“automatic car washing system”2 shri guru gobind singhji institute of engineering &...

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].

2

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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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

5


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.

8


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.

9


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:-

12


IV. Brushing for wheel/tires:

V. Clean wash

13


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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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

15


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

16


17


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.

18


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:-

20


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

21


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

23


Chapter 5

Stages of Car Washing System

1. Entry :-

2. Pre-wash/ Foam Wash Section :-

24


3. Brushing :-

4. Clean Wash Section :-

25


5. Drying Section :-

6. Exit :-

26


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.

Fig Brush Motor

http://en.wikipedia.org/wiki/Universal_motor

27


Specifications of DC Motors:-

We are using DC Motors for two main purpose.

Rotation of Conveyor

-Supply Voltage : 24V

-RPM : 30 rpm

Wheel Brushes

-Supply Voltage : 24V

-RPM : 200 rpm

Fig: Conveyor Motor

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6.2 Solenoid Valve

A solenoid valve is an electromechanically operated valve. The valve is controlled

by an electric current through a solenoid: in the case of a two-port valve the flow is

switched on or off; in the case of a three-port valve, the outflow is switched between

the two outlet ports. Multiple solenoid valves can be placed together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks

are to shut off, release, dose, distribute or mix fluids. They are found in many

application areas. Solenoids offer fast and safe switching, high reliability, long service

life, good medium compatibility of the materials used, low control power and compact

design.

Besides the plunger-type actuator which is used most frequently, pivoted-armature

actuators and rocker actuators are also used.

A solenoid valve has two main parts: the solenoid and the valve. The solenoid

converts electrical energy into mechanical energy which, in turn, opens or closes the

valve mechanically. A direct acting valve has only a small flow circuit, shown within

section E of this diagram (this section is mentioned below as a pilot valve).

This diaphragm piloted valve multiplies this small flow by using it to control the flow

through a much larger orifice.

Specifications:

Operating Voltage:- 24 V DC

Simple ON-OFF

2 Way Valve

Fig 5.2 Solenoid Valve

29


6.3 Infrared sensor

Fig: IR Sensor Module

Principle:

IR LED emits infrared radiation. This radiation illuminates the surface in

front of LED. Surface reflects the infrared light. Depending on reflectivity of the

surface, amount of light reflected varies. This reflected light is made incident on

reverse biased IR sensor. When photons are incident on reverse biased junction of this

diode, electron-hole pairs are generated, which results in reverse leakage current.

Amount of electron-hole pairs generated depends on intensity of incident IR radiation.

More intense radiation results in more reverse leakage current. This current can be

passed through a resistor so as to get proportional voltage. Thus as intensity of incident

rays varies, voltage across resistor will vary accordingly. This voltage can then be

given to OPAMP based comparator. Output of the comparator can be read by uC.

Alternatively, you can use on-chip ADC in AVR microcontroller to measure this

voltage and perform comparison in software.

30


IR LED & IR Sensor:-

Fig: Radiation in IR Sensor

IR LED is used as a source of infrared rays. It comes in two packages 3mm or

5mm. 3mm is better as it is requires less space. IR sensor is nothing but a diode, which

is sensitive for infrared radiation.

This infrared transmitter and receiver are called as IR TX-RX pair. It can be

obtained from any decent electronics component shop and costs less than 10Rs.

Following snap shows 3mm and 5mm IR pairs.

Colour of IR transmitter and receiver is different. However you may come

across pairs which appear exactly same or even has opposite colours than shown in

above pic and it is not possible to distinguish between TX and RX visually. In case

you will have to take help of multimeter to distinguish between them.

The sensitivity of the IR Sensor is tuned using the potentiometer. The

potentiometer is tuneable in both the directions. Initially tune the potentiometer in

clockwise direction such that the Indicator LED starts glowing. Once that is achieved,

turn the potentiometer just enough in anti-clockwise direction to turn off the Indicator

LED. At this point the sensitivity of the receiver is maximum. Thus, its sensing

distance is maximum at this point. If the sensing distance (i.e., Sensitivity) of the

receiver is needed to be reduced, then one can tune the potentiometer in the anti-

clockwise direction from this point.

Further, if the orientation of both TX and RX LED’s is parallel to each other,

such that both are facing outwards, then their sensitivity is maximum. If they are

moved away from each other, such that they are inclined to each other at their soldered

end, then their sensitivity reduces. Tuned sensitivity of the sensors is limited to the

surroundings. Once tuned for a particular surrounding, they will work perfectly until

the IR illumination conditions of that region nearly constant. For example, if the

31


potentiometer is tuned inside room/building for maximum sensitivity and then taken

out in open sunlight, it will require retuning, since sun’s rays also contain Infrared (IR)

frequencies, thus acting as a IR source (transmitter). This will disturb the receiver’s

sensing capacity. Hence it needs to be returned to work perfectly in the new

surroundings. The output of IR receiver goes low when it receives IR signal. Hence

the output pin is normally low because, though the IR LED is continuously

transmitting, due to no obstacle, nothing is reflected back to the IR receiver. The

indication LED is off. When an obstacle is encountered, the output of IR receiver goes

low, IR signal is reflected from the obstacle surface. This drives the output of the

comparator low. This output is connected to the cathode of the LED, which then turns

ON.

