Automatic Car Washing System

Transcription

1 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 2 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 VIII th semester during academic year 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)

3 3 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.

4 4 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 5 Sr. No. TOPIC INDEX Page No. 1. Introduction Introduction 2. PLC 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 SCADA Introduction 4.2 Project Development Steps 5. Stages of Car Washing System Components of System 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

6 6 11) Output interfacing Diagram 7. Working of System Entry -Car Detection 7.2 Foam Wash 7.3 Brushing 7.4 Clean Wash 7.5 Drying 7.6 Exit 8. Ladder Diagram SCADA MIMIC of Project Documentation Digital Input-Output Datasheet 10.2 Advantages 10.3 Cost Analysis 10.4 Result 11. Conclusion & References 49

7 7 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 8 Also visible is the conveyor. The carwash will generally start cleaning with presoaks 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 ribbonlike 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 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

10 10 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:

11 11 II. Brushing for side of car: III. Brushing for the top of car:-

12 12 IV. Brushing for wheel/tires: V. Clean wash

13 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

14 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 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 16

17 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 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:-

19 19 Compact Logix L43 Hybrid DCS Setup:-

20 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 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

22 22 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 23 Chapter 5 Stages of Car Washing System 1. Entry :- 2. Pre-wash/ Foam Wash Section :-

24 24 3. Brushing :- 4. Clean Wash Section :-

25 25 5. Drying Section :- 6. Exit :-

26 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

27 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

28 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 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 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 anticlockwise 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 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

32 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 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 : A Output Current : 1A & 0.5 A Figure:- Transformer

34 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

35 Car:- Scale: - 12cm X 16cm 6.9 BLOCK DIAGRAM:

36 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 Input interfacing circuit diagram of IR with Hybrid DCS: Output interfacing circuit diagram of DC Motor, Solenoid & Dryer with Hybrid DCS:-

38 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. Again conveyor starts moving until it will reach to the next ir sensor section(clean wash section) Final Wash Section Drying Valve (V2) gets open for 5 sec. and get closed. Again conveyor starts moving until it will reach to the next ir sensor section(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 39 Chapter 8 Ladder Diagram for project:

40 40

41 41

42 42

43 43 Ladder Diagram of project on Hybrid DCS

44 44

45 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 46 Figure: - SCADA MIMIC

47 47 Chapter 10 Documentation 7.1 Digital input/output datasheet: 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 3 ACNR:1:I.2 I:0/2 Input 1R-3 IR sensor 4 ACNR:1:I.3 I:0/3 Input 1R-4 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 Advantages Less Area Less amount of water is required Time requirement is less Pollution free Man power requirement is less

48 48 Cost Analysis: Sr. No. Components Quality Total Cost (Rs.) 1 IR sensor DC motor Conveyor Belt Dryer Tanks Relay Solenoid Valve Car Pipes Miscellaneous 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 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: