup a tag data base
Library:
The SCADA software is having its kinds of structures. It gives
different pumps, motors, control valves, tanks, switches, alarms
etc.
Animations:
When right click on the mimic, the animation function appears
which gives the filling effect for tanks etc.
Graphics:
Create & edit graphic display-
Use graphic display editor:
- Create graphic display using library.
- Setup behavior and properties.
Animate graphic display.
6. Testing and running project:
- Project path
- Run project
- Moving between run & edit modes
- Viewing alarms and project
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Chapter 5
Stages of Car Washing System
1. Entry :-
2. Pre-wash/ Foam Wash Section :-
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
3. Brushing :-
4. Clean Wash Section :-
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5. Drying Section :-
6. Exit :-
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Shri Guru Gobind Singhji Institute of Engineering & Technology, Nanded[431606].
Chapter 6
Components of Car Washing System
6.1 DC Motor
A DC motor is any of a class of electrical machines that converts direct
current electrical power into mechanical power. The most common types rely on the
forces produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic; to periodically change the
direction of current flow in part of the motor. Most types produce rotary motion; a
linear motor directly produces force and motion in a straight line.
DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed can
be controlled over a wide range, using either a variable supply voltage or by changing
the strength of current in its field windings. Small DC motors are used in tools, toys,
and appliances. The universal motor can operate on direct current but is a lightweight
motor used for portable power tools and appliances.