A PROTOTYPE PLC BUILT AUTOMATIC VEHICLE WASHING SYSTEM USING VFD

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 10, October 2019, pp. 206-216, Article ID: IJMET_10_10_019
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=10
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
A PROTOTYPE PLC BUILT AUTOMATIC
VEHICLE WASHING SYSTEM USING VFD
Arowolo, Matthew Oluwole*; Adekunle Adefemi A;
Martins Oluwaseun and Abiodun Adebimpe
Department of Mechatronics Engineering, Federal University Oye-Ekiti Ekiti State, Nigeria.
*Correspondence: E-mail: arowolo.oluwole@fuoye.edu.ng
ABSTRACT
Sustained infrastructural development in this modern era leaves vehicle surface
exposed daily to grime. Although manual vehicle washing has been in existence since
vehicle invention, it is arduous, time consuming and uses water excessively. This is not
to mention petite abrasion and rapid loss of vehicle surface brilliance with manual
vehicle washing. Automatic vehicle washing industry has improved from it first
innovation in the twilight of 1930’s through advancement in technology, the system is
more reliable and efficient. This paper’s emphasis is on the development of a scalable
prototype exterior automatic vehicle washing system. The system is built around a
Logo Zelio (SR3B261BD) PLC for inputs and output components control. VFD
moderates the conveyor belt motor speed as required for it smooth operation. Water
recirculation system is incorporated for water and detergent economy. The status
lamp on the control panel informs the user of the instantaneous stages of operation
and control of the entire system. Experimentation of the system presents an efficient
washing process between work station and minimal water and detergent usage with
the incorporated recirculation system. Application of control panel for monitoring and
control enhance the cost effectiveness of this system compared to it SCADA
counterpart. In the future, the authors will like to integrate dust particle detection
sensor for improved surface cleaning.
Keywords: automatic vehicle washing system, PLC, sensor, ladder logic
Cite this Article: Arowolo, Matthew Oluwole; Adekunle Adefemi A; Martins
Oluwaseun and Abiodun Adebimpe, A Prototype PLC Built Automatic Vehicle
Washing System Using VFD. International Journal of Mechanical Engineering and
Technology 10(10), 2019, pp. 206-216.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=10
1. INTRODUCTION
Sustained infrastructural development in this modern era leaves vehicle surface exposed daily
to grime. Although manual vehicle washing has been in existence since vehicle invention, it is
arduous, time consuming and uses water excessively (May et al., 2019). This is not to
mention petite abrasion and rapid loss of vehicle surface brilliance with manual vehicle
washing (Gaikwad et al., 2017). Automation relief humans of physical contact and sensory

A Prototype PLC Built Automatic Vehicle Washing System Using VFD
input toward the target process (Sorkhabi and Khazini, 2013). Hence, the advancement in
technology has improved significantly the reliability and efficiency of vehicle washing
through automation of the process. Automatic vehicle washing industry has improved from it
first innovation in the twilight of 1930’s (Meena et al., 2017) to the programmable logic
controller (PLC) vehicle washing system in the twenty first century. PLCs are a unique class
of microprocessor-built controller integrated with programmable memory for instruction
storage with logical, sequential, timing, counting and arithmetic function implementation
(Bolton, 2006). The outcome is the control of machines via pre-stored program. Automatic
vehicle washing system work station comprise of the; showery down, foaming, washing,
rinsing and drying. In this project, the authors adopted the cyclic process presented by Rana et
al (2017) for it 90 percent cleaning aftermath. Automatic vehicle washing system are complex
and expensive system; since they combine PLC and supervisory control and data acquisition
(SCADA). Hence, they are found in developed countries and in public locations. The
objective of this paper however, is to develop a scalable protoype automatic vehicle washing
system. Affordable for industrial applicaion even in developing countries and private
application by minimizing the component list for cost reduction. This system is intergrated
with water recirculation system for water economy and evironmental protection. Also the
authors replaced the SCADA with control panel which comprise of status lamps; this informs
the user of the instantaneous stages of operation and control of the whole system.
1.1. Related works
Shaikh et al (2019); Lalluwadia et al (2017); Gaikwad et al (2017) presented an automatic
vehicle washing system controlled by PLC with SCADA. The system is based on the cyclic
process for effective cleaning. However, water recirculation was not incorporated; thus
leading to excessive water usage. Although the system is effectual, the combination of PLC
and SCADA increases the cost of production significantly particularly in developing
countries. Sorkhabi and Khazini (2013); Meena et al (2017) proposed an automatic vehicle
washing system using PLC. The authors addressed the system cost of production by reducing
required hardware components. However, water recirculation was not integrated for water
management. May et al (2019) described hardware and software simulation of an automatic
vehicle washing system with Mitsubishi (FX 2N-25MR) PLC. System experimentation
explained it efficacy. Nevertheless, lack of water recirculation increases water usage and
environmental pollution. Also, authors did not present incorporation of SCADA or control
panel for system operations remote monitoring. Vidyasagar et al (2015) proposed the concept
of automatic vehicle washing with PLC and RFID-GSM platform for operation completion
status notification to the user. Authors focus is on hardware components reduction to achieve
cost requirement objective. This was done by adapting existing GSM technology for finish
operation status communication to the user. Tryouts revealed model practicability,
nonetheless, water recirculation with instantaneous operation status notification is equally
important for system operation optimization. PIC 16F778A microcontroller was used to
control the vehicle washing system. Utekar et al (2015) developed an automatic vehicle
washing system with two robotic arms. The arms were replacement of the twin rotary brushes
of the conventional automatic vehicle washing system. A Graphical User Interface (GUI) was
developed on a PC to control the system. Inputs form the GUI is transmitted via a USB to
UART converter to the microcontroller. Water usage was monitored by the vehicle profile
detection using an IR sensor and interfacing the output with the water nozzle. Nozzle is kept
open while output is available from the IR sensor. Although their model is promising for
more effective cleaning, however, the application of robotic arms becomes a crucial cost
component. Zhong, et al (2017) introduced the concept of Internet of Things (IoT) and big
data to automatic vehicle washing system. The vehicle wash cloud and terminal interface was

