Design of Automatic Car Washing System and Construct Prototype.pdf

Design of Automatic Car Washing System and Construct Prototype
Pune Vidyarthi Griha’s College Of Engineering Nashik.
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1. INTRODUCTION
Currently necessity of man is to live life in automatic way so as to perform tasks at higher
speed. Technology is best interconnecting channel in each part of world with the means of
transportation or communication or business which led to a highly increase in the number of cars.
So how to maintain or clean those? Using automated washing system? All peoples face big issue
called as Time i.e. time consumption essential for cleaning these vehicles or cars etc. Time
management is directly proportional to reduction of cost for maintenance. Project helps us to use
a conveyor belt on which customer stop the car. After it switch detector is used for detecting the
car then conveyor belt start moving. Sensor plays vital role on conveyor belt for car detection.
As soon as car is sensed functioning of conveyor assembly invokes. After specified delay for all
activities to perform conveyor get stops. The main objective of this project is to perform exterior
car washing automatically using Programmable Logic Controller integrated with PLC sends
information like arrival or departure of vehicle. Car washing technique is collection of various
things as spraying solution of detergent, cleaning with water and brushes, & then completing task
with forced air drying fans.
The first automatic car washes appeared in the late 1930s. Automatic car washes consist
of tunnel-like buildings into which customers (or attendants) drive. Some car washes have their
customers pay through a computerized point of sale unit (POS), also known as an "automatic
cashier". The mechanism inputs the wash Programming Logic Controller (PLC) into a master
computer or a tunnel controller automatically. When the sale is automated, after paying the car is
put into a line-up often called the stack or queue. The stack moves sequentially, so the wash
knows what each car purchased. After pulling up to the tunnel entrance, an attendant usually
guides the customer onto the track or conveyor. At some washes, both tires will pass over a tire
sensor, and the system will send several rollers. The tire sensor lets the wash know where the
wheels are and how far apart they are. On other systems the employee may guide the customer
on and hit a 'Send Car' button on the tunnel controller, to manually send the rollers which push
the car through. When the customer is on the conveyor, the attendant will instruct the customer
to put the vehicle into neutral, release all brakes, and refrain from steering. Failure to do so can
cause an accident on the conveyor. The rollers come up behind the tires, pushing the car through
a detector, which measures vehicle length, allowing the controller to tailor the wash to each
individual vehicle. The equipment frame, or arches, vary in number and type. [1]

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A good car wash makes use of many different pieces of equipment and stages of chemical
application to thoroughly clean the vehicle. The carwash will generally start cleaning with pre-
soaks applied through special arches. They may apply a lower pH (mild acid) followed by a
higher pH (mild alkali), or the order may be reversed depending on chemical suppliers and
formula used. Chemical formulas and concentrations will also vary based upon seasonal dirt and
film on vehicles, as well as exterior temperature, and other factors. Chemical dilution and
application works in combination with removal systems based on either high pressure water,
friction, or a combination of both. Chemical substances, while they are industrial strength, are
not used in harmful concentrations since car washes are designed not to harm a vehicle's
components or finish. The customer next encounters tire and wheel nozzles, which the industry
calls Chemical Tire Applicators (CTA). These will apply specialized formulations, which remove
brake dust and build up from the surface of the wheels and tires. The next arch will often be
wraparounds, usually made of a soft cloth, or closed cell foam material. These wraparounds
should rub the front bumper and, after washing the sides, will follow across the rear of the vehicle
cleaning the rear including the license plate area. [1]
Past the first wraps or entrance wraps may be
a tire brush that will scrub the tires and wheels. This low piece is often located beneath a mitten
(the hanging ribbon-like curtains of cloth that move front to back or side to side) or top wheels.
There may also be rocker panel washers which are shorter in size (ranging in size from 18 inches
[45 cm] up to 63 inches [160 cm] tall) that clean the lower parts of the vehicle. Most rocker
brushes house the motor below the brush hub so they don't inhibit cloth movement and allow the
brush to be mounted under a support frame or below a mitten. Some car washes have multiple
mittens, or a combination of mittens and top brushes after the mutter or top brushes the car may
pass through a second set of wraparounds. This may also be where high pressure water streams
are used to clean difficult to reach parts of the vehicle. The car generally passes over an under
carriage wash and/or has high pressure nozzles pointed at it from various positions. Next may be
a tire spinner, High pressure nozzles angled specifically to clean wheels and tires. [1]
After the
several wash stations the vehicle may go through triple foamers, usually red, blue, and yellow,
although colors can be customized with higher end chemical suppliers. The triple foam process
includes special cleaners as well as some protective paint sealant. Protectants vary by
manufacturer. Near the rinse is where a tire shining machine is often installed, which is designed
to apply silicone tire dressing to the tires. This application makes the tires look good (new, and
glossy) and preserves the rubber. Next the vehicle is treated with a drying agent and a final rinse.
Many carwashes utilize a "spot free" rinse of soft water that has been filtered of chlorine and sent

