Method and system for detecting and controlling the dose and residual concentration of hard surface cleaner and rinsh aid in

Abstract

The present disclosure relates to methods and systems for detecting and controlling the dose and residual concentration of hard surface cleaners and rinse aids in automotive part scrubbers. In particular, these methods and systems are particularly suited for washing systems employed prior to painting of outer plastic parts. These methods and systems include a UV meter (302), a controller (306), and a metering pump (310); wherein the controller is in electrical communication with the UV meter and the metering pump.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. §119 to provisional application serial number 63 / 368,544, filed on July 15, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates to methods and systems for detecting and controlling the dosage and residual concentration of hard surface cleaners and rinse aids in automotive parts washers. In particular, these methods and systems are particularly suitable for washing systems employed prior to painting exterior plastic parts. Background Art

[0004] After the manufacture of automotive parts, exterior plastic parts and automotive dashboards must be thoroughly washed and rinsed before the manufacturer paints them. Washing systems typically have multiple stages, where the plastic undergoes at least one washing stage (where the wash water contains detergent) followed by a rinsing stage. In some washing systems, there are multiple washing stages and / or rinsing stages. During the process, wash water and rinse water are typically sprayed in their respective stages and collected in a drain for reuse. The detergent concentration in the reused wash water is often affected by: (1) detergent remaining on the product (which enters the rinse stage); (2) soil that is washed away and captured in the reused wash water; and (3) wash water loss caused by splashing and spraying outside the drain on the parts. To this end, the wash water must be continuously and routinely tested to obtain the correct detergent concentration associated with one or more wash chambers. The current process for testing wash water is performed via titration, and then the detergent concentration is manually adjusted. This is very time-consuming, labor-intensive, and may require the washing system to be adjusted multiple times a day.

[0005] It is therefore an object of the present disclosure to provide an alternative method and system for testing detergent concentration in wash water.

[0006] It is another object of the present disclosure to provide an alternative method and system for adjusting detergent concentration in wash water.

[0007] It is yet another object of the present disclosure to reduce downtime of a washing system in order to test and correct detergent concentration in the wash water.

[0008] It is yet another object of the present disclosure to improve the operation of a washing system by maintaining a desired residual detergent concentration in the wash water.

[0009] Other objects, advantages and features of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. Summary of the invention

[0010] A preferred embodiment is a plastic automotive parts and dashboard washing system comprising: a washing stage, the washing stage including a conveyor belt, a sprayer and a drain pipe; a metering pump; a sensor; and a controller; wherein the sprayer is configured to spray water and / or water containing detergent; wherein the drain pipe includes an inlet leading to a collected wash water container; wherein the conveyor belt is configured to carry plastic automotive parts and / or dashboards; wherein the metering pump is configured to release detergent into the water body and / or collected wash water; wherein the sensor includes a UV meter; wherein the sensor is configured to perform UV transmittance measurements on the collected wash water; wherein the controller is in electrical communication with the sensor and the metering pump; wherein the controller stores a calibration curve graph of UV transmittance versus concentration of surfactant species in the detergent; and wherein the calibration curve graph includes set points.

[0011] A preferred embodiment is a kit for modifying a plastic automotive parts and dashboard washing system, comprising: a sensor; a metering pump; and a controller, the controller comprising a transmitter and a receiver for electrically communicating with the sensor and the metering pump; wherein the sensor comprises a UV meter; wherein the controller stores a calibration curve graph of UV transmittance or absorbance versus concentration of a surfactant species in a detergent; and wherein the calibration curve graph includes set points.

[0012] A preferred embodiment is a method for cleaning plastic automotive parts and / or dashboards, comprising: placing plastic automotive parts and / or dashboards on a conveyor belt; activating the conveyor belt to pass through one or more washing stages of a washing system; spraying the plastic automotive parts and / or dashboards with wash water in one or more washing stages of the washing system; wherein the wash water contains a detergent; wherein the detergent contains a surfactant; collecting the wash water from the one or more washing stages after spraying; sensing the UV transmittance or absorbance of the surfactant in the collected wash water via a sensor; comparing the UV transmittance of the collected wash water with a set point on a calibration curve chart; dosing water or the detergent into the collected wash water; wherein the amount of water and / or detergent is determined by the difference between the measured UV transmittance or absorbance and the set point on the calibration curve chart; and recycling the collected wash water that has been dosed with water or the detergent into the washing system.

[0013] Although multiple embodiments are disclosed, other embodiments of the present invention will be apparent to those skilled in the art from the following detailed description, which shows and describes exemplary embodiments of the present invention.Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Examples of washing systems for plastic automotive parts and dashboards are illustrated.

[0015] Figure 2A An example of a four-stage scrubbing system is illustrated.

[0016] According to at least some aspects of the present disclosure, Figure 2B Modify advantageously Figure 2A washing system.

[0017] Figure 3A A graph is plotted of conductivity based on detergent concentration (in wt %) in the RO water.

[0018] Figure 3B Draw the corresponding Figure 3A A graph of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in RO water.

[0019] Figure 3C A graph of the calibration of the conductivity of the wash water based on the wash detergent concentration (in wt %) in the RO water was plotted.

[0020] Figure 3D Draw the corresponding FIG. 3A to FIG. 3C A graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in RO water.

[0021] Figure 4A The conductivity of wash water containing detergent after various washing stages was analyzed and compared with RO and city water without any detergent; Figure 4A based on FIG. 3A to FIG. 3D Comparison of urban water used in.