Arowolo, Matthew Oluwole; Adekunle Adefemi A; Martins Oluwaseun and Abiodun Adebimpe
created using IoT and big data. This built a synergy of cloud operators, vehicle washing
shops, vehicle washer manufacturers and customers. Their system is based on customer
feedback on service delivery in using any of their automatic vehicle washing outlets. This
platform is based on Linux operating system, which is a stable multi user network operating
system. This architecture is divided into 5 layers: data layer, data access layer, services layer,
authorization and access control layer and application layer. The data layer uses an open
source MySQL database that can be distributed or clustered according to performance
requirements. Mhaske et al (2016) used Wecon PLC module for automatic control of a
vehicle washing system prototype. PLC was interfaced with the PC via RS-232
correspondence link for downloading or transferring program of the system. The system is
compact and adaptable for private applications, but, water recirculation with instantaneous
operation status notification is not incorporated. Akilandeswari et al (2014) integrated a PLC
with GSM modem in an automatic vehicle washing system. Status information such as
vehicle entry/exit and emergency stops is sent to operator and customer via SMS through the
GSM-PLC plathform. Similarly, the control of the system is achieved through SMS.
HORNER PLC was connected to the PC through a RS-232 communication cable for
downloading or uploading the program. System hardware is reduced base on PLC-GSM
platform application leading to cost reduction. Conversely, GSM is network based system;
inadequacy of such services by network providers will affect the practicability of the proposed
method. Therefore, development of practicable automatic vehicle washing system with
minimal hardware component for marginal cost objective actualization; notwithstanding
demands the complement of a water recirculation system with a real-time operation status
notification and control. This is the area the authors aim to address in this paper.
2. MATERIALS AND METHODS
2.1. Hardware implementation
Circuit diagram of this system is presented in figure 1. The system is built around Logo Zelio
(SR3B261BD) PLC, this is the nucleus of this system. This PLC controls the systems input
and output component operations. From figure 1, A 220 AC source voltage is coupled to a
Miniature Current Circuit Breaker (MCCB) for effective electrical power control. A power
supply module converts the 220 AC source voltage from the MCCB to 24 V DC, because
PLC operates on 24 V DC. Digital or analog input and output components are connected to
the PLC through the terminal block and address. The transport conveyor is driven with an AC
motor; this convey the vehicle through the system work stations. A variable frequency drive
(VFD) is used to regulate the speed of the AC motor via it frequency from 60 Hz to 14 Hz.
The motor is powered by the 220 V AC, control panel, pump, relays, inductive sensor are
powered by the 24 V DC. Control and monitoring of the system’s operation is achieved by an
operator through the control panel. The panel in figure 2, operator control the system’s
operation via the green, small red and large red push buttons; to start operation, end operation
and emergency stop respectively. Status lamp; green, amber and red on the control panel
informs the operation of the system; start, washing and stop instantaneous work stations.

Figure 1 Circuit diagram
Figure 2 Control panel

2.2. System flowchart
Figure 3 and 4 presents the flowchart of the automatic vehicle washing system showing the
sequence of the process and the systems block diagram respectively.
Figure 3 System flowchart
Figure 4 System block diagram
2.3. System operation
With the vehicle parked on the transport conveyor, a capacitive proximity sensor at this entry
point detects the presence of the vehicle. This gives an output that energize the AC motor to
drive the conveyor leading the vehicle into the washing tunnel. Vehicle reaches the showery
down/foaming stage. A proximity sensor at this stage detects the vehicle, energizes a solenoid
pump to discharge water and foaming water over the vehicle. This stage spans for 15 sec. The
off-delay timer arrangement stops the solenoid pump. A proximity sensor at the washing stage
detects the vehicle, energize the twin cotton brush to commence the exterior brushing of the
already lather laden vehicle. This continues for a period of 10 sec. Then the off-delay timer
deactivates the cotton brushes. Conveyor moves the vehicle to the rinsing stage. Here another
proximity sensor detects the vehicle and energizes the solenoid pump to discharge water on