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through semi permeable membranes to produce highly purified water that will not leave spots.
After using spot free water, the vehicle is finished with forced air drying, in some cases utilizing
heat to produce a very dry car. [1]
Older automatic washes-a majority of which were built prior to 1980-used to use brushes with
soft nylon bristles, which tended to leave a nylon deposit in the shape of a bristle, called brush
marks, on the vehicle's paint. Many brushes in the US are now either cloth (which is not harmful
to a car's finish, as long as it is flushed with plenty of water to remove the grit from previous
washes), or a closed cell foam brush, which does not hold dirt or water, thus is far less likely to
harm any painted finish, and can, in fact, provide a gentle polishing effect to leave the paint much
shinier. In order to avoid paint marking issues, "touch less" or "no-touch" car washes were
developed. This means the car is washed with high water pressure instead of brushes. There is no
contact with friction so the chance of any damage is less, however the actual cleaning, or removal
of film from the paint, is nearly impossible with no touch systems. At "full-service" car washes,
the exterior of the car is washed mechanically with conveyor equipment, or in some cases by
hand, with attendants available to dry the car manually, and to clean the interior (normally
consisting of cleaning the windows, wiping the front and side dashes, and vacuuming the carpet
and upholstery). Many full service car washes also provide "detailing" services, which may
include polishing and waxing the car's exterior by hand or machine, shampooing and steaming
interiors, and other services to provide thorough cleaning and protection to the car. [2]

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1.2 Problem Statement
While studying and manually operating the existing model of car washers it was observed
that they require soap solution to be applied separately as it sprays water only. Further a separate
sponge is to be used to squeeze the soap solution. All this increase the time spent on cleaning the
car. The model was thus redesign eliminating the above problem by designing the washer such a
that it will contain two separate container for soap solution and water both embedded in the same
machine and can be ejected as a user desire.
That is only soap solution, only water and soap solution along with that it will also have and
attached and rotating scrubber and brush.so the user can use it directly after applying soap
solution to the car body, which will result in faster and less tedious cleaning operation.

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1.3 Objectives
1. Ensure customer satisfaction and build a repeat customer base.
2. Improve our position in the local market and strengthen our brand
3. To provide high quality full service car wash.
4. To provide better service to customer.
5. This system clean the car 95%.
6. To provide service in less time.
7. To avoid rusting of external body of the car.
8. It clean the car in less water.

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1.4 Motivation
The car wash industry has been in an upward trend for the past few years and many are asking
the question “where is the car wash industry heading?” There have been a number of articles and
conversations about this subject, however I believe that most of them just reiterate what is
actually happening in the industry right now. I believe the car wash industry is headed to an
exciting place in the next in the next 5 to 10 years, but it will look a lot different. Focusing,
understanding and marketing towards millennials is the key to the next generation of successful
car washing businesses. Millennials have exponential purchasing power and influence in their
social networks. Their influence can already be seen in other industries like the toy, beauty and
restaurant industries. These industries are already altering their business models to compete in
this new arena. I believe that the car wash industry will continue to grow and change at an extreme
pace and will weed out the businesses that fail to keep up with the times. Below is a list of changes
that I feel will really speak to the next generation of car wash industry leaders [2]
1.4.1 Speed of Service
The tunnels are already pretty efficient in this regard but the name of the game is speed of service
and Intermediate Bus Architecture (IBA) will get faster and faster, time is money in all
regards. This type of equipment will need to stand the test of time and be able of washing 30
plus cars per hour. Do not be fooled with perceived value, we as a society, are so strapped for
time and people will pay more for less time. 30 second wash in the future? I wouldn’t bet against
it. [2]
1.4.2 Automation
Automation will continue to increase at a spectacular pace and we will have systems in place to
monitor our doors, chemicals, temperatures, rails and other pieces of equipment. These systems
will notify us even better and faster of problems or preventative maintenance issues making the
owners more and more passive. [2]

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1.5 Methodology
1. Market survey of different market requirement.
2. Selection of Automatic car washing system prototype for construction.
3. Selection of material for Automatic car washing system prototype.
4. Design the components of system.
5. Development of frame and roller conveyor.
6. Selection of electrical components like sensors, Relay, Arduino, motor, pump.
7. Programing the Arduino according to the requirement.
8. Mounting of electrical component on frame.
9. Building of car washing stations on frame.
10. Trial on prototype car washing.