[0022] Figure 4B The conductivity of wash water containing detergent at different wash stages was compared with the actual concentration of detergent in the wash water; Figure 4B based on FIG. 3A to FIG. 3D Comparison of RO and city water used in.

[0023] Figure 5A A graph of the calibration of wash water conductivity based on wash detergent concentration (in wt %) in city water was plotted.

[0024] Figure 5B Draw the corresponding Figure 5A Graph of percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in city water.

[0025] Figure 5C Draw the corresponding FIG. 5A to FIG. 5BA graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in city water.

[0026] Fig. 6A The conductivity of wash water containing detergent after various washing stages was analyzed and compared with city water without any detergent; Fig. 6A based on FIG. 5A to FIG. 5C Comparison of urban water used in.

[0027] Figure 6B The conductivity of wash water containing detergent at different wash stages was compared with the actual concentration of detergent in the wash water; Figure 6B based on FIG. 5A to FIG. 5C Comparison of urban water used in.

[0028] Fig. 7A The percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in municipal water was plotted, comparing transmittance data from three separate sample sets (including two separate different municipalities and one reverse osmosis water) from different geographic locations.

[0029] Figure 7B Indicated are the results of measurements of percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in municipal water, comparing transmittance data from three separate sample sets (including two separate different municipalities and one reverse osmosis water) from different geographic locations.

[0030] Fig. 8A A graph is plotted showing conductivity based on detergent concentration (in wt %) in city water.

[0031] Figure 8B Draw the corresponding Fig. 8A Graph of percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in city water.

[0032] Figure 8C The corresponding FIG. 8A to FIG. 8B A graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in city water.

[0033] Fig.8D The corresponding FIG. 8A to FIG. 8B A graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in city water.

[0034] Fig.9A A graph is plotted of conductivity based on detergent concentration (in wt %) in the RO water.

[0035] Fig. 9B Draw the corresponding Fig. 8A A graph of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in RO water.

[0036] Fig. 9C The corresponding FIG. 9A to FIG. 9B A graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in RO water.

[0037] Fig.9D The corresponding FIG. 9A to FIG. 9B A graph of the calibration of the percent ultraviolet (UV) transmittance at 254 nm based on detergent concentration in RO water.

[0038] Fig.10 The transmittance, absorptivity and conductivity of wash water from different wash grades were compared.

[0039] Various embodiments of the preferred embodiments are described in detail with reference to the accompanying drawings, wherein the same reference numerals represent the same parts in several views. The reference to the various embodiments does not limit the scope of the invention disclosed herein. The drawings shown herein are not limited to the various embodiments according to the disclosed invention, but are presented for exemplary purposes of the invention. DETAILED DESCRIPTION

[0040] In the following detailed description, reference is made to the accompanying drawings which form a part of this document. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein.

[0041] The present disclosure relates to a method and system for testing wash water of an automobile parts washing system, and a method and system for adjusting the detergent concentration in the wash water of an automobile parts washing system. The system and method have many advantages over conventional and existing systems and methods for testing and adjusting wash water in an automobile parts washing system. One benefit of the present disclosure is that a faster test of wash water is provided. Another benefit is that the testing method can be automated to reduce the need for manual testing. Yet another advantage of the present disclosure is that the testing method can be combined with the adjustment of the detergent concentration so that an automatic system can test the wash water and automatically adjust the detergent concentration. Another benefit of the present disclosure is that the method and system can reduce the downtime of the washing system.

[0042] The embodiments of the present disclosure are not limited to specific automobile parts washing systems (including those with more or fewer stages), which are variable and understood by those skilled in the art. It should also be understood that all terms used herein are for the purpose of describing specific embodiments only and are not intended to be limited in any manner or scope. For example, unless the context clearly indicates otherwise, the singular forms "one" and "the" used in this specification and the appended claims may include plural referents. In addition, all units, prefixes and symbols may be expressed in their SI accepted form.

[0043] The numerical ranges listed in the specification include the numbers defining the ranges, and include each integer within the defined ranges. Throughout this disclosure, various aspects of the preferred embodiments are presented in range format. It should be understood that the description in range format is only for convenience and clarity, and should not be understood as a rigid limitation on the scope of the invention. Therefore, the description of the range should be considered to have explicitly disclosed all possible subranges, fractions, and individual values ​​within the range. For example, the description of a range such as 1 to 6 should be considered to have explicitly disclosed subranges, such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as individual numbers within the range, such as 1, 2, 3, 4, 5, and 6, as well as decimals and fractions, such as 1.2, 3.8, 1 1 / 2 and 4 3 / 4. This applies regardless of the range width.

[0044] In order to more easily understand the present invention, some terms are first defined. Unless otherwise defined, all technical and scientific terms used herein have the same meanings commonly understood by those of ordinary skill in the field to which embodiments of the present invention belong. Many methods and materials similar to the methods and materials described herein, modified or equivalent can be used in the practice of embodiments of the present invention without too much experimentation, and preferred materials and methods are described herein. When describing and requiring embodiments of the present invention, the following terms will be used according to the definitions set forth below.

[0045] As used herein, the term "about" refers to a variation in a value that may occur, for example, by typical measurement techniques and devices, relative to any quantifiable variable, including, but not limited to, concentration, mass, volume, time, temperature, wavelength, pH, etc. In addition, given the solid and liquid handling procedures used in the real world, there are certain inadvertent errors and variations, which may be due to differences in the manufacture, source, or purity of the ingredients used to prepare the composition or implement the method, etc. The term "about" also encompasses amounts that differ due to different equilibrium conditions for a composition formed from a particular initial mixture. The term "about" also encompasses these variations. Whether or not modified by the term "about," the claims include equivalents to this quantity.

