Metered Dispensing System

Abstract

An improved flow rate metering device that provides for the mixing and dispensing of two or more fluids to form final mixture, for example, for automatic washing of cars and trucks. More specifically, the invention is a system that mixes and ejects chemicals, creating a very precise mixture of one or more chemicals with a dilutant, such as water. The device also has the capability of monitoring an entire chemical dilution and release system, comprising multiple chemicals, and using software to document past and current usage rates, along with predicting future usage rates based upon both past usage rates and environmental conditions.

Claims

1. A device for mixing and delivering products, consisting of a programmable logic controller (PLC), a local database, a cloud database, a power source, a smart metering device, and an internet connection, where the smart metering device consist of a water control valve, a chemical control valve and an air control valve, where the programmable logic controller (PLC) sends a signal to the smart metering device, where the signal comprises a plurality of wash figures relating to a chemical signal, a wash package signal, and a wash counter signal, where the smart metering device analyzes the chemical signal, the wash package signal and the wash counter signal, and sends a cloud database signal to the cloud database, and adjust a plurality of valve controls for the water control valve, the chemical control valve and the air control valve, where the programmable logic controller (PLC) monitors a tank level for each of a plurality of tanks and ambient temperature inside a mechanical room or wash bay, where the smart metering device monitors a quantify of water from the water control value, a quantity of chemical from the chemical control valve and a quantity of air from the air control valve into a quantity of car wash liquid, where the quantity of car wash liquid is directed onto a car at a carwash.

2. The device of claim 1, where the Smart metering device comprises the water control valve, the chemical control valve and the air control valve for each single channel.

3. The device of claim 1, where the device relates to the cleaning of a plurality of cars in a carwash, where the device additionally comprises volumetric pump, where the volumetric pump is used for each separate channel to control and regulate a chemical pressure delivered to the chemical control valve.

4. The device of claim 1, where the device additionally comprises an additional air control valve, where the additional air control valve receives an activation signal from the smart metering device when prompted from a site controller to activate and send compressed air to the volumetric pump to apply a set amount of pressure required in each run time during the wash.

5. The device of claim 1, where the device additionally comprises a plurality of monitoring probes, where each of the plurality of monitoring probes measures the tank levels, where the tank levels are transmitted to the cloud database, where the smart metering device receives the tank levels from the cloud database and estimates a number of car washes remaining for a particular chemical for a particular type of the car wash.

6. The device of claim 1, where the programmable logic controller (PLC) determines an amount of the chemical used by calculating the number of times the chemical control valve has opened, and closed, further based on the ambient temperature inside the mechanical room or the wash bay, and an air pressure of the volumetric pump, and a pre-determined formula table.

7. The device of claim 1, where the programmable logic controller (PLC) calculates data from all connected sensors, the chemical signals, the wash package, and the wash counter and puts these into a user-friendly Graphical User Interface (GUI), where a user can monitor, setup, change, and receive alerts remotely through the internet connection.

8. The device of claim 1, further comprising a pressure transducer that reads data of water pressure from a bladder pump/a city water connection and sends the data to the programmable logic controller (PLC) about a constant line pressure and also recognizes any variances in the water pressure.

9. The device of claim 1, where the programmable logic controller (PLC) emits output signals to control on/off wash cycles of the chemical control valve allowing the quantity of chemical to be introduced and mixed with water.

10. The device of claim 1, where the programmable logic controller (PLC) controls the chemical signal, the wash package, and the wash counter to control on/off wash cycles, further calculates a total flow by a number of times a chemical valve is turned on and turned off during the wash cycles, and tracks a number of cars and types of car wash during the wash cycles and/or in a day.

11. A device for mixing and delivering products, comprising a programmable logic controller (PLC), a local database, a cloud database, a power source, a smart metering device, and an internet connection, where the smart metering device comprises of a water control valve, a chemical control valve and an air control valve, where the programmable logic controller (PLC) sends a signal to the smart metering device, where the signal comprises a plurality of wash figures relating to a chemical signal, a wash package signal, and a wash counter signal, where the smart metering device analyzes the chemical signal, the wash package signal and the wash counter signal, and sends a cloud database signal to the cloud database, and adjust a plurality of valve controls for the water control valve, the chemical control valve and the air control valve, where the programmable logic controller (PLC) monitors tank level for each of a plurality of tanks and ambient temperature inside a mechanical room or wash bay, where the smart metering device monitors a quantify of water from the water control value, a quantity of chemical from the chemical control valve and a quantity of air from the air control valve into a quantity of car wash liquid, where the quantity of car wash liquid is directed onto a car at a carwash.

12. The device of claim 11, where the device additionally comprises a plurality of monitoring probes, where each of the plurality of monitoring probes measures the tank levels, where the tank levels are transmitted to the cloud database, where the smart metering device receives the tank levels from the cloud database, and estimates a number of car washes remaining for a particular chemical for a particular type of car wash.

13. The device of claim 11, where the programmable logic controller (PLC) determines the amount of the chemical used by calculating the number of times the chemical control valve has opened, and closed, further based on the ambient temperature inside the mechanical room or the wash bay, and an air pressure of the volumetric pump, and a pre-determined formula table.

14. The device of claim 11, where the programmable logic controller (PLC) calculates data from all connected sensors, the chemical signals, chemical run package selections, and “end of chemical run” signals and puts these into a user-friendly Graphical User Interface (GUI), where a user can monitor, setup, change, and receive alerts remotely through the established Internet connection.

15. The device of claim 11, further comprising a pressure transducer that reads water pressure from a bladder pump/a city water connection and sends the data to the programmable logic controller (PLC) about a constant line pressure and also recognizes any variances in the water pressure.

16. The device of claim 11, where the programmable logic controller (PLC) emits output signals to control on/off wash cycle of the chemical control valve allowing a drop of chemical to be introduced and mixed with water.

17. The device of claim 11, where in the carwash, the programmable logic controller (PLC) controls the chemical signal, the wash package, and the wash counter to control on/off the cycles, further calculates a total flow by a number of times a chemical valve is turned on and turned off during the wash cycles, and tracks a number of cars and types of car wash during the wash cycles and/or in a day.

18. A device for mixing and delivering products, comprising a programmable logic controller (PLC), a local database, a cloud database, a power source, a smart metering device, and an internet connection, where the smart metering device consist of a water control valve, a chemical control valve and an air control valve, where the programmable logic controller (PLC) monitors tank level for each of a plurality of tanks, and ambient temperature inside a mechanical room or wash bay, where the smart metering device monitors a quantify of water from the water control value, a quantity of chemical from the chemical control valve and a quantity of air from the air control valve into a quantity of car wash liquid.

19. The device of claim 18, where the device additionally comprises a plurality of monitoring probes, where each of the plurality of monitoring probes measures the tank levels, where the tank levels are transmitted to the cloud database, where the smart metering device receives the tank levels from the cloud database, and estimates a number of car washes remaining for a particular chemical for a particular type of car wash.

20. The device of claim 18, where the programmable logic controller (PLC) determines an amount of the chemical used by calculating the number of times the chemical control valve has opened, and closed, further based on the ambient temperature inside the mechanical room or the wash bay, and air pressure of the volumetric pump, and a pre-determined formula table.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0026] FIG. 1 is a flowchart showing the assembly of the various components into the final product, and how this assembly is monitored.

[0027] FIG. 2 is a flowchart showing the relationship between the various water and product control valves, air valves and the final spray arches, along with the process of the systems basic operation

[0028] One preferred form of the invention will now be described with reference to the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:

[0029] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in a computer-readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.

DETAILED DESCRIPTION OF THE FIGURES

[0030] Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0031] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the number of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0032] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.

[0033] In the present document, the word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0034] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[0035] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the tennis “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.

[0036] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

[0037] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the Page 12 of 19 art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0038] FIG. 1 is a flowchart showing the assembly of the various components into the final product, and how this assembly is monitored. At the carwash, there is an equipment controller that controls the product activation signal(s), the wash package, and the wash counter, which keeps track of how many of what type of car washes have occurred that day. The Smart iMeter couples with the signals from the carwash controller to initiate the product “run” signals to control the water control valve, the product control valve, and the air control valve. The history of adjustments made to these devices are then stored in the cloud.

