Patent Application
20240317188
The present disclosure relates to vehicle treatment systems. More particularly, the present disclosure relates to a smart vehicle treatment system with lighting features and application control for automated vehicle treatment systems, such as automated car washes.
Current vehicle treatment systems are in use today to provide various vehicle treatment aspects, including but not limited to vehicle washing devices and vehicle drying devices. Such systems may be fluid-based which are typically considered a “touchfree” system in which fluids (water, soap, chemical) and air are used to clean. Other systems may be friction wash systems, which use rotating brushes, hanging cloth, fabric, foam, etc., or other physical media that touches the vehicle surface, and also include a combination of fluids, such as water, soap, and/or chemicals.
These various vehicle treatment systems can be used both in conveyor type systems, in which the vehicle is conveyed through a vehicle treatment facility, or stationary systems, in which the vehicle remains stationary and the vehicle treatment devices move relative to the generally stationary vehicle. Combination systems in which the vehicle is conveyed during treatment and also treated while remaining stationary are also possible.
During vehicle treatment processes a treatment device, such as a spray arch or elongated member (such as an application manifold member, which may be straight, curved, or other shape) for providing pressurized fluid to the vehicle surface via nozzles or other fluid outlets, will move relative to the vehicle to treat the various exterior surfaces of the vehicle, including the front/rear bumpers, side panels, roof, wheels, and the like. The vehicle treatment device, during this movement, may rotate or move in linear translation in order to direct the fluid outlets toward the desired exterior surface of the vehicle at a correct optimal distance.
The rotation of the treatment device may be provided by a rotatable shaft supported by a bearing element, with treatment fluid conveyed through the center of the shaft. Fluid flows generally through the shaft and into the downstream portions of the treatment device, which may include a generally horizontal upper arm and/or a generally vertical side arm. The treatment device may be only a generally vertical member or may be only a generally horizontal member, which may move up and down, fore-and-aft, and/or rotate.
While rotation of the device is generally not limited by the provision of fluid, other non-fluid connections to the treatment device cause physical limitations on the amount that the device can rotate. For example, power and communication wires/cabling extending along the treatment device can be provided with a small amount of slack to allow limited rotation. However, continuous rotation of the device will cause such wires and cables to wrap around the device as it rotates, thereby causing the device to lock up or otherwise be prevented from rotating to the desired position. Moreover, the provision of slack in the wire to allow for limited rotation leads to exposed and/or dangling cable/wires that are susceptible to damage. Accordingly, while some rotation of the treatment device having cables or wires is possible, the rotation is limited.
One example of an additional control element is a strip of lights that may be added to the arms of the treatment device. However, the control of the lights is limited to controlling the strip of lights off and on to provide the single color of the strip of lights. Providing specifically controlled sections or different colors would require additional wires for each section and additional color, which can ultimately be too cumbersome to implement for rotational devices.
Another aspect of vehicle treatment systems includes the detection of an impact between the vehicle and the vehicle treatment device. During a vehicle treatment operation, the vehicle may be directed to a desired central location relative to the vehicle treatment device. However, whether due to an error in placement of the vehicle by the operator or an error in the detection of the vehicle surfaces by the treatment system, the moveable vehicle treatment device may unintentionally come into contact with the vehicle. The device may also unintentionally make contact with a person or other obstacle during a treatment operation.
In response to impact, vehicle treatment systems may be configured to stop operating or otherwise alter the operation to minimize negative effects of the undesired impact. To provide this modification of the control, the system first receives a signal indicating that the impact has occurred. One type of impact sensing system includes the use of multiple moving mechanical parts, many of which have tight tolerances, which can lead to high cost and unreliability if tolerances and quality is not met. Sensors and associated structure are typically disposed within a trolley frame that includes the motor controlling the position of the treatment device as well as other control components. Prior impact detection structure requires multiple moving components with tight tolerances, where issue with any of those can result in an impact not being detected.
In addition to impact detection, rotational orientation detection of the treatment device may be performed by the use of a single analog distance sensor relative to a complicated machined flag member having a specified sloped surface. Based on the rotational position, the sloped surface is at a varying distance from the sensor, with the distance being measured relative to the sloped surface. However, the sloped surface is expensive and difficult to machine, and also takes up a substantial amount of space within the control housing, along with the corresponding expensive sensor that relies on a precise quantitative distance measurement.
Thus, both the orientation sensor and mechanical components, combined with the impact sensing components, take up a substantial amount of space and are subject to errors due to associated tolerances. Due to space constraints, the use of these sensing systems limits the ability to make improvements to other mechanical and electrical control components of the vehicle treatment system.
Accordingly, improvements can be made to such vehicle treatment systems.