[0046] The terms "actives" or "active percentage" or "active percentage by weight" or "active concentration" are used interchangeably herein and refer to the concentration of those ingredients that participate in cleaning, expressed as a percentage minus inert ingredients such as water or salt.

[0047] "Anti-redeposition agents" refers to compounds that help remain suspended in water, rather than redepositing onto the object being cleaned. Anti-redeposition agents are useful herein to help reduce the redeposition of removed soil onto the surface being cleaned.

[0048] As used herein, the term "cleaning" refers to methods for promoting or assisting in soil removal, bleaching, reduction of microbial populations, and any combination thereof. As used herein, the term "microorganism" refers to any non-cellular organism or unicellular (including bacterial colonies) organism. Microorganisms include all prokaryotes. Microorganisms include bacteria (including cyanobacteria), spores, lichens, fungi, protozoa, prions, viroids, viruses, bacteriophages, and some algae. As used herein, the term "microbe" is synonymous with microorganism.

[0049] The term "hard surface" refers to solid, substantially non-flexible surfaces such as automotive parts, including those of automobiles, trucks, ATVs, tractors, boats, etc. Hard surface parts can include, for example, doors, fenders, handles, panels (including exterior panels), roofs, trim, etc. Hard surfaces can include, for example, health care surfaces and food processing surfaces, production equipment, parts, belts, conveyors, instruments, countertops, tiles, floors, walls, panels, windows, plumbing fixtures, kitchen and bathroom furniture, appliances, engines, circuit boards, and plates.

[0050] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and syndiotactic copolymers, terpolymers and higher order "x" polymers, and also includes derivatives, combinations and blends thereof. In addition, unless otherwise specifically limited, the term "polymer" shall include all possible isomeric configurations of the molecule, including, but not limited to, isotactic, syndiotactic and random symmetries, and combinations thereof. In addition, unless otherwise specifically limited, the term "polymer" will include all possible geometric configurations of the molecule.

[0051] As used herein, the term "soil" or "stain" refers to a non-polar, oily material that may or may not contain particulate matter such as mineral clay, sand, natural minerals, carbon black, graphite, kaolin, environmental dust, and the like.

[0052] As used herein, the term "substantially free" means that the composition is completely lacking a component or has an amount of a component so small that the component does not affect the performance of the composition. The component may be present as an impurity or as a contaminant and should be less than 0.5% by weight. In another embodiment, the amount of the component is less than 0.1% by weight, and in yet another embodiment, the amount of the component is less than 0.01% by weight.

[0053] As used herein, the terms "weight percent," "weight %," "percent by weight," "% by weight," and variations thereof refer to the concentration of a substance in the form of the weight of the substance divided by the total weight of the composition and multiplied by 100. It should be understood that as used herein, "percent," "%," and the like are intended to be synonymous with "weight percent," "weight %," and the like.

[0054] The methods and compositions of the present invention may comprise, consist essentially of, or consist of the components and ingredients of the present invention and other ingredients described herein. As used herein, "consisting essentially of" means that the methods and compositions may include additional steps, ingredients, but only if the additional steps, ingredients do not materially change the basic and novel characteristics of the claimed methods and compositions.

[0055] System and method for monitoring and adjusting detergent concentration

[0056] Plastic and dashboard washing systems are a critical step in cleaning and removing contaminants such as mold release compounds, oils, dust, dirt and grime from dashboard parts prior to the painting process. If the parts are not thoroughly cleaned, paint adhesion issues will occur and cause defects in the painted parts, which will require expensive rework or may result in having to discard the part. Therefore, plastics and other dashboard components must be thoroughly cleaned before painting.

[0057] It is very difficult to standardize the process across wash system locations or even within a specific wash facility. This is because the water at each location is typically different (and therefore, mineral content and pH), and the wash process itself causes variations in the wash water based on variations in detergent concentration and variations in contaminants in the water. As a result, wash systems employ manual titration procedures that are repeated over the course of a day or at most a week. Titration methods have proven to be highly variable and inaccurate for a number of reasons. First, the titration system itself is very dependent on local water sources, such as local city water and potential reverse osmosis water quality. The titration method also relies on uniform detection of colorimetric changes in chemical indicators through acid / base titration. The endpoint detection used to derive concentrations through calibration tables is very operator and location dependent. While this method is more accurate in practice (i.e., in field use) by a skilled single operator in a laboratory setting, it is impractical and presents significant challenges. Being able to accurately detect, monitor (without titration), and control concentrations at different scrubber stages provides a key mechanism for maintaining program performance at all scrubber stages in plastic parts and instrument panel cleaning systems and methods.

[0058] In one embodiment, the wash water may be sprayed while the parts are moving through a tunnel (or other location) where the formulation is sprayed. This process may be manual, partially or fully automated. In one exemplary embodiment, the process may be performed on a fixed or moving surface (such as a conveyor belt that carries the parts through the sprayer). In another embodiment, the use solution of the composition may be dosed into a storage tank or other holding device and the parts immersed therein.

[0059] The contact of the surface with the detergent wash water can be a part of a multi-part process or a multi-phase system. In one embodiment, before a coating or paint is applied to the surface that needs to be cleaned and rinsed, the detergent wash water is contacted with the surface. Exemplary steps in the method or system that adopts the hard surface rinse aid composition can include an initial pre-wash or hot wash step, a washing step with other soap and / or detergent, one or more rinsing steps and a drying step. The contact of the surface with the use solution of the composition can last for about 60 seconds to several hours, several minutes to several hours or about 10 minutes to about 60 minutes.

[0060] In a preferred embodiment, the detergent wash water cleans and dries the surface within about 30 seconds to several minutes, or within about 30 to about 90 seconds after the aqueous solution is removed (i.e., the surface is removed from the storage tank where it was immersed in the composition). Preferably, the detergent wash water provides a dynamic contact angle that provides an effective sheet without leaving debris on the treated surface even with high use concentrations. As disclosed herein, the correct detergent concentration will provide optimal conditions for detergent-induced filming, ensuring that no debris remains on the treated surface despite the use of a high concentration of the surfactant system, and confirming that no filming is formed on the surface.

[0061] Although not limited to the following concentrations, preferably the detergent wash water has a concentration of at least about 0.25% to 1% detergent and / or rinse aid in water, at least about 2% detergent and / or rinse aid in water, or at least about 3% detergent and / or rinse aid in water. Preferably, the concentration of detergent is less than about 10%, 9%, 8%, 7%, 6%, or 5% by weight.

[0062] Now referring to the accompanying drawings, Figure 1 A plastic and instrument panel washing system 100 is shown. The system 100 includes a pre-treatment scrubber 102 for cleaning metal and plastic substrates 98 before liquid or powder coating and before and after machining or forming parts. The scrubber 102 is made of heavy-duty materials for greater durability. For example, the tank 104 on the pre-treatment scrubber 102 can be double welded inside and outside to prevent leaks. The tank 104 may also include stainless steel or mild steel, overflow tanks and / or drain pipes 106 on all stages, valves for the drain pipes 106, a filter screen 108 with a bottom sludge dam, a clamping support 110, a gas-fired submerged burner 112, a removable inspection cover (e.g., a ship tank cleaning hole) and an inclined bottom for easy cleaning. The pre-treatment scrubber 102 also includes an overhead conveyor 116 protected by a conveyor guard 118. The conveyor guard 118 is particularly beneficial when used in the spraying stage and the drainage stage. The modular design of the pretreatment scrubber 102 allows for easier and faster installation.

[0063] The pretreatment scrubber 102 may also have a clamp-on nozzle 120. Each nozzle 120 may be adjusted so that the nozzle 120 is aimed at a desired part or product in the scrubber 102.

[0064] The housing 122 may include stainless steel or mild steel. The housing 122 may also include a sloped drainage platform, bulkhead access doors 124 in the drainage stage 102N, inlet and outlet exhaust vestibules, contours between all spray sections 102N, and bolt configurations.

[0065] The piping system may include quick, overhead disconnects, standpipes with quick disconnects, drain, overflow and reverse flow piping, fast fill bypasses on all stages, vertical pumps 126, temperature gauges on the heating stages, and pressure gauges on all stages.

[0066] The scrubbing system 100 may be further enhanced by using a particle filtration system 128 , an oil separation system, and / or a recirculating air blow-off system 130 .

[0067] The number of stages 102N and the design of the pretreatment scrubber 102 depends on the complexity of the parts and the surface treatment specifications. A typical multi-stage scrubber includes a chemical cleaning stage 102A, followed by a water stage and a rinse stage. A complex multi-stage scrubber may also include additional stages 102B-102D, and may include, but is not limited to, a phosphate stage, an additional rinse stage, and a reverse osmosis or surfactant final rinse stage.

[0068] For example, Figure 2A is a schematic diagram showing an example of a typical four-stage washing system 200 for cleaning plastics. The bath / spray scrubber system 200 is both an energy-intensive and water-intensive process that utilizes 4 or 5 stages to move clean water (city water 204 or RO water 210) at high temperatures as a medium. More specifically, the clean water 204 / 210 moves between at least three different areas 202A, 202B, 202C after undergoing 1 or more stages in the process. Figure 2A The plastic parts in the tank move from level 1 area 202A to level 2 area 202B to level 3 area 202C.

[0069] The fluid capacity of regions 202A, 202B, and 202C may decrease as the stages progress. In an exemplary embodiment, stage 1 region 202A has a fluid capacity of approximately 3480 gallons and facilitates mixing of city water 204 and soap 206; stage 2 has a fluid capacity of approximately 2085 gallons and receives city water 204; and stage 3 has a fluid capacity of approximately 1775 gallons and receives RO water 210.

[0070] Stage 1 is a chemical cleaning stage. As shown, the chemical cleaning stage receives water directly from a city water supply 204, which is fluidly positioned upstream of the chemical cleaning stage. A soap supply 206 is also fluidly positioned upstream of stage 1 area 202A. As shown, the city water supply 204 and the soap supply 206 are fluidly parallel to each other. Nozzles, pumps, mixing devices, etc. may be used in stage 1 to best promote the mixing of soap 206 and water 204. After the mixture of soap 206 and water 204 is applied to the plastic, the spent mixture is allowed to leave stage 1 area 202A via drain 208. A shut-off valve 216 may be included near the fluid input of stage 1 area 202A to facilitate repair of any conduits downstream of the city water supply 204.

[0071] Stages 2 and 3 occurring at areas 202B and 202C are optionally performed. Stages 2 and 3 are water and rinse stages. Similar to stage 1, stage 2 can receive fluid input directly from a city water supply 204, which is positioned upstream of stage 2 area 202B. It is particularly beneficial to use a pump 218 to facilitate the movement of water throughout stage 2 area 202B. Optionally, pump 218 can also be configured to move water from the stage 2 area through bypass conduit 212 to stage 1 area 202A, so that the water can be used and / or reused in stage 1 area 202A. Stage 2 area 202B can also include fluid inputs from other stages (e.g., stages 3 and 4) located upstream thereof.

[0072] Similar to stage 2, stage 3 is a water stage and a rinse stage, however instead receives clean water from an RO water source 210. The clean water may be received directly from the RO water supply 210 or indirectly from the RO water supply 210 after passing through an RO storage unit 222 having a fluid capacity of approximately 1150 gallons. Optionally, a pump may help move the clean water from the RO storage unit 222 to the stage 3 area 202C. After the water passes through stage 3, the water may pass through an overflow tank 224 having a fluid capacity of approximately 55 gallons before being removed to stage 2 by a pump 214.

[0073] Still further, clean water may be supplied indirectly after passing through stage 4 (the "reverse osmosis" stage) to simulate a water source that has undergone an advanced water filtration system.

[0074] According to at least some aspects of the present disclosure, Figure 2B Modified favorably Figure 2AThe washing system of the present invention, wherein the system 200 includes and / or is substantially composed of a sensor 302, a controller 306, a metering pump 310, and a detergent source 312. The controller 306 communicates with the sensor 302 via a sensor signal 304, and also communicates with the metering pump 310 via a control signal 308. Preferably, the communication is electrical communication, including but not limited to wired electrical communication and / or radio communication (including but not limited to Wi-Fi communication, Bluetooth communication, radio communication).

[0075] sensor

[0076] Sensor 302 is preferably an ultraviolet (UV) meter. Suitable UV meters can be selected based on the wavelength corresponding to the excitation of the surfactant contained in the detergent used in the washing process. Although not limited to this spectrum, since the surfactant species can change, it is believed that the range of 100nm to 280nm covers the excitation of many surfactant species commonly contained in automotive detergents. In a preferred embodiment, the sensor is a UV meter that measures the transmittance between 100nm and 280nm, more preferably between 150nm and 280nm, still more preferably between 200nm and 280nm, and most preferably between 240nm and 280nm. For the purpose of this disclosure, a 254UV meter is always used; this is because it corresponds to the excitation of the surfactant used in the test detergent, and the system and method are evaluated and verified without changing the detergent species or equipment used in different locations and other test conditions. The system and method disclosed herein need not be limited to a 254nm UV meter.

[0077] In one embodiment, additional sensors may be employed including, but not limited to, a pH meter and / or a device for measuring conductivity.

[0078] Sensor 302 may be disposed at the location of the wash water collected after the cleaning application. At this location, sensor 302 may be used to test a parameter that may correspond to the concentration of detergent in the wash water. Therefore, additional water 204 / 210 and / or detergent 312 may be added to the wash water to reach a set detergent concentration.

[0079] Sensor 302 informs a UL listed, PLC based control panel which is in operational communication with the electronic solution level controls on all stages. Manual solution level controls may be included with the electronic solution level controls on all stages to account for potential electrical failures.

[0080] Controller

[0081] The controller 306 includes a human-machine interface (HMI) and components for establishing communications. Examples of such a controller 306 may be a separate processing unit, a programmable logic controller (PLC), an industrial computer that has been hardened and adapted to control a manufacturing process, a robotic device, or even simply other subcomponents of a computing device. The controller 306 may also include other components and may be partially or fully implemented on a semiconductor (e.g., a field programmable gate array ("FPGA")) chip (e.g., a chip developed through a register transfer level ("RTL") design process).

[0082] Metering Pumps

[0083] Metering pump 310 moves precise volume of liquid in a specified time period, thereby providing accurate volume flow rate. Delivering fluid with accurate adjustable flow rate is sometimes called metering. Metering pump 310 is specific to application or does not need to use accurate type of pump, although several types of pumps are more suitable than most other types of pumps. Metering pump 310 can pump water, chemicals, solutions and other liquids. Metering pump 310 is preferably rated to be able to pump to high discharge pressure. Metering pump 310 is made to measure with a flow rate that is actually constant (when averaged over time) in a wide discharge (outlet) pressure range.

[0084] How to use

[0085] The system and method can be applicable to detergent 312 and / or rinse aid for cleaning automotive parts.Automobile parts can be made of various materials, including for example plastics and plastic-containing metal parts, wherein metal can include aluminum that needs aluminum compatibility.Because aluminum is a soft metal, the composition needs aluminum compatibility.As mentioned herein, aluminum compatibility ensures that any degree of etching occurring on the surface will not cause corrosion and / or significant weight loss (due to the etching of aluminum).Although some applications used benefit from acidic compositions (these acidic compositions may cause etching on the surface, making it possible to adhere to coatings (such as paints)), the corrosion on the surface is undesirable.

[0086] The detergents 312 to which these methods and systems may be applied vary and may be used in a variety of applications where a clean, spot-free, film-free, dry surface is desired.

[0087] The temperature of the wash water may also vary. The water temperature is preferably low temperature, tap water temperature, or room temperature. As referred to herein, low temperature includes temperatures at or below about 145°F (63°C). In one embodiment, the temperature of the rinse water is up to about 145°F (63°C), preferably within the range of 125°F (51°C) to 145°F (63°C). As referred to herein, "low temperature" refers to those rinse water temperatures below about 145°F (63°C).

[0088] All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which the invention pertains. All publications and patent applications are incorporated herein by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0089] Example Implementation

[0090] The invention is defined in the claims. However, the following is a non-exhaustive list of non-limiting embodiments in a numbered format. Any one or more features of these embodiments may be combined with any one or more features of another example, embodiment or aspect described herein. Therefore, the following numbered embodiments also form part of the present disclosure:

[0091] A plastic automobile parts and dashboard washing system comprising:

[0092] a washing stage comprising a conveyor belt, a sprayer, and a drain pipe; wherein the sprayer is configured to spray water and / or water containing detergent; wherein the drain pipe includes an inlet leading to a collected washing water container; wherein the conveyor belt is configured to carry plastic automotive parts and / or dashboards;

[0093] A metering pump; wherein the metering pump is configured to release detergent into the body of water and / or collected wash water;

[0094] sensor; wherein the sensor comprises a UV meter; wherein the sensor is configured to perform UV transmittance measurement on the collected wash water;

[0095] a controller; wherein the controller is in electrical communication with the sensor and the metering pump; wherein the controller stores a calibration graph of UV transmittance versus concentration of a surfactant species in a detergent; wherein the calibration graph includes a set point.

[0096] The system of claim 1, wherein the UV meter measures transmittance or absorbance at a wavelength of 240 nm to 270 nm.

[0097] The system of claim 1 or 2, wherein the electrical communication is wireless communication.

[0098] The system according to any one of claims 1 to 3, further comprising a pH meter or a device for measuring conductivity.

[0099] The system of any one of claims 1 to 4, wherein the system further comprises a rinse stage; wherein the rinse stage comprises a sprinkler configured to spray water and a second drain.

[0100] The system of any one of claims 1 to 5, wherein the container comprises a cartridge, a barrel and / or a tube.

[0101] The system according to any one of claims 1 to 6, further comprising a guard for protecting the conveyor belt.

[0102] A system according to any one of claims 1 to 7, further comprising a recirculation air blow-off system.

[0103] The system of any one of claims 1 to 8, further comprising a particulate filter.

[0104] A kit for modifying plastic automotive parts and dashboard washing systems, including:

[0105] sensor; wherein the sensor comprises a UV meter;

[0106] Metering pumps;

[0107] A controller comprising a transmitter and a receiver for electrically communicating with the sensor and the metering pump; wherein the controller stores a calibration graph of UV transmittance or absorbance versus concentration of surfactant species in a detergent; wherein the calibration graph includes set points.

[0108] The kit of claim 10, wherein the UV meter measures transmittance at a wavelength of 240 nm to 270 nm.

[0109] A kit according to claim 10 or claim 11, wherein the transmitter and receiver communicate wirelessly.

[0110] A kit according to any one of claims 10 to 12, wherein the kit further comprises a water pump; wherein the water pump has an output readable by the controller.

[0111] A method of cleaning plastic automotive parts and / or dashboards comprising:

[0112] Placing plastic automotive parts and / or instrument panels on a conveyor belt;

[0113] activating the conveyor belt to pass through one or more wash stages of a wash system;

[0114] spraying the plastic automotive parts and / or dashboard with wash water in one or more wash stages of the wash system; wherein the wash water comprises a detergent; wherein the detergent comprises a surfactant;

[0115] collecting the wash water from the one or more wash stages after spraying;

[0116] Sensing UV transmission of the surfactant in the collected wash water via a sensor

[0117] rate or absorption rate;

[0118] The UV transmittance of the collected wash water was compared to the set points on the calibration curve graph.

[0119] Compare rows;

[0120] dosing water or the detergent into the collected wash water; wherein the amount of water and / or detergent is determined by the difference between the measured UV transmittance or absorbance and the set point on the calibration curve graph;

[0121] The collected wash water, which has been dosed with water or the detergent, is recirculated to the washing system.

[0122] The method of claim 14 wherein there is a wash stage.

[0123] The method of claim 15, wherein the wash water is collected via a drain in the one wash stage.

[0124] The method of claim 14 wherein there are at least two wash stages.

[0125] The method of claim 17, wherein the wash water is collected via a drain pipe in each of the two wash stages and combined in a collected wash water container.

[0126] The method of claim 17, wherein the wash water is collected from the at least two wash stages via a single drain pipe located downhill.

[0127] The method of claim 14, wherein said comparing is performed by a controller in communication with said sensor.

[0128] The method of claim 20, wherein the controller is in wireless communication with the sensor.

[0129] The method of claim 20, wherein the controller is in communication with a metering pump.

[0130] The method of claim 22, wherein the metering pump doses the detergent into the collected wash water.

[0131] The method of claim 20, wherein the controller is in communication with a water pump.

[0132] The method of claim 24, wherein the water pump doses water into the collected wash water.

[0133] A method according to any one of claims 14 to 25, wherein the drain comprises a filter.

[0134] Example

[0135] Embodiments of the present invention are further limited to the following non-limiting examples. It should be understood that these examples, although revealing certain embodiments of the present invention, are given only by way of illustration. From the above discussion and these examples, those skilled in the art can confirm the basic characteristics of the present invention, and, without departing from its spirit and scope, various changes and modifications of the embodiments of the present invention can be made to adapt it to various uses and conditions. Therefore, in addition to those shown and described herein, various modifications according to the above description of the embodiments will be apparent to those skilled in the art. Such modifications are also intended to fall within the scope of the appended claims.

[0136] The methods and systems disclosed herein were evaluated and tested with two separate water sources to simulate different applications that would be encountered in actual practice. Additionally, one of these water sources was reverse osmosis treated to simulate water that had passed through an advanced water filtration system. To support these examples, a RealTech UV 254 UVT meter and a Hach DR-6000 were used.

[0137] Example 1

[0138] Water samples were taken from a city water source. Detergent wash waters with varying concentrations of detergent were prepared using water directly from the city water source. Additionally, the city water was reverse osmosis filtered and the detergent wash water was prepared with RO water to compare any differences in the ability to monitor city water (with hardness ions) and filtered water. Conductivity measurements were taken with increasing detergent concentration using a microS instrument. The conductivity measurements were plotted against detergent concentration (on a weight percent basis) and the results are provided in Figure 3A Then, the UV transmittance was measured and plotted against detergent concentration (on a weight percent basis); the results are provided in Figure 3B Transmittance data were collected using both a Hach DR-6000 and a RealTech UV 254UVT.

[0139] Prepare the calibration curve ( Figure 3C), to determine the standard target concentration of detergent for cleaning plastic automotive parts and dashboards. This graph was tested to evaluate the changes in detergent concentration that may be caused by splashing, residual detergent on automotive parts, and the increase of soil in the wash water, and the ability to monitor these changes based on UV transmittance. This test was graphed and provided in Figure 3D The data supporting this graph are in Figure 4A and Figure 4B The table is provided in the table. Figure 3D , Figure 4A and Figure 4B It can be seen that changes in detergent concentration in the wash water can be monitored via UV transmittance data. This can be monitored without the need for titration and can be monitored automatically. Furthermore, the data demonstrates that adjustments to correct detergent concentration can be applied based on a calibration graph that determines the set point to adjust the concentration back to. Additionally, the data demonstrates the ability to apply the system and method to city water and highly filtered (RO) water.

[0140] Example 2

[0141] The water samples were taken from a different municipal water source than in Example 1. Conductivity measurements were made using a microS instrument with increasing detergent concentration. The conductivity measurements were plotted against detergent concentration (on a weight percent basis) and the results are provided in Figure 5A Then, the UV transmittance was measured and plotted against detergent concentration (on a weight percent basis); the results are provided in Figure 5B In this example, only the RealTech UV 254UVT was used to collect transmittance data.

[0142] The ability to monitor and adjust detergent concentration and the ability to monitor and adjust concentration based on UV transmittance readings were evaluated. This test was graphed and provided in Figure 5C The data supporting this graph are in Fig. 6A and Figure 6B The table is provided in the table. Figure 5C , Fig. 6A and Figure 6B It can be seen that changes in detergent concentration in the wash water can be monitored via UV transmittance data. This data based on different water sources shows that it can be monitored without the need for titration and can be monitored automatically. In addition, the data again shows that adjustments to correct detergent concentration can be applied based on a calibration curve graph that determines the set point to adjust the concentration back to.

[0143] Example 3

[0144] For comparison purposes, the logarithmic plot ( Fig. 7A ) compares the data collected in Example 2 and Example 3, and compares the UV transmittance data based on the detergent concentration in city water of Example 1, Example 1 and Example 2. The data compared is only RealTech data, because not all samples were tested by Hach instruments. Data in the chart Figure 7B Provided in tabular form.

[0145] Again, data based on different water sources with different levels of filtration showed that monitoring and adjustments can be made without titration. In addition, the data again showed that adjustments to correct detergent concentration can be applied based on a calibration curve graph that determines the set point to adjust the concentration back to.

[0146] Example 4

[0147] Water samples were taken from the city water source of Example 1 and subjected to reverse osmosis filtration. Detergent wash water with different concentrations of detergent was prepared using reverse osmosis water. Conductivity measurements were made using a microS instrument with increasing detergent concentration. The conductivity measurements were plotted against detergent concentration (on a weight percent basis) and the results are provided in Fig. 8A The UV absorbance was then measured and plotted against detergent concentration (on a weight percent basis); the results are provided in Figure 8B Medium. Only the RealTech UV 254UVA was used to collect transmittance data.

[0148] The ability to monitor and adjust detergent concentration and the ability to monitor and adjust concentration based on UV transmittance readings were evaluated. This test was graphed and provided in Figure 8C and Fig.8D middle. Figure 8C The transmittance was measured using a RealTech UV 254UVT, and Fig.8D The transmittance was measured using a Hach DR-6000. Figure 8C and Fig.8D It can be seen that changes in detergent concentration in the wash water can be monitored via UV transmittance data. This data based on different water sources shows that it can be monitored without the need for titration and can be monitored automatically.

[0149] Example 5

[0150] The water samples were taken from a different city water source than in Examples 1 and 2. Detergent wash water with different concentrations of detergent was prepared using water directly from the city water source. Conductivity measurements were made using a microS instrument with increasing detergent concentration. The conductivity measurements were plotted against detergent concentration (on a weight percent basis) and the results are provided in Fig.9A The UV absorbance was then measured and plotted against detergent concentration (on a weight percent basis); the results are provided in Fig. 9B Medium. Transmittance data was collected using only the RealTech UV 254UVT.

