DESIGN OF CAR WASHING MACHINE

INDUSTRIAL DESIGN PROJECT REPORT

Supervisor:PROF. B.B.L.V. DEEPAK

PROFESSORDEPT. OF INDUSTRIAL DESIGN

NIT ROURKELA

Submitted By:PRATIK SHUBHANKAR

Roll. No: 111ID0489PARINAV

Roll. No: 110ID0534ABHINAV KUMAR

Roll. No. 111ID0470ANSH MAHIL

Roll. No. 111ID0573ASUTOSH SAHOO

Roll. No. 111ID0274DEPT. OF INDUSTRIAL DESIGN

NIT ROURKELA

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ACKNOWLEDGEMENT

This project was not possible without the continued support ofa number of people. In the very beginning we would like tothank our advisor, Prof. B.B.L.V DEEPAK who at each and everystep provided us with proper guidance, advice, encouragementand taught us various important concepts. Then, we would alsolike to convey our sincere thanks to Prof. B.B BISWAL, HOD,Department Of Industrial Design for providing us thefacilities and equipment’s in CAD and PRODUCT DEVELOPMENT LAB.Along with them the contribution of PhD and M.Tech scholarscannot be neglected who guided us and showed us way toovercome our problems. Lastly we would also like to thank someof the users who operated those car washers as their help andexperience of using the machine helped us largely to bringrequired modifications.

With sincere regards,

ABHINAV KUMAR PARINAV

PRATIK SHUBHANKAR

ASUTOSH SAHOO &

ANSHMAHIL

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ABSTRACT

The car washing machine is a widely used machine for washingcars, even bikes sometimes without much of manual load. Avariety of car washer machines and techniques exist today beit the completely automated tunnel washes or machines operatedby user. Though the hand operated machines mostly focusses onspraying the water and in some cases the soap solution to thecar body, and the user has to use his other hand to squeezeand soak the solution using a sponge which makes the worktedious. This report is focussed on the study and design of acar washing machine which will have separate tanks forspraying the water and soap solution in the same machine andit will also have an attached sponge for squeezing thesolution from the car body. 3D CAD model of the machine wasmade and it was being analysed with the help of Digital HumanModelling Software to test its efficiency and usefulness for50th percentile male .The redesigned model will thus help inreducing time in carrying out the cleaning operation andreduce the user’s effort required for cleaning.

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CONTENTS

Acknowledgement 2

Abstract 3

List of figures 5

1. Introduction

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1.1 Problem Statement 6

1.2 Objectives 6

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2. Review Literature 07-10

2.1 Existing design 7 2.2 Working Principle

8 2.3 Digital Human Modelling and Simulation

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3. Methodology 11-17

3.1 Nozzle Calculations 11

3.2 Generation of 3D CAD models 3.4.11 Assembled Machine 13

3.3 2-D Drafting 14 3.4 Generation of Digital Human Models 15 3.5 Evaluation Using DHMS 15

4. Discussion 18 4.1 Merits 18 4.2 Future Scope and Limitations 18

5. Conclusion 19

References 20

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LIST OF FIGURES:

Fig 1.2.1 Car wash using squeeze and soap solution separately--------------------------- 07Fig 2.1.1 Automatic car wash system----------------------------------------------------------08Fig 2.1.2 Portable car washers------------------------------------------------------------------09Fig 2.2.1 Motor and pump used along with the washer-------------------------------------10Fig 2.3.1 Development Cost vs. Development phase plot for

Traditional and CAE based Design process (Adapted from Chaffin, 2001) -----------------------------------11

Fig 3.1.1 Nozzle flat spray----------------------------------------------------------------------12

Fig 3.2.1.1 CAD model of Assembled machine------------------------------------------------14

Fig 3.2.1.2 Final assembled model along with pump andplatform--------------------------15Fig 3.5.1 2D-Drafting of the grip-------------------------------------------51Fig 3.4.1 Digital Human Models (5th, 50th and 95th )

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Fig 3.5.2.1 50th percentile operating the machine-------------------------------------------- 16

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1. INTRODUCTION

1.1: PROBLEM STATEMENT

While studying and manually operating the existing modelof car washers it was observed that they require soapsolution to be applied separately as it sprays wateronly. Further a separate sponge is to be used to squeezethe soap solution. All this increases the time spent oncleaning the car. The model was thus redesignedeliminating the above problem by designing the washersuch that it will contain two separate container for soapsolution and water both embedded in the same machine andcan be ejected as the user desire i.e. only soapsolution, only water or a mix of water and soap solution.Along with that it will also have an attached androtating scrubber or brush. So the user can use itdirectly after applying soap solution to the car body,which will result in a faster and less tedious cleaningoperation.