6.4 Dryer

A blow Dryer or Dryer is an electromechanical device designed to blow

cool or hot air over wet or damp car, in order to accelerate the evaporation of water

particles and dry the car. It is used to remove the water drops and make the car dry

within less time.

Fig: Dryer

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6.5 Conveyor:-

A conveyor system is an common piece of mechanical handling equipment

That moves materials from one location to another. Conveyors are especially useful in

applications involving the transportation of heavy or bulky materials.

Conveyor systems allow quick and efficient transportation for a wide variety of

materials.

Specifications:-

Length : 1.8 meter

Width : 0.2 meter

Material : Nylon cloth

Sections:

Detection of car : 0.3 meter

Prewash : 0.3 meter

Brushing : 0.3 meter

Clean Wash : 0.3 meter

Drying : 0.3 meter

Entry & Exit : 0.3 meter

33


6.6 Step down Transformer:-

A transformer is a device that transfers electrical energy from one circuit to

another through inductively coupled conductors—the transformer's coils. A varying

current in the first or primary winding creates a varying magnetic flux in the

transformer's core and thus a varying magnetic field through the secondary winding.

This varying magnetic field induces a varying electromotive force (EMF), or

"voltage", in the secondary winding. This effect is called inductive coupling.

These are of two types.

Step-up transformer.

Step-down transformer.

1. Step-up transformer:

In this transformer, the voltage generated at the secondary is higher than the

voltage applied at its primary.

2. Step-down transformer:

In this, the voltage generated at the secondary is lower than the voltage applied

at its primary.

Here, we have used a step down transformer to generate 12 volt ac supply from 220

volt ac supply.

Specifications:

Input AC Voltage : 220 V

Output AC Voltage: 12 V

Input current : 10 -20 A

Output Current : 1A & 0.5 A

Figure:- Transformer

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6.7 Relay

A relay is an electrically operated switch. Many relays use

an electromagnet to mechanically operate a switch, but other operating principles are

also used, such as solid-state relays. Relays are used where it is necessary to control a

circuit by a low-power signal (with complete electrical isolation between control and

controlled circuits), or where several circuits must be controlled by one signal. The

first relays were used in long distance telegraph circuits as amplifiers: they repeated

the signal coming in from one circuit and re-transmitted it on another circuit. Relays

were used extensively in telephone exchanges and early computers to perform logical

operations.

Fig:- Relay Coil Circuit

Fig : Relay 24V

http://en.wikipedia.org/wiki/Electric

http://en.wikipedia.org/wiki/Switch

http://en.wikipedia.org/wiki/Electromagnet

http://en.wikipedia.org/wiki/Solid-state_relay

http://en.wikipedia.org/wiki/Electrical_telegraph

35


6.8 Car:-

Scale: - 12cm X 16cm

6.9 BLOCK DIAGRAM:

36


DESCRIPTION:

The figure shows the block diagram of Automatic Car Washing

System. A 230V AC Supply is given as input to the SMPS for obtaining 24V DC, since

PLC can operate at 24V DC. Terminal Block is used for multi inputs and outputs.

PLC is connected to PC through RS-232 communication cable for

downloading or uploading the program. Conveyor is used for shifting the car through

various stages of washing. We use 100 rpm DC motors for driving the conveyor belt

via pulley and for driving brushes When conveyor`s components are in good condition

and well aligned, it will operate properly. Proper clamping of car wheels on the

conveyor is needed in order to avoid displacement. Generally brushes are now either

cloth (which is not harmful to a cars finish, as long as it is flushed with plenty of water

to remove the grit from previous washes), or a brush, which does not hold dirt or water.

Thus it does not harm any painted finish. It provides a gentle polishing effect to leave

the paint much shinier. High pressure nozzles are pointed at various position for

spraying soap solution and water to clean difficult to reach parts of the vehicle. At the

end, hot steam air is generally used for drying the car. Construction of this system is

depends upon the requirement. A visual programming language known as the Ladder

Logic was used to program the PLC. An Infrared sensor is used which emits radiation

in order to sense presence of car at the entry level. Once the Infrared radiation is cut by

the car an input signal is given to PLC. Switches are present in the HMI screen. As an

input signal is received, PLC starts executing the Ladder Program.

First the conveyor moves by fixing a timer for few sec. After that,

it stops at the stage of washing. In general process, Car is cleaned by spraying soap

solutions, rinsing, brushing, drying, waxing, etc. depends on the requirement of

customer. We have chosen spraying water, Brushing and finally drying for cleaning the

car.