[0151] The ability to monitor and adjust detergent concentration and the ability to monitor and adjust concentration based on UV transmittance readings were evaluated. This test was graphed and provided in Fig. 9C and Fig.9D middle. Fig. 9C The transmittance was measured using a RealTech UV 254UVT, and Fig.9D The transmittance was measured using Hach DR-6000. Fig.10 Monitoring of % transmission and % absorption for different wash stages is shown. It also includes a comparison of conductivity data. Detergent wash water was introduced into wash stage 2 (it is worth noting that the conductivity measurement corresponding to this stage is incorrect due to the water source).

[0152] from Fig. 9C , Fig.9D and Fig.10 It can be seen that changes in detergent concentration in the wash water can be monitored via UV transmittance and absorbance data. This data based on different water sources shows that it can be monitored without the need for titration and can be monitored automatically. In addition, monitoring transmittance and / or absorbance at different wash levels will indicate when detergent has been completely rinsed off parts within the washer; for example, Fig.10 It can be seen that at scrubber stage 5, no detergent remains, and at scrubber stage 4, essentially no detergent remains.

[0153] Having thus described the present invention, it will be apparent that it may be varied in many ways. Such variations will not be considered as departing from the spirit and scope of the present invention, and all such modifications are intended to be included within the scope of the appended claims. The above description provides a description of the manufacture and use of the disclosed compositions and methods. Since many embodiments may be performed without departing from the spirit and scope of the present invention, the scope of protection of the present invention is defined by the claims.

Claims

1. A plastic automobile parts and dashboard washing system comprising: a washing stage, the washing stage comprising a conveyor belt, a sprayer and a drain pipe; wherein the sprayer is configured to spray water and / or water containing a detergent; wherein the drain pipe includes an inlet leading to a collected wash water container; wherein the conveyor belt is configured to carry plastic automotive parts and / or instrument panels; A metering pump; wherein the metering pump is configured to release detergent into the body of water and / or collected wash water; sensor; wherein the sensor comprises a UV meter; wherein the sensor is configured to perform UV transmittance measurement on the collected wash water; Controller; wherein the controller is in electrical communication with the sensor and the metering pump; Wherein the controller stores a calibration graph of UV transmittance versus concentration of surfactant species within a detergent; wherein the calibration graph includes set points.

2. The system of claim 1, wherein the UV meter measures transmittance or absorbance at a wavelength of 240 nm to 270 nm.

3. A system according to claim 1 or 2, wherein the electrical communication is wireless communication.

4. The system according to any one of claims 1 to 3, further comprising a pH meter or a device for measuring conductivity.

5. The system of any one of claims 1 to 4, wherein the system further comprises a rinse stage; wherein the rinse stage comprises a sprinkler configured to spray water and a second drain pipe.

6. The system of any one of claims 1 to 5, wherein the container comprises a cartridge, a barrel and / or a tube.

7. The system of any one of claims 1 to 6, further comprising a shield to protect the conveyor belt.

8. The system of any one of claims 1 to 7, further comprising a recirculating air blow-off system.

9. The system of any one of claims 1 to 8, further comprising a particulate filter.

10. A kit for modifying plastic automotive parts and dashboard washing systems, comprising: sensor; wherein the sensor comprises a UV meter; Metering pumps; a controller including a transmitter and a receiver for electrically communicating with the sensor and with the metering pump; wherein the controller stores a calibration graph of UV transmittance or absorbance versus concentration of surfactant species in the detergent; Wherein the calibration curve graph comprises set points.

11. The kit of claim 10, wherein the UV meter measures transmittance at a wavelength of 240 nm to 270 nm.

12. A kit according to claim 10 or claim 11, wherein the transmitter and receiver communicate wirelessly.

13. A kit according to any one of claims 10 to 12, wherein the kit further comprises a water pump; wherein the water pump has an output readable by the controller.

14. A method of cleaning plastic automotive parts and / or dashboards comprising: Placing plastic automotive parts and / or instrument panels on a conveyor belt; activating the conveyor belt to pass through one or more wash stages of a wash system; spraying the plastic automotive parts and / or dashboard with wash water in one or more wash stages of the wash system; wherein the wash water comprises a detergent; wherein the detergent comprises a surfactant; collecting the wash water from the one or more wash stages after spraying; sensing, via a sensor, UV transmittance or absorbance of the surfactant in the collected wash water; comparing the UV transmittance of the collected wash water to a set point on a calibration graph; dosing water or the detergent into the collected wash water; wherein the amount of water and / or detergent is determined by the difference between the measured UV transmittance or absorbance and the set point on the calibration curve graph; The collected wash water, which has been dosed with water or the detergent, is recirculated to the washing system.

15. A method according to claim 14, wherein there is a wash stage.

16. The method of claim 15, wherein the wash water is collected via a drain pipe in the one wash stage.

17. The method of claim 14 wherein there are at least two wash stages.

18. The method of claim 17, wherein the wash water is collected via a drain pipe in each of the two wash stages and combined in a collected wash water container.

19. The method of claim 17, wherein the wash water is collected from the at least two wash stages via a single drain pipe located downhill.

20. The method of claim 14, wherein the comparing is performed by a controller in communication with the sensor.

21. The method of claim 20, wherein the controller communicates wirelessly with the sensor.

22. The method of claim 20, wherein the controller is in communication with a metering pump.

23. The method of claim 22, wherein the metering pump doses the detergent into the collected wash water.

24. The method of claim 20, wherein the controller is in communication with a water pump.

25. The method of claim 24, wherein the water pump doses water into the collected wash water.

26. A method according to any one of claims 14 to 25, wherein the drain comprises a filter.

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