1.2: OBJECTIVES

The aim of redesigning the model is to make the machinemultitasking so that not only it can spray water on thebody but also eject soap solution on it and an attachedsponge scrubber can further complete the cleaningoperation. A 3D CAD model of the product was made using CATIA V5R20. Further a physical prototype was made for theproduct using wood or 3D printer.

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Fig 1.2.1: Car Wash using squeeze and soap solution separately

2. REVIEW LITERATURE

2.1 EXISTING CAR WASHERS

At present, the car washing techniques are applied on smallas well as the large scale sector. Today, there are varioustechniques which are used for the purpose of car washing.Mainly the existing models are manually operated andautomatically operated.The various techniques presently in use are:- Hand car wash facilities, where the vehicle is washed by

employees. Self-service facilities, which are generally coin-

operated, where the customer does the washing, including"jet washing".

In-bay automatics, which consist of an automatic machinethat rolls back and forth over a stationary vehicle -

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often seen at filling stations and stand-alone washsites.

Tunnel washes, which use a conveyor to move the vehiclethrough a series of fixed cleaning mechanisms.

Chemical car wash, also known as waterless car wash, useschemicals to wash and polish car surface. Thought to haveoriginated in Australia and claims to be an eco-friendlycar wash method.

Steam car washes use a jet of steam and micro fibretowels, some include detergent injection. Known to haveoriginated from South Korea, steam car washes have beenespecially popular as a low-investment, eco-friendly carwash solution in Asia, Middle East and Europe thanks toits sanitizing features and mobility.

Mobile Car Washes, often also serving as mobile detailingsystems, which carry plastic water tanks and use pressurewashers. Sometimes these systems are mounted on trailers,on trucks, or in vans. Generally these operators alsohave a generator to run a shop vac., buffers and othertools as well.

Mechanized car washes, especially those with brushes, wereonce avoided by some meticulous car owners because of therisk of damaging the finish. Paint finishes have improved ashave car washing processes, and this perception of vehicledamage is much less today. However, this perception was themotive behind the rise of facilities utilizing "brushless"(cloth) and "touch-free" (high-pressure water) equipment, aswell as modern "foam" washing wheels made of closed cellfoam.

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Fig 2.1.1: Automatic car wash system

In today's modern car wash facilities, whether tunnel, in-bay automatic or self-serve, soaps and other cleaningsolutions used are designed to loosen and eliminate dirt andgrime. This is in contrast to earlier times, whenhydrofluoric acid, a hazardous chemical, was commonly usedas a cleaning agent in the industry by some operators. Therehas been a strong move in the industry to shift to safercleaning solutions. Most car wash facilities are required bylaw to treat and/or reuse their water and may be required tomaintain waste-water discharge permits, in contrast tounregulated facilities or even driveway washing (at one'shome), where waste-water can end up in the storm drain and,eventually, in streams, rivers and lakes.

Fig 2.1.2: Portable Car washers

2.2 WORKING PRINCIPLE

Mainly the car washer works on the principle, that the waterand the solution is released with pressure from the nozzle andwater can be released either individually or with thesolution.

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This device discloses a power driven rotary brush mounted in ahandle with water and detergent, or soap, inlet means andmeans to discharge the water, with or without the soap, ontothe brush. The main invention in this product is that thesponge type brush is rotated with the help of an electricmotor which is fitted into the handle or the nozzle.Another criteria used in this device is that the pressure andthe speed of the water flowing or coming out through thenozzle can be controlled during washing and rinsing of thevehicle. Also the solution and the water is separated with twodifferent pipes which comes in the nozzle or handle throughpump. After the vehicle is washed with soap or detergent sudsthe vehicle may be rinsed by cutting off the supply of soap ordetergent.

Fig 2.2.1: Motor and pump used along with the

washer

The pressure of the flowing water and the solution can becalculated by the ' Bernoulli’s theorem' and velocity cancalculated with the help of the equation of the continuity.The pump used for providing speed to the fluid can be operatedthrough battery and also the electric used is operatedelectrically. The outflow of the fluid in the nozzle can

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controlled with the spring and the trigger given in thenozzle.

2.3: DHMS (DIGITAL HUMAN MODELLING AND SIMULATION)

According to Chaffin and Zhang, 2000 as: “As aTechnology, Digital Human Modelling is a mean to create,manipulate and control human representation and human-machine system scenes on computers for interactiveergonomics and design problem solving.”While human modelling has always been at the forefront ofergonomics research, it is being propelled at anunprecedented tempo in the digital age by the advancementof computer technology. Digital human modelling israpidly emerging as an enabling technology and a uniqueline of research, with the promise to profoundly change

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how products or systems are designed, how ergonomicsanalyses are performed, how disorders or impairments areassessed, and how therapies or surgeries are conducted.Digital human representations in various forms areincreasingly being incorporated in the computer-aideddesign of human-machine systems, such as a driver-vehiclesystem or a manufacturing workstation.