Each activity is carried out for a certain time period. Water is

sprayed for few sec and nozzle is closed. Then four brushes rotate for few sec and stops.

Now the conveyor starts moving to next stage. After few sec, it stops for drying. Two

fans are used for drying the car up to few sec. Then the conveyor carrying car moves to

the exit level. Again an IR sensor senses the car and sends an input signal to

Programmable logic controller.

Timings are set by using timers in ladder programming. These timings can be varied

depending upon the requirement.

37


6.10 Input interfacing circuit diagram of IR with Hybrid DCS:-

6.11 Output interfacing circuit diagram of DC Motor, Solenoid & Dryer with

Hybrid DCS:-

38


Chapter 7

Working of System

Input-IR sensor:

When car comes on IR-sensor, sensor sense and conveyor starts moving

with the help of motor (M2) until it will reach to the next IR sensor

section

As car reached to next ir section then entry gate start to open for 2sec

Pre-Wash Section

As the car reaches in pre-wash chamber, shampoo water falls on the car

by opening valve (V1).

Valve will remain on for 5 sec. After 5sec. valve will close

automatically.

Again conveyor starts moving until it will reach to the next ir sensor

section(Brushing section)

Brushing Section

As the conveyor stops vertical brushes starts brushing the car for

10sec. and stop.


section(Clean wash section)

Final Wash Section

Valve (V2) gets open for 5 sec. and get closed.


section(Drying)

Drying

Start dryer for 10 sec. and stop.

Exit

After drying stage completion open exit gate with the help of motor

(M6) for 2 sec. and stop.

Again conveyor starts starts moving until it will reach to the next ir

sensor section.

Close the gate (M6)

39


Chapter 8

Ladder Diagram for project:

40


41


42


43


Ladder Diagram of project on Hybrid DCS

44


45


Chapter 9

The SCADA for our project is shown below. It contains the conveyor belt,

control valve, IR sensor, Tanks, Dryer and electric motors with the different washing

sections namely prewashing, brushing, wheel brushing, washing and drying.

SCADA Mimic:-

46


Figure: - SCADA MIMIC

47


Chapter 10

Documentation

7.1 Digital input/output datasheet:

Advantages

Less Area

Less amount of water is required

Time requirement is less

Pollution free

Man power requirement is less

Name Address

(Hybrid DCS)

Address

(PLC)

Input/output Tag no

IR sensor 1 ACNR:1:I.0 I:0/0 Input IR-1

IR sensor 2 ACNR:1:I.1 I:0/1 Input 1R-2



IR sensor 5 AENT:1:I.0 I:0/4 Input 1R-5

IR sensor 6 AENT:1:I.1 I:0/6 Input LL-1

Conveyor motor (M2) ACNR:2:O.0 O:0/0 Output CONV

Entry motor (M1) ACNR:2:O.1 O:0/1 Output EN1

Entry motor (M2) ACNR:2:O.2 O:0/2 Output EN2

Foam Valve (V1) AENT:2:O.2 O:0/3 Output FM

Brush motor (M3) ACNR:2:O.3 O:0/4 Output BRUSHING

Clean Valve (V2) AENT:2:O.3 O:0/5 Output CW

Dryer AENT:2:O.1 O:0/6 Output DRYING

Exit Motor(M1) AENT:2:O.0 O:0/7 Output EX1

Exit Motor(M2) - O:0/8 Output EX2

Pump - O:0/9 Output PUMP

48


Cost Analysis:

Sr. No. Components Quality Total Cost (Rs.)

1 IR sensor 6 300

2 DC motor 8 1500

3 Conveyor Belt 1 150

4 Dryer 1 400

5 Tanks 2 150

6 Relay 9 300

7 Solenoid Valve 2 300

8 Car 1 150

9 Pipes - 300

10 Miscellaneous - 1500

Total cost required for the implementation of PLC Based Automatic Car Wash System

is

Rs. 6000/-

Result:-

In Automatic Car Washing System, we performed all the operations needed

to clean the car successfully by using PLC and hybrid compact logix L43 DCS, also

developed mimic of the whole system on SCADA RS VIEW 32 Works and checked

the overall process step by step by visualization.

49


Chapter 11

Conclusion:-

This prototype will help to perform car washing automatically results

in high quality end product. Thus it will be User-friendly and capable to wash multiple

cars at a time. Also require less man power, time and no pollution.

References:-

1 .www.philips.com

2. www.ieee.com

3. www.kkeindia.com

4. www.rockwellautomation.com

5. www.indiamart.com/3-brush-automatic-car-wash-system.html

6.www.youtube.com/automatic-car-wash

http://www.philips.com/

http://www.rockwellautomation.com/

http://www.indiamart.com/3-brush-automatic-car-wash-system.html

http://www.youtube.com/automatic-car-wash

“automatic car washing system”2 shri guru gobind singhji institute of engineering &...

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