In one aspect of the present disclosure, a vehicle treatment system includes: a main controller, having a processor and software configured to provide power and control signals for controlling the vehicle treatment system; a vehicle treatment device configured for movement relative to at least two degrees of freedom; a movement mechanism mechanically supporting the vehicle treatment device and configured for providing the movement of the vehicle treatment device; at least one activatable component disposed on the vehicle treatment device; at least one sub-controller disposed on the vehicle treatment device and configured to control the at least one activatable component; wherein the main controller is disposed on a first operable side of the movement mechanism and the at least one sub-controller is disposed on a second operable side of the movement mechanism opposite the first operable side; and a multiplexed communication connection and a power connection provided between the main controller and the at least one sub-controller, wherein the multiplexed communication connection provides a multiplexed signal across the movement mechanism between the main controller and the sub-controller, wherein the sub-controller receives the multiplexed signal and activates the at least one activatable component in response to receiving the multiplexed signal during the movement of the vehicle treatment device.
In one aspect, the activatable components are individually activatable lights, actuators, valves, and/or the like. In one aspect, the multiplexed communication is provided via a slip ring to a rotatable treatment device such as a spray arch or a brush.
In another aspect, a vehicle treatment system is provided, including: a main controller, having a processor and software configured to provide multiplexed control signals for controlling the vehicle treatment system; a vehicle treatment device configured for movement relative to at least two degrees of freedom; at least one activatable component disposed on the vehicle treatment device configured for being selectively activated via the control signals from the main controller; and at least one sub-controller disposed on the vehicle treatment device and configured to receive the control signals and to control the at least one activatable component based on the control signals; wherein the main controller is disposed remote from the vehicle treatment device; wherein the sub-controller receives the multiplexed signal and activates the at least one activatable component in response to receiving the multiplexed control signals during the movement of the vehicle treatment device.
In yet another aspect, a method for of operating a vehicle treatment system is provided, the method including the steps of: providing a vehicle treatment device configured for movement along multiple degrees of freedom; performing the movement of the vehicle treatment device relative to a vehicle treatment area, vehicle, and/or vehicle shape; providing a multiplexed communication connection across a movement mechanism that supports the vehicle treatment device and provides the movement along multiple degrees of freedom; providing a multiplexed communication signal from a main controller on a first operable side of the movement mechanism, through the movement mechanism, and to a sub-controller disposed on the vehicle treatment device during the movement; receiving the multiplexed communication signal at the sub-controller and controlling multiple activatable components disposed on the vehicle treatment device
These and other aspects will be described in more detail below and with reference to the drawings.
With initial reference to
The treatment device 12 is capable of full rotation and complicated rotation schemes (combined rotation and/or translation along multiple degrees of freedom) via a rotational connection 18, and is further configured for smart control, in which its rotational and directional positon, and treatment schemes, may be operated by multiple controllers, with specific activatable operation schemes provided via the same treatment device 12. For instance, as described throughout the specification, the treatment device 12 can include a plurality of various illumination states, with various colors illuminated, various quantities of lights illuminated, various intensity of illumination, and the like.
Additionally, various controllable treatment schemes may be activated. For example, various controllable valves may be operated and controlled to provide treatment at select areas of the treatment device 12 while other sections of the treatment device 12 are not activated.
Smart control of the vehicle treatment device 12 may be provided by the combination of a main controller 20 and a sub-controller 22 in communication with the main controller 20. The sub-controller 22 (which may be in the form of multiple sub-controllers 22) is provided directly on the treatment device 12, with the main controller 20 provided remote from the treatment device 12 “upstream” from a movement mechanism that provides multiple degrees of freedom. The movement mechanism of the present disclosure includes the rotational connection 18 of the treatment device 12, as described in further detail below, and may also include trolley 24 (which moves laterally side-to-side) and wash bridge 26 (which moves fore-and-aft), described in further detail below. It will be appreciated that other movement mechanisms and combinations may be used to provide movement along multiple degrees of freedom, including linear and/or rotational movement With the sub-controller 22 provided on the treatment device, and receiving multiplexed communication from the main controller 20, the number of wire conductors or connections for electrical communication between the main controller 20 and the sub-controller 22 passing through the movement mechanism and the rotational connection 18 can be reduced, with increased communication and control provided via the various outputs of the “downstream” sub-controllers 22, thereby providing for an ability to increase the overall amount of electrical communication while decreasing the number of physical connections and using a multiplexed communication method.
With reference to
With reference to
As shown in
The first portion 36a of the slip ring 36 includes a plurality of inputs/outputs connected to corresponding inputs/outputs from the main controller 20. Because the first portion 36a is fixed relative to the trolley housing 30, cabling/wiring may extend and connect to the first portion 36a from the main controller 20 without substantially restricting or limiting the necessary movement of the trolley 24, because the trolley 24 simply translates relative to the bridge 26. Thus, the trolley 24 still has an energy chain (not shown) from the main controller 20 that is moveable along this relatively simple linear motion.