With the computing power and computational methodsavailable today, we are able to render digital humanmodels that are an order of magnitude more sophisticatedand realistic than the ones produced a decade ago. Thereis however still a long way to go before we achieve the“ultimate” digital human surrogates—ones that look, act,and even think like we do. Some of the limitationsassociated with the current digital human models areunlikely to be solved as the performance of computerswill get more advanced.

Fig 2.3.1: Development Cost Vs Development phase plotfor Traditional and CAE Based Design process(Adapted

from Chaffin, 2001)

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3. METHODOLOGY

3.1 NOZZLE CALCULATIONS

A nozzle is a device designed to control the direction orcharacteristics of a fluid flow (especially to increasevelocity) as it exits (or enters) an enclosed chamber or pipe.A nozzle is often a pipe or tube of varying cross sectionalarea, and it can be used to direct or modify the flow of afluid (liquid or gas). Nozzles are frequently used to controlthe rate of flow, speed, direction, mass, shape, and/or thepressure of the stream that emerges from them.

Fig 3.1.1: Nozzle flat

spray

The nozzle used in this device is of the type of "Flat HighPressure Even Sprayer".

Selection of the Nozzle Provides high and uniform impact capabilities. Even spraypattern eliminates the need to overlap patterns from adjacentnozzles.Spray Angle - 5o to 65o.

Velocity of the flowing liquid through the nozzle can becalculated with the help of the equation of continuity.

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Equation of continuity:-

a1v1= a2v2Where:-a1, a2 are area of cross-section of the nozzle inlet and outletresp.v1, v2 are velocity of the fluid or liquid flowing in and outthrough the nozzle.

Formula that can be used in this device for variouscalculations of the numerical parameters.The flow rate of the fluid can be calculated with the help ofthe following formula as:-

Q=P*n/ΔP

Where the various parameters are:

Q = Fluid flow rate in m3/sP = Power of the pump in wattn = Efficiency of the pumpΔP = Change in pressure in Pa

The change in pressure for the nozzle inlet and outlet can becalculated with help of the Bernoulli's equation, which can begiven as:-

ΔP= ((v2)2 - (v1)2)/2 + ΔZ*g +ΔPstatic /d

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ΔP = Change in pressure in Pav2, v1 = Velocity of inlet & outlet fluid in m/s.ΔZ = Change in height in m.g = Acceleration due to gravity m/s2.d = Density of the fluid in kg/m3.ΔPstatic = Change in pressure at static condition in Pa.

Specifications for the nozzle

Velocity of the fluid through the outlet.r1 = 20mm r2 = 5mma1 = 3.14*20*20 a2 = 3.14*5*5 = 1256 mm2 = 78.5 mm2

v1 = 5 m/s (for the inlet) v2 = (a1*v1) /a2 = 80m/s

Change in pressure for inlet and outlet:-ΔZ= 1m (considering height of 1m).ΔPstatic = 0 ( at static condition pressure diff. is 0 ).ΔP= (6400-25)/2 +1*10 + 0 = 3197.5 PaFlow rate of the fluid:-Efficiency n, = 60% Power of the pump = 80WQ = .6*80/3197.5 = 0.015 m3/s

3.2 GENERATION OF 3D CAD MODELS

After finalising our basic design for the car washerwe moved forward to create its 3D CAD model which wasthen used to interact with a virtual human model with theuse of digital human modelling software. The 3D CADmodelling software which was used for this purpose wasCATIA V5 R20 as it provided us a base not only to createthe model but also to carry out the interaction of humanand the product. Each and every part of the grasstrimming machine were made in different .CATPart files in‘Part Design’ module of ‘Mechanical Design’ Workbench andwere then assembled in .CATProduct file in ‘Assembly

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Design’ module of same workbench. All the parts of themachine were made keeping in mind the dimension ofexisting models and anthropometric data of Indianpopulation.

3.2.1 ASSEMBLED MACHINE

Fig 3.2.1.1: Final assembled model of theproduct

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Fig 3.2.1.2: Final assembled model along with pump andplatform

3.3 2-D DRAFTING

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Fig 3.3.1: 2D Drafting of the final mode

3.4 GENERATION OF DIGITAL HUMAN MODELS

Digital Human models or the manikins were created usingCATIA human modelling software. Male digital manikinsrepresenting 95th, 50th and 5th percentile anthropometricdata respectively were developed using Indiananthropometric data. The anthropometric data was manuallyentered in the human measurements editor workbench forcreating the manikins.

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Fig 3.4.1: Digital Human Models (5th, 50th and 95th)

3.5 EVALUATION USING DHMS

3.5.1 Methodology

First the manikin was positioned along

with the product in ‘Human Activity Analysis’ section of

the ‘Ergonomic Design & Analysis’ workbench in CATIA

environment. Next some selected segments of the manikin

body were given preferred angles. These preferred angles

define the comfort range within which the muscles of the

respective segment would work with negligible

biomechanical stress.