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1.6 Work Plan
Sr. No. Expected Target To be Achieved Month
June July Aug Sept Oct Dec Jan Feb Mar April May
1 Design ofroller conveyor a
2 Design ofchain drives a
3 Design ofkey a
4 Design ofbearing a
5 Selection ofpump a
6 Design ofstructure a
7 Design ofNut & Bolt a
8 Selection ofdifferent components a
9 Assembly drawing in design software a a
10 Fabrication a a a a
11 Programming for arduino a
12 Report a a a a a a
13 Power Point Presentation a a a a

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2. LITERATURE SURVEY
2.1 Introduction
 Mr. Abhishek Pansare, Ms. Priyanka Yadav, Ms. Vrushali Thigale, Mr. S.C.Rajgade, “PLC
Based Automatic Car Washing System”, The main objective of this research is to perform
exterior car washing automatically using Programmable Logic Controller integrated with
PLC sends information like arrival or departure of vehicle. Car washing technique is
collection of various things as spraying solution of detergent, cleaning with water and
brushes, & then completing task with forced air drying fans.
 Mr. sreenivasa reddy, ch. vidya, ch. hinduja, d soumith, k pavankumar, “Automatic
car washing system with is module using conveyor belt”, In this project we are using AT
mega 16 Microcontroller, motor drivers IC’s and relay motor drivers to drive the DC motors
with the regulated power supply to run the respective motors to fulfil the output requirement.
 P.B.Patel, S.V.Rokade, P.S.Tujare, “Automatic car washing system”, the main aim of our
project is use less water, more efficient washing. Practically at home we use 150 gallons of
water but using this process 35 gallons of water gets used up. By using this process we can
clean up the car up to 95.
 Nidhi Bhatia, jayana rana, (International journal of innovative research in technology) Our
car washing system has three main processes namely washing, cleaning & drying, hence the
exterior of the car will be washed by detecting the car on conveyor belt & further controlled
by PLC & SCADA.
 Akilandeswari.k, Haripriya.j, Sangavi Nirmala.v, (International journal of innovative
research in science, engineering & technology), The main objective of this paper is to perform
exterior car washing automatically used in PLC Integrated with GSM modem. GSM-PLC
sends information like entry, exit of entry, emergency conditions to the customer or operator
through SMS. After acquiring the information from PLC, the operator can able to act upon it.
2.2 Market Survey
Car washing systems are the systems that are being used for cleaning the exteriors and interiors
of the cars. It facilitates easy washing and cleaning of the automobile. The growth in automotive
industry leads to an increase in demand for the car wash systems. The other factors driving the
growth of the car wash systems market are the increase in production and sales of vehicles,
reduced instances domestic car washing, and high disposable income. Also, the growth of the

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market is driven by features such as improved efficiency, higher safety, easy management,
reliability and time efficiency.
Car washing systems are very common in developed countries. These systems are fully
automated with different stages of rinsing, shampooing, washing, and drying. Consumers are
becoming more aware of the benefits of car wash services such as improved efficiency and safety.
Also, the increasing environmental awareness among people is driving the growth of car wash
services, which ensures optimal deployment of water resources and proper dumping of solid
waste, thus helping the growth of market for car wash systems. Using an automatic car
wash service, is a good way to be environmentally conscious and protect the resale value of the
car. Automatic car washes also save water, reduce groundwater pollution, and retain the car’s
paint and finish. Technological advancement and heavy investments in car wash systems also
add to the car wash system market. There is an increase in the need for professional car cleaning
organizations, which are capable of providing flawless car cleaning. So, there is high demand for
a professional and reliable cleaning brand over the forecast period. Other factors contributing
growth of the market are continuous rise in industrialization, increasing new car registrations,
decline in gasoline prices and lower interest rates on loans. Increase in the installation of
mechanized and automated car wash systems is further propelling the growth of the market.
Consumers have become smarter and machine savvy. Hence, there will be growth in the car
washing system market during the forecast period. However, the growth of the market is expected
to be restrained by the high cost associated with manufacturers along with the low degree of
awareness among consumers. Owing to this, the global car wash systems market is expected to
expand with a CAGR of approx. 3% over the forecast period.
2.3. Worldwide Market survey
Asia Pacific is dominating the market of car wash system due to the growth of the automotive
industry. With the global economy undergoing an unprecedented level shift, major developing
countries in Asia Pacific region such as China, India, Thailand, and Indonesia have become
manufacturing hubs for global automotive players. The income levels of individuals have been
steadily increasing, resulting in a rise in their disposable income. The currently booming
automotive industry, combined with steadily increasing disposable income, is expected to
contribute significantly in the growth of the market. The automotive repair shops and dealers are
focusing on the installation of car wash systems for easy washing and cleaning of cars on a large
scale.

