Patent Application
20210165429
This invention was not federally sponsored.
This invention relates generally to the field of pump systems for mixing and metering viscous fluids. In particular, the present disclosure relates to an improved flow rate metering device that provides for the mixing and dispensing of two or more fluids to form final mixture, for example, for automatic washing of cars and trucks. More specifically, the invention is a system that mixes and ejects chemicals, creating a very precise mixture of one or more chemicals with a dilutant, such as water. The device also has the capability of monitoring an entire chemical dilution and release system, comprising multiple chemicals, and using software to document past and current usage rates, along with predicting future usage rates based upon both past usage rates and environmental conditions.
One preferred embodiment of the invention is a system that mixes concentrated chemicals into precise, desired diluted fluids and uses these fluids in a car wash. While the technologies behind this invention are expressly not limited to car washes, and indeed are equally applicable to a variety of other fields ranging from beverages such as soda and beer to laundry detergent and any other liquid, the car wash is used as an example because the function—or rather, the current inefficient function—of a car wash is easily understood. Indeed, the technology contained in this patent application can be used for food and beverage industries, for application of cleaning chemical dispensing, control, and monitoring.
the system relies on both a cloud and on-site storage of data compiled from a customer's car wash. This storage system provides a back-up of data in case there is a malfunction at either the cloud or on-site system. This data is then provided to the customer in a UI format. Because the entire process is computer-controlled, it allows for a completely automatic car wash delivery system.
Truck and car wash apparatus are generally well known in the art. A great variety of configurations have been and are being employed in the field. These vary from largely manually-operated devices to nearly completely automated machines. Whether the washing fluids are applied to a vehicle by an automated gantry, or the like, or by a hand-held wand, there must be some method or means for mixing fluids, such as chemicals or soaps, with the water. Such method or means should be accurate, economical and reliable.
There are several methods in use, all of which have some problem or another. One method which has been used is to mix one or more chemicals before being applied to a vehicle that is to be washed. Prior to being applied to the vehicle, each chemical is diluted using water. Dilution may occur in a solution tank, from which a point-of-use dispenser pulls the chemical(s)-water combination for application to a vehicle. Alternatively, dilution may also occur as the chemical(s) and water are being dispensed at substantially the same time by a point-of-use dispenser to a vehicle. In either case, the actual solution applied to each vehicle includes a concentration of one or more chemicals and water. A responsibility typically reserved for a vehicle wash operator relates to defining the type and amount of appropriate chemicals, and thus, concentrations thereof, that are to be applied by a vehicle wash facility to the various vehicles utilizing the facility.
Currently, vehicle wash operators will use an assortment of measuring beakers and scales along with chemical viscosity calculations to determine flow rate and usage. The chemicals being applied will be poured into a beaker that sits on a high-end scale. When the chemical flaw's and is drawn out of the beaker, the amount drawn is noted along with the difference in weight. There is some critical math at this point that must be calculated into the process based on the chemical's viscosity and any other volume influence that affect the draw such as the size of a feed tubing that was dropped into the beaker. If any of the math that has been injected into this process is not accurate, the results are inaccurate. The manufacturers of the products typically provide this math for their chemicals, unfortunately, it is not always accurate. This then opens the door for a sizable percentage of error in the final calculations, as any errors can be magnified significantly further down the line of the operation. More or less, the vehicle wash operators have tolerated this issue due to being “close enough” is good enough.
Most modern car washes, since they have little idea of the exact amount of chemicals being used, have very little guidance on when to order new drums of chemicals. The general method is to open the drum and put a stick down the opening, to look down the opening and estimate, or by using a sonar measuring device. But, while these methods can give a good estimate of how much of a particular chemical is left, because the owner has little idea of how much is being used, he/she cannot realistically place orders for new drums of a particular chemical with much certainty that such an order is timely.
One method car wash owners used to make sure they have adequate supplies is to buy smaller drums of a particular chemical and pour it into a larger container. This method raises the chances of contamination, and also requires a car wash owner to have both 55-gallon drums, and extra drums of some of the more often-used chemicals. This makes the operational footprint even worse than if the owner just replaced an empty 55-gallon drum with a full one.
Therefore, there is a need in the art to move into an electronic space for metering the amount of chemicals applied on a vehicle during a washing cycle which eliminates the need for any scales, beakers or math from the vehicle wash operators. The system would also allow for precise ratios of chemicals and dilutants, and allow a computer system to constantly monitor the system such that these ratios can be changed if desired. The system would have a small physical and environmental footprint, and be safe for workers.
The current invention provides just such a solution by having a chemical delivery system that combines a variety of sensors and bullet valves with various pumps and pressure regulators in a computer-controlled environment such that precise ratios of a chemical to a dilutant such as water can be achieved, monitored, and easily changed if the circumstances so require. A preferred embodiment is a car wash system with a small rack of concentrate chemicals are mixed in precise ratios as they are sprayed onto the cars. This system allows for the precise measurement of chemicals used, which allows for the prediction of when future boxes of the chemicals should be purchased, along with an accurate estimate of how much car washes of which type had been administered in the past.
It is therefore an object of the present invention to provide a system capable of being connected to a public water supply via a hose that provides a self-regulatory system of chemical deliver.
A general object of the present disclosure is to move into an electronic space for metering the amount of chemicals applied on a vehicle during a washing cycle which eliminates the need for any scales, beakers or math from the vehicle wash operators.