The first portion 36a may be fixed relative to the trolley housing 30 via a support plate 37 having a plurality of support posts 37a that are fixed to the base of the trolley housing 30. The first portion 36a may have a generally cylindrical shape, and is shown disposed below the support plate 37 and above the base of the housing 30. The first portion 36a supports the rotatable second portion 36b therein and thereby also supports the rotatable shaft 32 that is fixed to the second portion 36b. A further bearing housing 37b is disposed above the support plate 37 and also supports the shaft 32 for rotation therein. A drive element or sprocket 33 may be disposed above the bearing housing 37b, the sprocket 33 being fixed to the shaft 32 and which is driven by the motor 34 to rotate the sprocket and attached shaft 32 relative to the bearing housing 37b and the fixed first portion 36a of the slip ring 36. An anti-rotation bracket 37b (disposed below plate and attached to the posts 37a) is part of the overall support structure that also includes the support plate 37, the support posts 37a, and the bearing housing 37b. The shaft 32 is hollow and rotatable relative to a fixed upper portion (which receives fluid provided by the vehicle treatment system, such as water, soaps, chemicals, etc.) The rotatable shaft 32 rotates along with the sprocket 33 and the second portion 36b of the slip ring 36, such that the fluid is delivered to the treatment device 12 via the shaft 32 during the full rotation of the treatment device 12.
To continue the electrical communication downstream, the second portion 36b of the slip ring 36 includes a plurality of inputs/outputs connected to the sub-controllers 22 on the treatment device 12. Each sub-controller 22 may include multiple additional inputs/outputs extending therefrom and connected to various controllable devices such as lights, actuators, valves, and/or the like. Thus, both fluid transmission and signal transmission is maintained throughout the complete rotation of the treatment device 12.
The number of inputs/outputs extending from each side/portion of the slip ring 36 is preferably minimized in order to minimize the physical size of the slip ring 36 at the rotational connection. The electrical connections and contacts at the slip ring 36 require physical surface for each connection. Accordingly, it is not feasible to include a connection on the slip ring 36 for each of the multiple desired controllable devices (such as lights or valves) on the treatment device 12, because such a slip ring would be prohibitively large. Thus, in one approach, three connections are provided at the slip ring 36: power P, common C, and communication M (for multiplexed communication). In one approach, communication M may be provided wirelessly to the sub-controller 22, such as via Wi-Fi, Bluetooth, or other radio signal, and the slip ring 36 may be sized and configured to include only two connections: power P and common C. It will be appreciated electrical terminology may vary, and that various numbers of wires or connections may be provided in line with the spirit and scope of the disclosure. For instance, wires may also be referred to as “hot” or “ground” wires, and the common wire may provide grounding. Grounding may also be provided through various structural connections between the components of the system. In the illustrated embodiment, the three wires are provided at the rotational connection of the slip ring 36, but it will also be appreciated that additional wires can be provided (typically with a corresponding increase in size of the supporting structure to accommodate the additional connections). In general, the purpose of the slip ring is to provide both power and communication across the movement mechanism that is disposed in the operable path between the main controller 20 and the sub-controllers 22 that are disposed on the treatment device 12. The movement mechanism in the illustrated embodiment may include the slip ring, trolley, and wash bridge, but other movement mechanisms providing multiple degrees of freedom may also benefit from providing power and multiplexed communication via a reduced set of wires between a main controller 20 (remote from the treatment device 12) and a sub-controller 22 (on the treatment device). For purposes of the discussion, the three-wire embodiment will be further described.
The first portion 36a and the second portion 36b of the slip ring 36 are disposed below the support plate 37 and may extend through an aperture formed in the base of the trolley housing 30. The second portion 36b is fixed relative to the shaft 32 and rotates along with the shaft 32. Any wires extending from the second portion 36b will not hinder rotation of the shaft 32 due to the common rotation therebetween.
As discussed previously, lights have been generally provided on vehicle treatment devices, but with greater restrictions on functionality. For instance, a strip of LEDs have been provided on a rotatable vehicle wash brush, for instance at 3 or more locations, such that the lights are visible during rotation of the brush. However, these LED strips are not configured for complex control and illumination. Rather, the entire strip is either turned on/off, and the strip illuminates only the single color of the installed strip. While power and an on/off signal are provided through a slip ring connection from the main controller, the slip ring is limited in the number of connections that can be provided. Such treatment devices do not include any sort of sub-controller or microchip installation on the treatment device downstream from the slip ring, and rely solely on the basic on/off control and power provided from the upstream side of the slip ring.
Similarly, for spray arches having a light feature, these spray arches are typically disposed on both sides of the vehicle and are generally limited to 180-270 degree rotation, requiring the spray arch to return to a zero state, and never completing a full rotation, due to the cable bundling that extends along the arch to provide basic on/off functionality. While these arches may include multiple lights in some approaches, these lights are separate and also individually controlled by the upstream main controller and require their own control cable that extends across the pivot connection, and are therefore also limited in the number of possible lighting or other control combination. Even with a few extra colors provided by the additional cables, the light strips still fully illuminate, with the single activated color along the entire length of the strip. Each strip of light has its own individual wires extending into the moving arch. A larger quantity of wires is less reliable and more costly to run to a dynamic (and still limited) arch.
With reference to
Thus, the use of the sub-controller 22 and additional associated microchips into a moving treatment device 12 allows for simplified physical wiring, while still allowing complicated functions and algorithms used to control components on the treatment device 12.
Running advanced communication methods through a single line/wire/channel/bus to the treatment device 12 takes up less space than running individual wires to the arch. Having a smart treatment device 12 allows lights to have smaller increments and pixels. A single communication channel/wire/connection/bus passing through the rotational connection 18 can control hundreds of light sections/colors (without requiring hundreds of wires). The advanced communication provided by the sub-controller 22 on the treatment device 12 also allows for control of multiple electromechanical devices in addition to lights. For example, these electromechanical devices may include fluid valves, actuators, motors etc. This advanced communication, and smart device, will also allow feedback from the moving treatment device 12 back into main controller 20 of the vehicle treatment system. This feedback may include sensor feedback, position/angle data, preventative maintenance feedback, diagnostics, etc. to allow the main software at main controller 20 to perform proper actions.
It will be appreciated that the reference to the multiplexed data channel is not intended to be strictly limited to a single line or wire. While one current embodiment may have a single ‘data line’, such line also relies on the ground line as a reference. Furthermore, there are many communication buses that utilize a differential pair and/or multiple sets of lines/pairs for data transmission (such as with RS485, Ethernet, etc.). Accordingly, the present disclosure is not limited to communication protocols that only have a single physical line.
With reference to
The main controller 20 of vehicle treatment systems typically has various sub-controllers 22 with a communication distribution and network, with the main controller 20 having the high level software. The main controller 20 may be located in a fixed location within the facility or may be located on the main wash assembly, which might be referred to as frame/gantry/bridge/carriage/head assembly.
By using the single multiplexed connection 38 from the main controller 20, the size of the slip ring 36 can be minimized, such that fewer wires and connections are necessary at the moving machine interface of the rotational connection 18. Thus, for a given size, wash capability can be increased (higher capability in a smaller package, allowing installation in smaller spaces), and costs may be decreased. Additionally, by using fewer wires, the potential failure points are decreased. Thus reliability is improved using fewer dynamic conductors, while still allowing complex functionality provided by the treatment device 12 (arch, brush, etc.). These advantages of reduced wires are also present for non-slip ring connections, such as a wire/cable connection across a rotational interface that does not use full rotation.
As described previously, one example of the smart vehicle treatment device system (whether slip ring or cabled) includes the use of three wires (power P, common C, communication M). Using this approach, in one example, the light color on the treatment device 12 can be changed/controlled with software (via sub controller 22) on about 80 sections of an arch (8000 mm arch length, with specific control of 100 mm sections). In a traditional design, in which no controller is provided on the arch and a three-color RGB LED strip is used, to achieve the same level of 80 sections of multi-color control, the traditional approach would require 320 wires extending across the moving machine interface (80 sections each having 4 wires), which is impractical.
As described, the ability for the treatment device 12 of the present disclosure to rotate fully and be positionable around the entire vehicle body (such as in
While a full rotational spray treatment device 12 is illustrated herein, it will be appreciated that rotational wash brushes may also fully rotate and perform complicated movement according to the present disclosure, and other treatment devices may similarly benefit from the ability to perform complicated movement while also containing a high quantity of controllable elements. Thus, the present disclosure is not limited to trolley-mounted spray arches.
The present disclosure also generally illustrates a full rotational spray treatment device 12 in various positions relative to a vehicle being in a fixed position (such as in
Complicated movement can therefore also include other vehicle treatment devices that do not necessarily have the same full rotational capability of the present disclosure. For instance, a pair of generally vertical spray devices may be disposed on both sides of the vehicle and pivot/rotate relative to the vehicle while at the same time translating along the length of the vehicle and/or side to side to face the front/rear bumper. Such movement does not require full rotation of the treatment device. However, the use of the sub-controller 22 on such a limited rotation treatment device provides for substantially increased control of the controllable components mounted to the device, with the specific control signals being provided to the sub-controller 22 by the multiplexed communication cable/wire. As mentioned above, complicated movement can therefore also exist in non-rotational settings, such as translation front to back and side to side at the same time, and does not necessarily require partial or full rotational travel.
With reference to
As shown in
As shown in
The lighting provided on the treatment device 12 may be independently controlled relative to the motion of the treatment device 12 that is occurring. Lighting may be controlled and changed while the treatment device 12 is stationary, or may be constant while the treatment device 12 moves, and may change during movement of the treatment device 12.
The treatment device 12 is shown with an upper portion 12a and a side portion 12b. The lights 40 on each portion may be controlled to be the same color, or may be different colors, depending on the signal provided by the main controller to the sub-controllers 22 via the multiplexed communication wire. Thus, it will be appreciated that the multiplexed communication provided to the lights 40 allows for a variety of lighting schemes that may be changed and controlled according to user preferences.
In one aspect, shown in
As the treatment device 12 rotates relative to the trolley 24, the second portion of the slip ring 36b and the multiple wires 38b extending therefrom remains in generally the same position relative to the treatment device 12, such that continuous rotation of the treatment device 12 does not affect the communication and power being provided to the lights 40.
The various control schemes for the lights 40 may be provided in a similar manner to other types of controllable components, such as actuators and/or valves, attached to the treatment device 12, such that the lights 40 or other components may be activated only at the top or the bottom of the middle of the treatment device 12, as desired. The particular lights 40 or other components to activate may depend on the type of control scheme being activated by the main controller 20 and on the particular phase of the vehicle treatment process.
With reference to
In one aspect, a dark green spot (or traveler 40b) may be provided on the treatment device 12 that travels upward at a first rate (for example along the arrows 50 illustrated in
Upon reaching the desired location, shown in
For example, when the vehicle is centered, as shown in
When the vehicle is offset to the right, for example in
A similar movement of the traveler 40b is shown in
Thus, the lights 40, whether on a single arch or double arch design, can use an animated traveling light 40b to signal to the driver both to proceed forward or stop and also to shift the vehicle in a particular direction. The particular signal being provided to the driver by the control of the lights 40 is based on vehicle detection sensors that communicate to the main controller 20 the actual position of the vehicle, with the main controller 20 using this information to determine the particular lighting scheme, and providing the resulting light scheme signals over the multiplexed communication 38 to the treatment device 12 and the sub-controllers 22 disposed thereon.
In another aspect, not explicitly shown, the color of the lights 40 may be pulsed or otherwise animated depending on other environmental conditions. For example, the lights 40 may be controlled to correspond to the beat or volume of music being played at the facility. Such audio and light entertainment may be provided, for example, during low noise volume phases of a vehicle treatment process, such as when low pressure applications are being performed, or a chemical treatment is being given time to complete.
As described above, in addition to the lights 40, other components can be specifically controlled along the arch 20 via the single multiplexed communication wire, either as an alternative to a lighting scheme or in addition to the lighting scheme.
With reference to
Fluid transfer, like electrically connectivity, can be difficult over complicated motion, such that providing fluid to specified outlets through a moving connection can be limited. However, the use of the single fluid path 61, with specific valve control via the sub-controllers 22 allows for specialized treatment using such a single fluid path 61. However, in some aspects, multiple fluid paths 61 may also be provided, such as a fluid path for high pressure/high volume wash water and another path for small volume/low pressure chemical fluid. The control valves 60 (or other components/actuators) described herein are therefore applicable to such additional fluid paths, and are not intended to be limited only to single fluid paths, even if a single fluid path is most commonly used in the industry.
For example, as shown in
In addition to using the control of select valves 60 to control which areas of the treatment device 12 provide treatment from corresponding outlets, valves 60 disposed within the treatment device 12 may also be used to control a desired mixture of various fluids, chemicals, soap or the like, which may then be provided from one or more outlets. Thus, as described above, whether with a single fluid line or multiple fluid lines, valve control may be used to create a desired mixture that is fed to the one or more fluid lines. For instance, different ratios of additives can be provided into the fluid stream, such as a desired color, in one aspect. Thus, in addition to using valve control to control which sections emit treatment from a given fluid line, valves control can also take multiple inputs and control what is fed into a given fluid line.
The smart control of the treatment device 12 can also be used to signal other events that occur during vehicle treatment, including unexpected events such as collision or interference with the vehicle treatment apparatus. Impact detection in vehicle treatment systems can be accomplished in a variety of ways (a vehicle impact detection mechanism provided by the present disclosure is described in further detail below). In short, sensors may be provided for the treatment device 12 that detect when the treatment device 12 has shifted due to impact and indicate which direction and at what degree of an angle it is impacted. Other vehicle impact detection mechanisms may also be used.
In response to detecting a vehicle impact, the main controller 20 may correspondingly alter the vehicle treatment process, such as by stopping the process to allow for the collision or impact to be remedied. The system 10 herein may also be used to signal to the driver that an impact has been detected.
As shown in
In one aspect, an impact sensor may be disposed on the treatment device 12 itself, with communication being provided through the multiplexed communication 38 back to the main controller 20. In another aspect, impact sensors may be disposed on or in the trolley 24, and may be provided via a separate communication to the main controller 20, with the main controller 20 relaying the resulting lighting scheme to the lights 40 and the sub-controllers 22 after receiving the impact signal. Impact sensors disposed at the trolley 24 are discussed in further detail below.
In yet another aspect, with reference to
A similar scheme may be used for setting an audio volume, such as music to be provided during certain processes. Other possibilities include a distance indicator for vehicle detection, dilution control (chemical concentration to be provided), foaming air pressure, etc. It will therefore be appreciated that the lights may be controlled in a variety of ways to provide an indication to the user and/or for aesthetic/marking reasons.
The programming of the lighting or other control schemes can be provided remotely, such as through the internet or corporate network to the main controller 20. Because the different types of control and lighting are provided via the same single control wire and the same set of multi-color lights, valves, etc., the system operator need not be present at the treatment facility to make any changes to the system to modify a desired appearance, for example.
Thus, at different times, the lighting schemes can change color, such as for different holidays, sporting events/teams, specific promotions, daily specials, etc. For example, if a half off special is being provided, the system 10 may illuminate in a specific promotional color to signal to people near the facility that the promotion is occurring. These colors schemes may be changed or controlled dynamically and remotely based on various data.
It will be appreciated that reference has been made to a single multiplex signal communication connection, but that multiples of such communication connections may be provided, without departing from the spirit and scope of the disclosure. Each multiplex communication connection allows for control of numerous devices, thereby reducing the overall number of wires, and the provision of additional multiplex communication connections is still a substantial reduction relative to the traditional approach of having single control wire for each activatable component.
Turning now to
One approach to determining a rotational position is the use of a single analog sensor mounted within the housing 30, along with a machined flag having a tapered surface, such that as the shaft 28 rotates, the specific distance between the analog sensor and the surface of the flag varies, thereby indicating the rotational position of the treatment device 12. However, the sloped and machined flag is expensive to machine and the single analog sensor may lack desired redundancy, and is difficult to adjust. Moreover, the positioning of such a sensor arrangement within the housing 30 occupies valuable space within the housing 30, making it difficult to incorporate a slip ring or other components.
Similarly, one approach of arch impact detection involves the use of a sensor within the housing 30, designed to be a predefined distance from a flag supported on the arch support structure. In the event of an impact, the arch structure pivots, causing the flag to move away from the sensor to indicate an impact. During normal rotation of the treatment device 12, the flag is designed to remain within the designed range of the sensor. However, the mechanical motion transfer system includes a variety of moving parts and tolerances, which can result in the flag being offset from the desired position within the range of the sensor, and therefore not moving away relative to the sensor in the manner as expected and designed, thereby resulting in an actual impact movement not being detected, which is a particularly undesirable failure mode. Similarly, if the various moving parts and tolerances result in an offset position relative to a nominal position, a false alarm may result, where a slight movement or vibration occurs without an actual impact. The false alarm is also undesirable in that it can result in the controller 20 interrupting the treatment process when no impact has occurred. Thus, both a failure to detect an actual impact and a false alarm are undesirable occurrences.
According to the present disclosure, shown in
In one approach, the plurality or set of sensors 110 includes four sensors 110, each of which are arranged in a common horizontal plane and spaced radially away at a common radial distance relative to the axis of rotation of the treatment device 12 and shaft 32. The sensors 110 are spaced apart from each other equally in the circumferential direction (every 90 degrees in the case of four sensors) around the axis of rotation. The sensors 110 are fixedly mounted relative to the housing 30 and therefore move with the trolley 24, with the treatment device 12 being rotationally carried by the trolley 24 and shaft 32. The bottoms of the sensors 110 are each disposed below the bottom of the housing 30, thereby extending through the base of the housing 30. The tops of the sensors 110 are electrically connected to the main controller 20 either directly or through a relayed connection, such that the main controller 20 receives signals from each of the sensors 110.
The sensors 110 are each configured to detect the presence or absence of a flag 112, shown in
The flag 112 has a curved shape, in one aspect, having a radius generally corresponding to the radial distance of the sensors 110 from the axis of rotation of the treatment device 12. In one example, the sensors 110 are arranged on a 6 inch diameter and the flag 112 has about a 6 inch diameter. The flag 112 has a curved length that, in one approach, extends greater than 90 degrees around the circumference defined by the sensors 110, but less than 180 degrees. Accordingly, the flag 112 is long enough to provide a signal to two of the sensors 110, depending on its location, but not three, and the flag 112 is similarly long enough to always be below at least one of the sensors 110 during normal operation. Preferably, the flag 112 is just long enough such that when two of the sensors 110 detect the flag, the treatment device 12 is at one of four distinct locations. Put another way, the flag 112 is just long enough to reach two sensors, without a substantial amount of extension circumferentially beyond either of the sensors 110 that it reaches. The flag 112 may also have other shapes, including but not limited to a rectangular shape, with a length/size that activates either one or two sensors in a manner similar to the above. It will be appreciated that other numbers of sensors 110 may be provided, with a correspondingly different length for the flag 112.
The flag 112 is rotationally fixed relative to the rotational position of the shaft 32 and treatment device 12, and, thus, depending on which of the sensors 110 detect the flag 112, the controller 20 can determine the rotational orientation of the treatment device 12 within a directional window corresponding to the range in which the flag 112 could be present. The controller 20 can then determine the direction to rotate the treatment device 12 to return it to a known position or to resume rotation in the correct rotational direction. As the treatment device 12 is controlled to rotate, the sensors 110 may continue to provide a signal to the controller 20. Thus, once a two sensor state is detected, the controller 20 may then determine a more precise location of the treatment device 12, and can thereafter control the treatment device 12 based on this more precise known position. Thus, even if a single sensor 110 detects the flag 112, the controller 20 only needs to rotate the shaft a limited amount until the two-sensor state is detected.
The flag 112 is supported on a portion of an arch support structure 114, which is arranged to cooperate with the sensors 110 via the flag 112 and to also provide impact detection.
During an impact state, shown in
The support structure 114 is mounted to the rotating shaft 28 of the treatment system, with the treatment device 12, including both the upper portion 12a and side portion 12b, attached to the support structure 114 to rotate along with rotation of the shaft 28. The support structure 114 includes a base 116 attached to the bottom of the shaft 28. A bracket 118 is pivotably mounted to the base 116 via pins or the like, having a first side 118b (also referred to as impact side 118b, because this is the side that is contacted during an impact to pivot/move the bracket 118) and a second side 118a (also referred to as flag side 118a, because this is the side that has the flag 112 and which moves away from the sensors 110 when the bracket 118 pivots) opposite the flag side 118a. The bracket 118 is biased to its normal state. In one approach, a spring 112a (
The side portion 12b of the treatment device 12 is designed such that it may pivot about two transverse axes relative to the upper portion 12a when there is an impact. It will be appreciated that reference to impact may include other changes in angle position of the treatment device 12 that is not expected, which may include other events or external forces, with vehicle impact being a common cause of such change in angle position or deviation from an expected position. The side portion 12b may include a shoulder portion 122 (also referred to as a first actuating portion) and a head portion 120 (also referred to as a second actuating portion) in the form of blocks or the like, shown in
The side portion 12b is also configured to pivot laterally outward about a fore-and-aft axis perpendicular to the lateral axis and the longitudinal extent of the upper portion 12a. For this impact type, shoulder portion 122 is pivotable relative to head portion 120. This type of impact can occur when the treatment device is in front of the vehicle to treat the vehicle (with the direction of fluid disposed toward the vehicle), and the vehicle pulls forward, for example. Pivoting of the shoulder portion 122 relative to the head portion 120 moves the side portion 12b in a direction generally parallel to the fluids that are expelled from the side portion 12b. During non-impact (or when an external force is not being applied against the side portion 12b), and during a normal treatment process in which fluid is expelled, returns forces will result that urge the side portion 12b in this outward direction away from the vehicle. To counter the return forces, a shear pin may be disposed between the shoulder portion 122 and the head portion 120, such that the side portion 12b remains in position relative to the upper portion 12a when fluids are delivered. However, during impact or an external force (which are typically greater than the return force that occurs from providing the fluid), the shear pin may be severed, allowing the side portion 12b to pivot outward relative to the upper portion 12a. Thus, in response to this type of impact (bottom of the side portion 12b moves outward relative to the top portion 12a, changing the relative angle enclosed between them, as shown in
Thus, in either type of impact with the side portion 12b (fore-and-aft or lateral), the side portion 12b is permitted to pivot relative to the support structure 114, causing the bracket 118 to pivot to move the flag 112 away from the sensors 110. The particular arrangement of the structure shown and described herein is one example, but it will be appreciated that other variations and/or bracket shapes, or specific locations of pivot axes for the side portion 12b, could be used resulting in a similarly advantageous operation of lifting the bottom of the impact side of the bracket 118 to cause movement of the flag 112 away from the sensors 110.
The arrangement of the sensors 110 relative to the trolley housing 30, and the flag 112 relative to the treatment device 12, may be selected as desired by the user. As shown in the Figures, the sensors 110 and flag 112 are arranged such that when two sensors 110 detect the flag 112, the treatment device 12 is positioned approximately 45 degrees offset from the translation direction of the trolley 24 along the wash bridge 26.
The sensors 110 and flag 112 may be calibrated as desired for different sensitivity based on tolerances. For instance, the air gap between the flag 112 and the sensors 110 may be adjusted to signal an impact over different amounts of pivoting. Similarly, the sensitivity of the sensors 110 may be adjusted relative to a given air gap value.