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Car washing systems are the systems that are being used for cleaning the exteriors and interiors
of the cars. It facilitates easy washing and cleaning of the automobile. The growth in automotive
industry leads to an increase in demand for the car wash systems. The other factors driving the
growth of the car wash systems market are the increase in production and sales of vehicles,
reduced instances domestic car washing, and high disposable income. Also, the growth of the
market is driven by features such as improved efficiency, higher safety, easy management,
reliability and time efficiency.
Car washing systems are very common in developed countries. These systems are fully
automated with different stages of rinsing, shampooing, washing, and drying. Consumers are
becoming more aware of the benefits of car wash services such as improved efficiency and safety.
Also, the increasing environmental awareness among people is driving the growth of car wash
services, which ensures optimal deployment of water resources and proper dumping of solid
waste, thus helping the growth of market for car wash systems. Using an automatic car
wash service, is a good way to be environmentally conscious and protect the resale value of the
car. Automatic car washes also save water, reduce groundwater pollution, and retain the car’s
paint and finish. Technological advancement and heavy investments in car wash systems also
add to the car wash system market. There is an increase in the need for professional car cleaning
organizations, which are capable of providing flawless car cleaning. So, there is high demand for
a professional and reliable cleaning brand over the forecast period. Other factors contributing
growth of the market are continuous rise in industrialization, increasing new car registrations,
decline in gasoline prices and lower interest rates on loans. Increase in the installation of
mechanized and automated car wash systems is further propelling the growth of the market.
Consumers have become smarter and machine savvy. Hence, there will be growth in the car
washing system market during the forecast period. However, the growth of the market is expected
to be restrained by the high cost associated with manufacturers along with the low degree of
awareness among consumers. Owing to this, the global car wash systems market is expected to
expand with a CAGR of approx. 3% over the forecast period.

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3. METHODS OF CAR WASHING
3.1 Manual Car Washing
The manual car washing is widely used method. This system required less space and it is
economical. Washing of car is done by hand wash .the device required for this system are water
spray gun, water treatment system, Submersible Pumps hand Cuffs. The main disadvantage of
that process is time consuming. [1]
Washing the Car Body:-
In order to avoid dips scratches the vehicle must be rinsed before sponge is applied. Make sure
that the section of the vehicle that is being washed is wet, dip the sponge into water and wet for
it absorbs soap water. Squeeze sponge repeatedly. And apply it on the roof of the vehicle in
straight method. [1]
Washing the wheel:-
Wheel are clean by the soap solution and wheel brush. Rinsing all the soap off of the vehicle
being at the top and spread downward. To avoid splashing soap back upto the top of vehicle. As
much as possible dry the vehicle throughout to prevent water spot and corrosion. Car dry by the
cloth. [1]
Procedure
 Clean wheels and tires:-
Fig.3.1.1 Clean wheels and tires

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 Exterior Prewash:-
Fig.3.1.2 Exterior Prewash
 Foaming:-
Fig.3.1.3 Foaming
 Post wash:-
Fig.3.1.4 Post wash

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 Drying:-
Fig.3.1.5 Drying
3.2 Semi-Automatic Car washing System
In semi-automatic car washing system it is a combination of automatic and semi-automatic car
washing system.it performs reliable operatons.in this system we use bulgers rollers for the
purpose of washing wheels and car body it takes less time as compared to manual car washing
system. It enhance fine quality of car washing.
Procedure
 Manual wheels & exterior washing:-
Fig.3.2.1 Manual wheels & exterior washing
 Automatic pre Exterior washing:-
Fig.3.2.2 Automatic pre Exterior washing

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 Foaming:-
Fig.3.2.3 Foaming
 Post Washing:-
Fig.3.2.4 Post Washing
 Drying:-
Fig.3.2.5 Drying

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3.3 Automatic Car Washing System
Mainly the car wash system works on the principal, that the water and solution is release with
pressure of the nozzle and water can release either individually or with the solution. This device
discloses a power driven rotary brush mounted in a handle with water and detergent, or soap inlet
means and means to discharge the water, with or without the soap, on to the brush.
The main invention in this system is that the sponge type brush is rotated with the help of an
electric motor which is fitted into the handle or the nozzle. Another criteria used in this system is
that the pressure and the speed of the water flowing or coming out through the nozzle can be
control during washing and rinsing of the vehicle. Also the solution and the water is separated
with to different pipes which comes in nozzle or handle through the pump. After the vehicle is
wash with soap or detergent suds the vehicle may be rins by cutting of the supply of soap or
detergent.
 Procedure:
1. Entry of car
2. Pre-wash
3. Foam Wash Section
4. Brushing
5. Clean Wash Section
6. Drying Section
7. Exit