An object of the present disclosure is to provide a method or apparatus whereby chemicals could readily be mixed with water in a vehicle wash system which would not waste chemicals and/or time, and which would be reliable and accurate in operation.
Another object of the present disclosure is to provide an automated mechanism metering the amount of chemicals applied on a vehicle during a washing cycle which removes the inefficient method of physical inspection of usage of one or more chemicals and/or products involved in a vehicle washing.
These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
This summary is provided to introduce concepts related to an improved flow rate metering device that provides for the mixing and dispensing of two or more fluids to form final mixture, for example, for automatic washing of cars and trucks. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
The present disclosure relates to a monitoring system for measuring the holding tank level of each chemical product that is consumed by the smart dispenser. The measuring device for this is a linear probe with a built-in float that sends micro data to a programmable logic controller
Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments. It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
It should be understood that while the preferred embodiments of the invention are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
One preferred form of the invention will now be described with reference to the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in a computer-readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.
Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
In the present document, the word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the tennis “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood byone of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
With respect to controlling the chemical dispensing, the Smart Dispenser causes the water bullet valve, the chemical bullet valve and the air stepper valve to affect the production of one or more products for the Water and Chemical Arch and the Air for Arch. The arch is a customer-supplied piece of equipment, usually a metal arch that has a series of nozzles imbedded into it. These nozzles are what sprays the chemical(s)/mixture(s) onto the car.
Smart software provides Data in the form of reports, live data, chemical controls and the results
The air pressure is mainly used for “foaming” the chemical and water components into a foam when it is applied to the car. The stepper motor controls how much PSI or air flow is needed to make the chemical more or less foaming. Chemical pump pressure can be created in two ways. First, the use of a volumetric pump with an internal piston that is air pressure driven. Second, a pressure vessel (“Smart Tank”) with an internal piston and piston return spring that constantly keeps the chemical under pressure for the delivery system, and auto-refills itself with chemical through air pressure.
The chemical pressure pump is preset and maintained, in a preferred embodiment of the invention, at 30-40 psi. This pressure is created by volumetric pressure pump that is backed by a check valve. A bullet control valve that has been properly sized for functionality in this invention regulates release of the chemical(s).
The PLC emits output pulses to control an on/off cycle, with a preferred embodiment teaching each 500 m/s on and 0.5 m/s off. The total flow is calculated by how many cycles the valve turned on and off during the product run time from the wash controller.
The air pressure to the stepper motor is controlled by the PLC, and can be adjusted by the user. Air is dispensed directly to the arch manifold. An air pressure transducer installed on the incoming air pressure line notifies the system if a loss in pressure occurs.
The size of the water bullet valve is determined from the arch properties, such as the number of nozzles, flow rate of each nozzle, size of arch pipes, size of delivery tubing, length of run, etc. The nominal output GPM is 2-15@15-60 psi. Multiple water and chemical distribution blocks are connected for single chemical use. Different blocks are setup in the same fashion for other applications.
Ambient temperature inside mechanical room or wash bay (where ever the dispensing unit is located) is measured. An algorithm determines chemical viscosity per degree of temperature change, and adjusts for the flow rate of the chemical through the chemical bullet valve to change as temperature changes.
The PLC controller receives one or more chemical demand signals from the carwash controller. A system of events then initiates the water and chemical bullet valves, controlling the stepper bullet valve the air to mix with the chemical(s). The software contains a parameter setup for the chemical bullet valve flow rate. On/off cycles build a usage report for that chemical used.
It should be noted that the present disclosure is not restricted to be used with a single vehicle-wash bay. Indeed, it is anticipated that the present disclosure will be used in conjunction with multiple vehicle-wash bays, wherein the variation of demand might be even greater and wherein the need for and desirability of the present inventive apparatus and method will be even greater.
The inventive system and device 100 and associated method for metering quantity of fluid supplied through the device 100 are intended to be widely used in the vehicle wash industry. In particular, the present disclosure is particularly applicable to vehicle washes, wherein a great quantity of chemicals is used and, thus, it is extremely important to keep the ratio of chemical to water solvent at an ideal proportion. It should be noted that the method and device proposed herein will work with almost any viscosity of chemical/product/fluid, and that the method and device can be adapted for use with a great variety of vehicle-washing facilities.
All of the above are only some of the examples of available embodiments of the present disclosure. Those skilled in the art will readily observe that numerous other modifications and alterations may be made without departing from the spirit and scope of the present disclosure. For example, the present disclosure may be used in systems other than vehicle-washing systems, such as conveyor-type vehicle wash systems, drive-through wash systems, or other types of stationary, variable demand spray-wash systems. Accordingly, the disclosure herein is not intended as limiting and the appended claims are to be interpreted as encompassing the entire scope of the invention.
While the foregoing describes various embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The present disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the present disclosure when combined with information and knowledge available to the person having ordinary skill in the art.
All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
This application claims priority back to U.S. Provisional Application Nos. 62/939,292, filed Nov. 22, 2019, and 62/942,813, filed Dec. 16, 2019, the contents of which are incorporated by reference into this application.
| Number | Date | Country | |
|---|---|---|---|
| 62942813 | Dec 2019 | US | |
| 62942813 | Dec 2019 | US |