[0039] With respect to controlling the product dispensing, the Smart iMeter causes the water control valve, the product control valve, and the air control valve to affect the production of one or more products for the Water and product Arch and the Air for Arch. The arch is a customer-supplied piece of equipment, usually a metal arch that has a series of nozzles imbedded into it. These nozzles are what sprays the product(s)/mixture(s) onto the car.

[0040] FIG. 2 is a flowchart showing the relationship between the various control valves. The supplied city water connection is stabilized by the bladder pump. Water can be obtained from city water supplies or well water. A pressure transducer reads the water pressure from the bladder pump/city water connection and sends the data to the programmable logic controller (PLC). The software component of the invention recognizes any variances in pressure.

[0041] The supplied form of compressed air is used for the volumetric chemical pump and used for “foaming” the product and water components into a foam when it is applied to the car. The control motor controls how much PSI or air flow is needed to make the product more or less foaming. Product pump pressure is produced and mainlined through a proprietary volumetric pump that uses a piston to exert the proper pressure needed for the chemical to enter the mixture manifold via the product control valve.

[0042] The product pressure pump is preset and maintained, in a preferred embodiment of the invention, at determined psi. This pressure is then maintained for the duration of the “run” signal. Using a series of check valves, the pump is able to “push out” the chemical, and “pull in” the chemical to refill the volumetric pump without disrupting the general operation. A chemical control valve that has been properly sized for functionality in this invention regulates release of the product(s).

[0043] The PLC emits output pulses to control an on/off cycle of the product control valve allowing a drop of product to be introduced into the manifold and mixed with water. The total flow of the product squirted is calculated by how many cycles the valve turned on and off during the product run time from the wash controller.

[0044] The air pressure to the control motor is controlled by the PLC and can be adjusted by the user. Air is dispensed directly to the arch manifold. An air pressure transducer installed on the incoming air pressure line notifies the system if a loss in pressure occurs.

[0045] The size of the water control valve is determined from the arch properties, such as the number of nozzles, flow rate of each nozzle, size of arch pipes, size of delivery tubing, length of run, etc. The nominal output GPM is 2-15@15-60 psi. Multiple water and product distribution blocks are connected for single product use. Different blocks are setup in the same fashion for other applications.

[0046] Ambient temperature inside mechanical room or wash bay (wherever the dispensing unit is located) is monitored and measured. An algorithm determines product viscosity per degree of temperature change and uses the data from a formula table developed in house that encompasses the volumetric pump pressure setting.

[0047] The PLC controller receives one or more product demand signals from the carwash controller. A system of events then initiates the water and product control valves, controlling the water control valve the air to mix with the product(s). The software contains a page for parameter setup for the product control valve flow rate. On/off cycles build a usage report for that product used.

[0048] It should be noted that the present disclosure is not restricted to be used with a single vehicle-wash bay. Indeed, it is anticipated that the present disclosure will be used in conjunction with multiple vehicle-wash bays, wherein the variation of demand might be even greater and wherein the need for and desirability of the present inventive apparatus and method will be even greater.

[0049] The inventive system and device 100 and associated method for metering quantity of fluid supplied through the device 100 are intended to be widely used in the vehicle wash industry. In particular, the present disclosure is particularly applicable to vehicle washes, wherein a great quantity of fluid is used and, thus, it is extremely important to keep the ratio of product to water solvent at an ideal proportion. It should be noted that the method and device proposed herein will work with almost any viscosity of product/product/fluid, and that the method and device can be adapted for use with a great variety of vehicle-washing facilities.

[0050] All of the above are only some of the examples of available embodiments of the present disclosure. Those skilled in the art will readily observe that numerous other modifications and alterations may be made without departing from the spirit and scope of the present disclosure. For example, the present disclosure may be used in systems other than vehicle-washing systems, such as conveyor-type vehicle wash systems, drive-through wash systems, or other types of stationary, variable demand spray-wash systems. Accordingly, the disclosure herein is not intended as limiting and the appended claims are to be interpreted as encompassing the entire scope of the invention.

[0051] While the foregoing describes various embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The present disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the present disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

[0052] All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.