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4. TIME STUDY
4.1 Manual Car Washing System:
Fig.4.1.1 Manual Car wash [1]
The manual car washing is widely used method. This system required less space and it is
economical. Washing of car is done by hand wash .the device required for this system are water
spray gun, water treatment system, Submersible Pumps hand Cuffs. In Comparison of semi-
automatic and automatic car washing time required for manual car washing is more. There are
many chances of human error.
 Procedure
1. Clean wheels and tires.
2. Wash exterior.
3. Foaming
4. Washing
5. Drying

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Table No. 4.1.1 Manual Car Wash Time Study
Sr.
No.
Procedure
Process
Time Idle
Time(Between
Two Process
In Min)
Total time
required
(in and out,
in Min.)
(In
Min)
1
Clean Wheel
And Tire
13 - 13
2 Prewash 12 1 26
3 Foaming 7 2 35
4 Post wash 10 1.5 46.5
5 Drying 10 1 58.5
Total 52 5.5 58.5
4.2 Semi-automatic
Fig.4.2.1 Semi-Automatic Car Washing System
In semi-automatic car washing system it is a combination of automatic and semi-automatic car
washing system.it performs reliable operatons.in this system we use bulgers rollers for the
purpose of washing wheels and car body it takes less time as compared to manual car washing
system. It enhance fine quality of car washing.

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 Procedure
1. Manual wheels & exterior washing
2. Automatic Exterior washing
3. Foaming
4. Washing
5. Drying
Manual Operations
Table No. 4.2.1 Semi-Automatic: Manual Operation
Sr.
No.
Procedure
Process
Time
Ideal
Time(Between
Two Process
In Min)
Total time
required
(in Min.)
(In
Min)
1
Manual
Wheel And
Tire Cleaning
10 - 10
Automatic Operation
Table No.4.2.2 Semi-Automatic: Automatic Operation
Sr.
No.
Procedure Process
Time
Idle
Time(Between
Two Process in
Min)
Total time
required
(in and
out, in
Min.)
(In
Min)
1 Pre Wash
Exterior
1 - 1
2 Foaming 1 0.5 2.5
3 Washing 2 0.5 5
4 Drying 2 1 8
Total 6 2 8

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4.3 Automatic Car Washing
Fig.4.3.1 Exterior washing [3]
 Procedure
1. Entry of car
2. Pre-wash
3. Foam Wash Section
4. Brushing
5. Clean Wash Section
6. Drying Section
7. Exit
Table No. 4.3.1 Automatic Car Washing Time Study
Sr.
No.
Station
Process
Time
Idle
Time(Between
Two Process
In Sec)
Total time
required (in
and out, in
sec.)
(In Sec)
1 Entry Of Car - - -
2 Pre-Wash 30 10 40
3
Foam Wash
Section
40 10 90
4 Brushing 70 10 170
5
Clean Wash
Section
30 10 210
6
Drying
Section
60 10 280
7 Exit 0 10 290
Total 230 60 290

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5. COST ANALYSIS
5.1 Manual Car Washing
Fixed Cost
Table No. 5.1.1 Manual Car Washing: Fixed Cost
Sr.
No.
Fixed Cost In Rs.
1 Compressor 20000
2 Spray Gun 4500
3 Hose Pipe 4300
4 Tank 7750
5 Pump 6000
Total 116430
Variable cost
Table No.5.1.2 Manual Car Washing: Automatic Cost
Sr.
No.
Variable Cost In Rs
1 Labour 8000
2 Electricity & Water 2500
3 Maintenance 1500
Total 12000

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5.2 Semi-Automatic Car Washing
Fixed Cost
Table No.5.2.1 Semi-Automatic Car Washing: Fixed Cost
Variable cost
Table No.5.2.2 Semi-Automatic Car Washing: Variable Cost
Sr. No. Variable Cost In Rs.
1 Labour 8000
3 Maintenance 1500
Total 12000
Sr. No. Fixed Cost In Rs.
1
Semi-Automatic Car Washing
Unit
1050000
2 Pump Station 6000
3 Compressor 20000
Total 1076000

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5.3 Automatic Car Washing
Fixed Cost
Table No.5.3.1 Automatic Car Washing: Fixed Cost
Variable Cost
Table No.5.3.2 Automatic Car Washing: Variable Cost
Sr. No. Fixed Cost In Rs.
1 Buffing Roller 55000
2 Wind Door 515800
3 Rain Arc 55000
4 Pump Station 15000
5 Arduino 17886
6 Compressor 35000
7 Chain 300000
8 Roller Conveyor 1000000
9 Structure 1000000
Total 2993686
Sr. No. Variable Cost In Rs.
1 Labour 5000/Per
3 Maintenance 3500
Total 13000

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6. PAY BACK PERIOD
Fig.6.1 Manual Car Washing
Fig.6.2 Semi-Automatic Car Washing

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Fig.6.3 Automatic Car Washing