the vehicle for rinsing for 10 sec. the pump is de-energized via the off-delay timing
instruction. Conveyor moves the vehicle till it is detection by the drying stage proximity
sensor. This detection activates the twin fans on the side of the tunnel for 20 sec. this dry’s the
vehicle. This fans are deactivated after the specified time by off-delay timing arrangement.
The conveyor moves the vehicle to the terminal of the tunnel for finish operation and the
cycle is repeated for the succeeding vehicle. Table 1 and 2 below presents the input and
output components of the system.
Table 1. Input components
S/N Input Address Tag no
1 Start Push button I 0.1 Activate the operation
2 Stop push button I 0.2 Stop the operation
3 Capacitive sensor
1
I 0.3 Capacitive sensor for
brushing
4 Capacitive sensor
2
rinsing
5 Capacitive sensor
3
drying
Table 2. Output components
S/N Output Address Tag no
1 Green LED Q 4.0 Indicate washing process
2 Motor Q 4.1 Energize the conveyor
3 Yellow
LED
Q 4.2 Energize the conveyor light
4 Brush Q 4.3 Activate the brush
5 Pump 1 Q 4.4 Activate the pump
6 Pump 2 Q 4.5 Energize the rinse water
7 Fan Q 4.6 Activate the dryer and exit
section
8 Pump 3 Q 4.7 Recycling pump
2.4. Water recirculation
Beneath the conveyor is a water recirculation tank. Every liquid discharged on the vehicle
drips on the conveyor and flows into the tank underneath. This tank has two compartment
separated by a strainer. The used liquids are collected in the first compartment and strained as
it flows to the second compartment. This prevents the dirt’s passage into the second
compartment. The water in the second compartment is lifted with a solenoid pump into the
foaming water tank. This reduce the volume of water and detergent required to make lather
for succeeding wash. Hence, water and detergent economy is achieved.
2.5. System simulation
Ladder logic is one of the methods of programing a PLC (Bolton, 2006). Therefore, for
simplicity, it is adopted in this work. Simulation has been explained to be very crucial for
evaluation of a proposed real-world system (Martins et al., 2013). Thus, simulation of the
ladder diagram of the Logo Zelio (SR3B261BD) PLC is presented in the subsequent figures.

Figure 5 Start simulation
Form figure 5; first rung of the ladder, I0.1 is a normally open contact (NOC), I0.2 is a
normally closed contact (NCC). Q4.0 is the output on this rung and it is latched with I0.1.
when the push button I0.1 is pressed, it energizes Q4.0 and it stays energized through the
latched arrangement.
Figure 6 Start conveyor
The second rung in figure 6 shows input I0.1 and Q4.0 as NOC, timer T0 as NCC, with
output Q4.1 and Q4.2 latched together. Q4.0 energizes Q4.1 and Q4.2

Figure 7 Washing operation
The third rung in figure 7 presents inputs Q4.0 and I0.3 (proximity sensor) as NOC with
outputs Q4.3, Q4.4 and Q4.7 latched together to be energized by single input. When I0.3
changes state due vehicle detection all outputs are energized.
Figure 8 Rinsing stage
The forth rung in figure 8 shows inputs Q4.0 and I0.4 (proximity sensor) as NOC with
outputs Q4.5 and Q4.7 latched together. Sensor I0.4 detects the presence of the vehicle in the
rinsing stage and changes state. This energizes the outputs on this rung.

Figure 9 Drying and exit stage
This is the fifth rung, Q4.0 and I0.5 (proximity sensor) are NOC inputs and the timer reset
register with Q4.6 as outputs. Vehicle detection by I0.5 in the drying stage changes the state
of this contact. This energizes the output accordingly.
Figure 10 shows the implementation of the prototype.
Figure 10 Prototype implementation
3. CONCLUSION
Deduction from the simulation and prototype implementation of the proposed automatic
vehicle washing system is that; adoption of control panel with status lamp for operation
monitoring and control of the entire system makes this system cost effective in relation to it
SCADA counterpart. Also, the integrated water recirculation improve it water and detergent
economy, hence, applicable where water economy and soil protection is paramount. These
facts will increase the demand and implementation of this design for public and private
applications. In this work, authors built the system control around the Logo Zelio

(SR3B261BD) PLC. PLCs are capable of controlling complex system with simple program as
presented in our simulation. Compared with other microcontrollers, PLC programming
languages are rather simpler to comprehend effectively. Although there are several
programming languages for PLC, but in this work we adopted the ladder logic. The
simulation with the ladder diagram presents the practicability of the system. Authors use VFD
for speed control of the conveyor motor to show the possibility of using AC motor compared
to the DC motor found in literature. Meanwhile, the practical implementation might not
express the esthetics of the real-world design, however, it presents it viability and scalability.
In the future, integration of dust particle detection sensor will enhance the surface cleaning of
the system.
ACKNOWLEDGEMENT
The authors will like to appreciate Federal University Oye-Ekiti and the Department of
Mechatronics Engineering for the teamwork. Also, we are thankful to TIJANI, Y. O and
HUNPE, M. E for technical inputs during the practical implementation.
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