Preferred angles where given by exporting all three

created models in the ‘Human Posture Analysis’ section of

the ‘Ergonomic Design and Analysis’ Workbench in CATIA V5

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R20. The required segments were selected and preferred

angles were provided by selecting ‘Edit the angular

limitation and the preferred angles’ option from ‘Angular

Limitation’ toolbar.

3.9.2 Posture Analysis

50th Percentile Male:

Fig 3.5.2.1: 50th percentile operating the machine

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Segment DOF Right Side

Hand 1 0 (flexion)2 0(radial deviation)

Thumb 1 1 -2.339 (flexion)

Thumb 2 1 -36.465 (flexion)

Thumb 3 1 -19.328(flexion)

Index 1 1 18.62(flexion)3 -2.92(radial deviation)

Index 2 127.049(Flexion)

Index 3 1 80(Flexion)

Middlefinger 1 1 11.662(Flexion)Middle

finger 2 148.85(Flexion)

Middlefinger 3 1 55.004(Flexion)Annular 1 1 1.275(Flexion)Annular 2 2 53.056(Flexion)Annular 3 1 41.817(Flexion)Auricular

1 1 7.304(Flexion)Auricular

2 1 -2.0(Flexion)Auricular

3 2 29.191(Flexion)

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Table 1: Postural analysis using DHMS

4. DISCUSSION

4.1 MERITS:

The car washer machine is designed in such a way sothat the drawbacks of the existing models can be removedto maximum extent. Certain drawbacks of the existingmodel as discussed before were considered and theredesigned model thus had following merits;

The most important feature of this product is it has twoseparate switches for controlling the flow of both water& detergent solution. So whenever we want to use water ordetergent solution we have to press the concerned switch.For using both we have to press both switches.

Washing your vehicle by hand (scrubbing with sponges andbrushes) actually produces tiny scratches in thepaint. This is caused by fine particles of dirt, sand andsilt that become trapped in your brush or sponge. Thescratches produced by washing with brushes and spongescan be as deep as 10% of the thickness of the paint. Ituses a high pressure spray of water to remove the dirtoff the surface before it is washed, and the materialsused to clean the surface of the vehicle are continuallybeing rinsed to prevent any accumulation of grit.

The product is designed ergonomically in such a way thatit could be light weight and easy to operate. The grip ofthe handle is designed ergonomically to provide maximumand comfortable grip.

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4.2 FUTURE SCOPE AND LIMITATIONS:

The car washer isn’t automatic. As we do it manually lotsof water is used. Also it takes time. There ispossibility of scratches if the nozzle touches the carsurface.Further research should be made to do the machineautomatic. We can use proximity sensor which will sensethe sponge touching the car surface. After sensing theactuator will start automatically & machine will startwashing the car. There should be some improvement in themachine so that it will use less amount of water. Autocar washer should reclaim the water used for washing. Thedesign should be in such a way that water is cleaned andtreated before being reused for subsequent car washes.

5. CONCLUSION

The product was designed and modified following thechanges such as applying soap and water simultaneously andattaching the self-rotating sponge scrubber to the machineitself, thus making the job easier and less tedious for theuser. The 3D CAD model of the product was made in CATIA and itwas then analysed by digital human modelling software with the50th percentile male manikin within the comfort range and theresults showed that it can be used by the targeted usercomfortably and safely.

The product can easily overcome most of the difficultyfaced while operating the existing models.

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REFERENCES:

1. Anonymous, Available from: http://www.carsite.com/archive/index.php/t- 339303.html [Accessed 10th Apr 2014]

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2. Arthur, W., 2010. Car washer mechanism, 3-12

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4. OPTION TOOLS EBAY, Car washer. Available from: http://www.ebay.com/itm/2300PSI-High-Pressure-Washer-Cleaner-Driveway-Porch-Car-Wash-Garden-New-/121314509403 [Accessed 16th Apr 2014]

5. Nozzle flow calculator for liquids. Available from:http://www.lmnoeng.com/nozzles.htm [Accessed 16th Apr 2014]

6. Venturi Effect, Instrumentation and measurementAvailable from: http://en.wikipedia.org/wiki/Venturi_effect [Accessed 13th Apr 2014]

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8. Reddy, K.A., Babu, N.M., Srikanth, L.H. and Srinivas, J., 2010.Design and analysis of a revised car washing device, 69, 1-4

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11. WIKIPEDIA, Percentile. Available from: http://en.wikipedia.org/wiki/Percentile

12. Chakrabarti, D., Indian Anthropometric Dimensions, Chapter: Statistical treatment of anthropometric data.

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13. Chakrabarti, D., Indian Anthropometric Dimensions, Chapter: Anthropometric Dimensions.

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