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7. SELECTION OF COMPONENTS
7.1 PLC
PLC is a microcontroller computer used for different process such as control and control
operation of manufacturing process and machinery. It provide automated specific process, system
function and whole production line.
7.2 DC Motor
A DC motor is any of a class of electrical machines that converts direct current electrical power
into mechanical power. The most common types rely on the forces produced by magnetic fields.
Nearly all types of DC motors have some internal mechanism, either electromechanical or
electronic; to periodically change the direction of current flow in part of the motor. Most types
produce rotary motion; a linear motor directly produces force and motion in a straight line. DC
motors were the first type widely used, since they could be powered from existing direct-current
lighting power distribution systems. A DC motor's speed can be controlled over a wide range,
using either a variable supply voltage or by changing the strength of current in its field windings.
Small DC motors are used in tools, toys, and appliances. The universal motor can operate on
direct current but is a lightweight motor used for portable power tools and appliances.
Specifications of DC Motors
 We are using DC Motors for two main purpose.
 Rotation of Conveyor
 Supply Voltage: 24V
 RPM: 30 rpm
 Wheel Brushes
 RPM: 200 rpm.
7.3 Roller Conveyor
A series of roller supported in a frame over which vehicle are advanced manually, by power.
These easy to install, low maintenance rollers are built to carry vehicle.
Specifications
 Length : 1.8 meter

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 Width : 0.2 meter
 Material : Nylon cloth
 Detection of car : 0.3 meter
 Prewash : 0.3 meter
 Brushing : 0.3 meter
 Clean Wash : 0.3 meter
 Drying : 0.3 meter
 Entry & Exit : 0.3 meter
7.4 Nozzles
Nozzle is a component which work on the instructions given by the microcontroller. It sprays a
soap/water mixture under relatively high velocity.
7.5 Sprocket
It is power transmitting component on which chain has being connected with their outer
peripheral mounted. In this system one sprocket is rotate like driver and another one is rotate like
driven.
7.6 Chain
The rollers are connected via sprockets and chain to a drive motor mounted to the side of
conveyor. Chain transmits the power from one sprocket to another sprocket.
7.7 Buffer
The brushes are provided which enhances the removal of dirt from the car and the cleaning of the
car without the use of abrasive cleansers.
7.8 Compressor
The compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air. An air compressor must be
differentiated from pump because it works for any air/gas and pump work on liquid.

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8. DESIGN
Material Selection for prepare any machine part, the type of material should be properly selected
considering design safety. The selection of the material for engineering application is given by
the following factor,
1. Availability of materials
2. Suitability of the material for the required components.
3. Cost of the materials.
The machine structure is basically made up of mild steel. The reasons for the selection are mild
steel is readily available in market. It is economical to use and is available in standard sizes. It
has good mechanical properties i.e. easily machinable. It has moderate factor of safety, because
it results in unnecessary wastage of material and heavy selection, low factor of safety results in
unnecessary risk of failure. It has high strength, low coefficient of thermal expansion. The
material of the plates to be cut and drill are taken as copper and plastic as they are replacing many
metals in the present scenario because of their distinguished properties and features.
8.1 Metallurgical Specification:
The machine is basically made up of mild steel.
Reasons
1. Mild steel is readily available in market.
2. It is economical to use.
3. It is available in standard sizes.
4. It has good mechanical properties i.e. it is easily machinable.
5. It has moderate factor of safety, because factor of safety results in unnecessary wastage of
material and heavy selection. Low factor of safety results in unnecessary risk of failure.
6. It has high tensile strength.
7. Low co-efficient of thermal expansion.

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8.2 Properties of Mild Steel
M.S. has carbon content from 0.15% to 0.30%. They are easily wieldable thus can be hardened
only. They are similar to wrought iron in properties. Both ultimate tensile and compressive
strength of these steel increases with increasing carbon content. They can be easily gas welded
or electric or arc welded. With increase in the carbon percentage weld ability decreases. Mild
steel serve the purpose and was hence was selected because of the above purpose.
8.3 Approach to mechanical design of system
In design the of parts we shall adopt the following approach;
Selection of appropriate material
 Assuming an appropriate dimension as per system design.
 Design check for failure of component under any possible system of forces.
8.4 Mechanical design
In mechanical design the components are listed down and stored on the basis of their procurement
in two categories.
1. Design parts
2. Parts to be purchased.
For designed parts detailed design is done and dimensions there obtained are compared to next
dimensions which are already available in market. This simplifies the assembly as well as the
post production and maintenance work. The various tolerances on work are specified. The
process charts are prepared and passed to manufacturing stage. The parts to be purchased directly
are selected from various catalogues and are specified so as to have case of procurement. In
mechanical design at the first stage selection of appropriate material for the part to be designed
for specific application is done. This selection is based on standard catalogues or data books; eg:-
( PSG DESIGN DATA BOOKS ) ( SKF BEARING CATALOGUE ) etc.
8.5 Motor Selection
Thus selecting a motor of the following specifications
Let us assume the force to be required for carrying the load of Car assume

