Rotary Brush Encoder PLC Control for Car Wash Contact
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Solution Overview
Problem
Existing automatic vehicle wash apparatuses face challenges in consistently managing rotating brush contact with the vehicle surface to achieve uniform contact and optimal wash outcomes, as mechanical and electromechanical biasing means often result in non-uniform force distribution.
Innovation Solution
The use of encoders connected to the rotating brush shafts to monitor revolutions per minute (RPM) and programmable logic controllers (PLCs) to control double-acting air pressure cylinders, adjusting brush position along a horizontal boom and laterally to maintain optimal brush-to-surface contact by increasing or decreasing air pressure through solenoid valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical or electromechanical biasing means are used to drive the brush, then the brush can be forced to contact the vehicle surface, but the force distribution becomes non-uniform resulting in inconsistent wash outcomes
Solution Approach 1:
The patent employs encoders to continuously monitor the rotational speed (RPM) of the brush shaft, providing real-time feedback to a control system. This feedback mechanism detects variations in brush rotation caused by non-uniform contact pressure with the vehicle surface, allowing the system to identify and correct contact inconsistencies dynamically during operation.
Solution Approach 2:
The patent replaces traditional mechanical biasing means with a pneumatic system using double-acting air pressure cylinders. This substitution allows for more precise and uniform force distribution through controlled air pressure application, eliminating the non-uniform contact pressure inherent in mechanical drive systems while maintaining reliable brush-to-surface contact.
2Force
If air pressure is increased to improve brush-to-surface contact, then contact pressure increases, but excessive pressure may damage the vehicle surface or brush
Solution Approach 1:
The encoder continuously monitors brush shaft rotational speed and provides feedback to the control system. When the brush contacts the vehicle surface, the rotational speed decreases due to increased friction. This feedback allows the system to detect optimal contact pressure and prevent excessive force application that could damage the vehicle surface or brush.
Solution Approach 2:
The system dynamically adjusts air pressure to the double-acting cylinder based on real-time encoder feedback rather than applying static pre-set pressure. This dynamic control allows the brush contact pressure to adapt continuously to varying conditions, maintaining optimal cleaning force while preventing damage from excessive pressure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures consistent and uniform brush-to-surface contact, enhancing the wash outcome by dynamically adjusting brush position based on RPM readings to maintain desired contact pressure, leading to improved cleaning efficiency.
Implementation Method 1
The encoder, recording the revolutions per minute (RPM) of the brush shaft, provides input to the programmable logic controller (PLC).
Implementation Method 2
The programmable logic controller (PLC), using the encoder input, then signals a pair of double-acting solenoid valves to increase or decrease air pressure to a double-acting air pressure cylinder to effect a move of the carriage of the brush along a horizontal boom
Implementation Method 3
signals a pair of double-acting solenoid valves to increase or decrease air pressure to a double-acting air pressure cylinder
Implementation Method 4
The encoder input, then signals a pair of double-acting solenoid valves to increase or decrease air pressure to a double-acting air pressure cylinder to effect a move of the carriage of the brush along a horizontal boom... to achieve a desired brush-to-washable surface contact.
Data Source
AI summary
This invention relates to an automatic vehicle wash apparatus employing one or more rotary cloth or foam rubber brushes, and more particularly to the way how the rotary brush to vehicle surface contact is managed using one or more encoders connected to the rotating shaft of each brush and one or more programmable logic controllers (PLC). The encoders, recording the revolutions per minute (RPM) of each brush shaft, provide input to the programmable logic controller. If the RPM value is at or above the high RPM limit, the pivoted boom will move the brush toward the vehicle to achieve a desired brush-to-washable surface contact. If, on the other hand, the RPM value is at or below the low RPM limit, the pivoted boom will move the brush away from the vehicle to achieve a desired brush-to-washable surface contact.