Because the flag 112 is long enough to activate more than one sensor 110 at the same time, the impact state causing the flag 112 to move downwardly away from the sensors 110 causes none of the sensors to be activated, which is not a normal operative state, a.k.a. impact is detected. During rotation, the known arrangement of the sensors 110 results in the controller 20 expecting to receive a certain progression of corresponding sensor activation, which will indicate the good working condition of sensors and non-impact state of the treatment device 12. It will be appreciated that reference to “normal” operation is intended to indicate operation in which the system is operating without a substantial impact where correction is desired. But it will also be appreciated that the act of detecting an impact is part of the designed functionality, and in a sense part of an overall normal operation.
Thus, during an impact, whether by the vehicle, debris, a person in the wash bay, or anything else imparting a force against the treatment device 12, the expected sensor activation is interrupted by the pivoting of the flag 112 away from the sensors 110. For example, a trailer hitch extending beyond the rear of the vehicle may be in the path of the spray treatment device 12. The treatment device 12 may be traversing the rear of the vehicle without rotation, and the controller will therefore expect to detect the currently activated sensor 110 to remain activated. Upon impact with the trailer hitch, the side portion 12b will pivot relative to the support structure 114, causing the bracket 118 to lift up at the impact side 118b and the flag side 118a to move downward, moving the flag 112 away from the sensor 110. The controller 20 will detect that the previously activated sensor 110 is no longer activated by the flag 112, and the process can be paused.
In response, the controller 20 can determine, based on the operation that was occurring, the likely cause of the impact, and can adjust its control algorithm based on pre-programmed correction schemes, via additional sensor readings, or the like.
For instance, one corrective action is to reverse the movement that was just occurring. For instance, if the treatment device 12 was moving to the left along the rear of the vehicle, the treatment device 12 can be moved back to the right, and the controller 20 can evaluate whether the expected sensor 110 becomes active again. The controller 20 can then shift the treatment device 12 further away from the vehicle to avoid whatever obstacle may have caused the impact, and can attempt the procedure again.
As described above, the controller may be programmed such that it expects certain sensor activation based on the treatment process that is being performed and the movement of the treatment device 12 that is being commanded, in order to detect an impact or deviation from the expected sensor signals 110. A deviation of an expected sensor signal may also occur due to a sensor malfunction, and the controller may therefore also be used to troubleshoot a faulty sensor. The expected movement and position of the treatment device 12 may be considered predetermined movement, and may include position, orientation, speed, etc. Indeed, the rate at which the sensors 110 activate can be expected for a specified speed, as well as an orientation at a particular stage of a predetermined treatment process. Thus, impact, sensor malfunction, rotational restriction, and/or the like can be considered a deviation from the expected predetermined movement of the treatment device 12.
The activation of the sensors 110 by the flag 112 accordingly provides the orientation of the treatment device 12 relative to an expected orientation during treatment, but the activation of the sensors 110 also provides an orientation of the treatment device in a standstill state, such as during a power up situation, during calibration, or after impact, to determine a relatively precise orientation and/or direction that the treatment device is pointing. For instance, in the illustrated embodiment, four sensors 110 are shown, with the flag 112 long enough to activate two of the sensors 110 at once in certain orientations, but short enough that only one sensor will activated in positioned between those four orientations. Thus, eight different orientations may be detected when the treatment device 12 is stationary. It will be appreciated that additional sensor arrangements may be selected to provide different static position detection, as desired, including the use of different spacing and/or quantities of sensors 110 and/or size and shape of the flag 112.
While the above orientation detection and impact detection mechanism having the described sensors 110 permits the use of the slip ring 36 as described herein, it will be appreciated that these advantages are not limited to instances in which a slip ring connection is used, just as the advantages of a multiplexed communication channel and sub-controllers disposed on the treatment device 12 itself can be provided with or without a slip ring 36. Thus, the orientation and impact detection mechanism described herein are usable in a variety of vehicle treatment processes and devices, including dual vertical arches on each side of a vehicle, rotatable brushes, and the like.
The above orientation detection and impact control could also be used on combination devices, such as rotatable brushes also including nozzles, such that the brush can be oriented specifically to align its nozzles in the desired direction.
It will be appreciated that the above example descriptions of the treatment device 12 includes reference to features that are likewise applicable to rotatable brushes and other vehicle treatment components, in particular with regarding to specific control via sub controllers of different components disposed along the treatment device.
The above described aspects of features of the present disclosure may be provided alone or in combination with other aspects and features disclosed herein and known in the art. It will be appreciated that the above described aspects and example embodiments are for the purposes of discussion and illustration, and are not limiting in that regard.
| Number | Date | Country | |
|---|---|---|---|
| 63454427 | Mar 2023 | US |