30
2000kg =19620 N = 20000 N
Length of car = 4.5 m
Width of car = 1.85 m
Length of conveyer belt = 24 m
So that power will transmitted by Chain drive having motor sprocket dia.75 mm.
Radiu of sprocket = 37.5mm.
Torque T = F x R
= 20000 x 37.5
= 750000 Nmm.
T = 750 Nm
Thus selecting a motor of the following specifications.
P = 2 П N T
60
2 П X 40 X 750
60
P = 3141.59 Watt.
P = 3.14159 KW.
P = 4.211 HP
We Select:
1. AC motor
2. Power = 5 HP
3. Speed= 40 rpm

31
8.6 Design of Chain Drive
(V.B. Bhandari, DME Book. Third edition, p.no.550, 551) (Table 14.2, 14.6)
Let speed of sprocket is 40 rpm. The driving sprocket is mounted on the same shaft of motor so
that,
Speed of driving sprocket N1 = 40 rpm
Speed of driven sprocket N2 = 40 rpm
Dia. of driving sprocket d1 = 75 mm
Dia. of driven sprocket d2 = 75 mm.
No. teeth on driving Z1 = 18
No. teeth on driven sprocket Z2= 18
Let, Ks = Service factor = 1.3 (Table 14.3)
K1 = Multiple strand factor = 1 (Table 14.4)
K2 = Tooth correction factor = 1.05 (Table 14.5)
Power P = 4.06 Kw For Maximum pinion speed 100 RPM.
Power rating of chain Kw =
𝑃𝑜𝑤𝑒𝑟 𝐾𝑤 𝑥 𝐾𝑠
𝐾1 𝑥 𝐾2
, Kw = 3.88
Let us we select simple roller chain having maximum speed 100 rpm is 16A
From table 14.1 dimensions of roller chain P.No. 547. Pitch P = 25.4 mm.
Pitch circle diameter D1 = D2 =
𝑃𝑖𝑡𝑐ℎ
𝑆𝑖𝑛
180
𝑍
=
25.4
𝑆𝑖𝑛
180
18
= 146.27 mm. = 150 mm.
Center distance between two sprockets a = 24 mtr. = 24000 mm.
No. of links on chain
Ln = 2 (
𝑎
𝑝
) + (
𝑍1+𝑍2
2
) + (
𝑍1− 𝑍2
2𝜋
)
2
x (
𝑝
𝑎
)

32
= 2 (
24000
25.4
) + (
18 + 18
2
) + (
18 − 18
2𝜋
)
2
x (
25.4
24000
)
Ln = 1907.76 Links.
Ln = 1910 Links Nos.
Corrected center distance (a) :-
a = (
𝑝
4
) { [ Ln - (
𝑍1+𝑍2
2
)] + √[ Ln − (
𝑍1+𝑍2
2
)]2 − 8(
𝑍2− 𝑍1
2𝜋
)2}
a = (
25.4
4
) { [ 1910- (
18+18
2
)] + √[ 1910 − (
18+18
2
)]2 − 8(
18− 18
2𝜋
)2}
a = 24066.24 mm.
a = 24.06 m.
8.7 Shaft design
To find diameter of shaft by ASME code
For commercial steel shaft C40, PSG DDB.1.9
Sut = 680 mpa.
Actual shear stress τact =
𝑆𝑢𝑡
2 𝑥 𝐹𝑂𝑆
=
680
2 𝑥 2
= 170 N/mm2
T = /16 x τact xd3
750000 = /16 x 170 xd3
d=28.218 mm select d= 30 mm
8.8 Bearing selection
As shaft dia. – is 30 mm so we have selection a ball bearing having shaft outer dia. – 30 mm.
Selection of shaft ball bearing
In selection of ball bearing the main governing factor is the system design of the drive i.e.; the
size of the ball bearing is of major importance; hence we shall first select an appropriate ball
bearing. Taking into consideration convenience of mounting of ball bearing.

33
Total radial load on eight bearings are = 20000 N
Load on each bearing Assume = 2500 N
Equivalent dynamic load
Pe = V.Fr.Ka
= 1 X 2500 X 1
Pe = 2500 N
bearing life is,
L10 =
𝐋𝐡𝟏𝟎 𝐗 𝟔𝟎 𝐗 𝐧
𝟏𝟎𝟔
Lh10 from graph 4.6 PSG Design data book for 13000 rpm maximum speed of ball bearing is
160000 Hours. For bearing No. 6206.
L10 =
𝟏𝟔𝟎𝟎𝟎𝟎 𝐗 𝟔𝟎 𝐗 𝟒𝟎
𝟏𝟎𝟔
L10 = 384 millions of revolutions.
L10
= (
C
Pe
)(
10
3
)
C = (L10)(
10
3
)
X Pe
C =(384)(0.33)
X 2500
C = 18171.20 N. ≥ 15300 N (Not Feasible.)
C = 18171.20 N. ≤ 22000 N (feasible)
Select bearing No.6306. PSG Design data book P.No. 4.14.

34
9. ADVANTAGES
 Diminish manual power.
 Proper exploitation of foam and water.
 Less amount of water is required.
 Pollution free.
 Easily operated system.
 Consumption of time is less in washing

35
10. FABRICATION OF SETUP
Fig.10.1 Frame Making
Fig.10.2 Bearing Mounting

36
Fig.10.3 Drilling of Pulley
Fig.10.4 Bush Making

37
Fig.10.5 Conveyor Belt Mounting
Fig.10.6 Mounting of stations

38
11. PROGRAM
#include <Wire.h>
#include <LiquidCrystal_I2C.h>
LiquidCrystal_I2C lcd(0x27,20,4); // set the LCD address to 0x27 for a 16 chars and 2 line
display
int sen1 = 2;
int sen2 = 3;
int sen3 = 4;
int sen4 = 5;
int relay1 = 6;
int relay2 = 7;
int relay3 = 8;
int relay4 = 9;
void setup() {
serial.begin(9600);
lcd.init();
// initialize the lcd
lcd.init();
// Print a message to the LCD.
lcd.backlight();
pinMode(sen1,INPUT);

39
pinMode(relay1, OUTPUT);
digitalWrite(relay1,HIGH);
// put your setup code here, to run once:
lcd.setCursor(1,0);
lcd.print("Car Wash System");
}
void loop() {
int s1 = digitalRead(sen1);
Serial.println(s1);

40
Serial.println(s2);
Serial.println(s3);
Serial.println(s4);
if(s1 == LOW && s2 == HIGH && s3 == HIGH && s4 == HIGH){
digitalWrite(relay1,LOW);
lcd.setCursor(1,1);
lcd.print("Car Washing");
}else if(s1 == HIGH && s2 == LOW && s3 == HIGH && s4 == HIGH){
lcd.clear();
lcd.setCursor(1,1);
lcd.print("Car Scrobing");
}else if(s1 == HIGH && s2 == HIGH && s3 == LOW && s4 == HIGH){

41
lcd.clear();
lcd.setCursor(1,1);
lcd.print("Car Washing Clear");
}else if(s1 == HIGH && s2 == HIGH && s3 == HIGH && s4 == LOW){
lcd.clear();
lcd.setCursor(1,1);
lcd.print("Car Drying");
}
}

42
12. COST ANALYSIS OF PROTOTYPE
Sr. No. Components Quantity Total Cost (Rs.)
1 Arduino 1 325
2 PR sensor 4 2000
3 DC motor 1 1500
4 Conveyor Belt 1 600
5 Dryer (fan) 1 210
6 Tanks 3 150
7 Relay 4 300
8 Car 1 150
9 Tube - 300
10 Angle - 1500
11 Other - 1500
Total cost required for the implementation of Aurdino Based Automatic Car Wash System is
Rs. 9000/-

43
13. 3D MODELING OF AUTOMATIC CAR WASHING SYSTEM
Fig.13.1 Top View
Fig.13.2 Front View
Fig.13.2 Side View

44
14. RESULT
In automatic Car Washing system, We performed all the operations needed to clean the car
fruitfully by using PLC after achievement of above processes by mechanism of this system car
washing will be cost effective, time saving and pollution free. By using this process we can clean
up the car up 95%.

45
15. CONCLUSION
This prototype will help to perform car washing automatically results in high quality end product.
Thus it will be User-friendly and capable to wash multiple cars at a time. Also require less man
power, time and no pollution. The prototype was designed and modified the following changes
such as applying soap and water simultaneously and it will go automatically to the scrubbing.
Thus making the job easier and less tedious for the user. The prototype made in 3d CAD model
of CATIA.

46
DECLARATION
We undersigned, hereby declare that we have completed the project report entitled
“Design of Automatic car washing system and construct prototype” on our own. This is our
original work and it was not previously submitted for the award of any degree or any diploma or
similar title in any other examining body or university as per our knowledge.
Roll
No.
Name of student University Seat No. Signature
06 Mr. Bagul Vinay Pradeep B150860805
13 Mr. Chaudhari Pratik Samadhan B150860807
14 Mr. Chaure Rahul Sampat B150860808
15 Mr. Chole Sachin Vilas B150860809

Design of Automatic Car Washing System and Construct Prototype.pdf

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