Touch-free loading system for an in-bay, automatic vehicle wash system

Abstract

A vehicle loading system for the wash bay of an automatic vehicle wash system that eliminates the use of a floor-mounted target to capture the front tire of the vehicle to be washed. The vehicle wash system includes a pair of side position sensors that detect and create a side profile of the vehicle as the vehicle enters into the wash bay. The vehicle wash system includes a front sensor array that includes a plurality of through-beam sensors that detect the front bumper of a vehicle and signal the vehicle operator to stop when the front bumper is in the correct position. An overhead sensor contained on the overhead gantry detects the top profile of the vehicle positioned within the open wash bay. A control unit receives the information from the variety of sensors and operates the overhead gantry based upon the detected parameters of the vehicle.

We claim:  
     
         1 . A vehicle wash system for washing a vehicle positioned within a wash bay, the system comprising: 
 a movable overhead gantry including a spray arm for washing a vehicle in the wash bay;    a control unit for controlling the movement of the overhead gantry and the spray arch within the wash bay during the washing of the vehicle;    a first vehicle position sensor operable to determine the distance from the first vehicle position sensor to a first side of the vehicle as the vehicle enters into the wash bay, the first vehicle position sensor being connected to the control unit; and    a second vehicle position sensor operable to determine the distance from the second vehicle position sensor to a second side of the vehicle as the vehicle enters into the wash bay, the second vehicle position sensor being connected to the control unit;    wherein the control unit controls the operation of the overhead gantry and the spray arch based upon the sensed distances of the vehicle from the first vehicle position sensor and the second vehicle position sensor.    
     
     
         2 . The system of  claim 1  wherein the first vehicle position sensor and the second vehicle position sensor are each ultrasonic proximity sensors.  
     
     
         3 . The system of  claim 2  wherein the first vehicle position sensor and the second vehicle position sensor determine the distance from the respective sensor to the vehicle at multiple times such that the control unit receives multiple distance measurements from the first and second vehicle position sensors as the vehicle enters into the wash bay.  
     
     
         4 . The system of  claim 1  further comprising an overhead sensor mounted to the movable overhead gantry, the overhead sensor being operable to determine the distance from the overhead sensor to the top of the vehicle positioned in the wash bay.  
     
     
         5 . The system of  claim 4  wherein the overhead sensor is an ultrasonic proximity sensor.  
     
     
         6 . The system of  claim 5  wherein the overhead sensor is connected to the control unit such that the control unit operates the overhead gantry and the spray arch based upon the distance from the overhead sensor to the vehicle.  
     
     
         7 . The system of  claim 6  wherein the overhead sensor makes multiple measurements during relative movement between the overhead gantry and the vehicle such that the overhead sensor determines the top profile of the vehicle.  
     
     
         8 . The system of  claim 1  further comprising a front sensor array positioned to detect the front of the vehicle as the vehicle enters into the wash bay, wherein the front sensor array is coupled to the control unit such that the control unit can generate a signal to stop the movement of the vehicle upon sensing the front end of the vehicle by the sensor array.  
     
     
         9 . The system of  claim 8  wherein the front sensor array includes a first front sensor and a second front sensor each operable to detect the presence of the vehicle, wherein the control unit signals the proper positioning of the vehicle when only the first sensor detects the vehicle and the control unit signals the improper positioning of the vehicle when both the first front sensor and the second front sensor detect the presence of the vehicle.  
     
     
         10 . The system of  claim 9  wherein both the first front sensor and the second front sensor are through-beam sensors.  
     
     
         11 . The system of  claim 9  further comprising an electronic sign positioned within the wash bay and coupled to the control unit, wherein the control unit operates the sign to indicate the proper and improper position of the vehicle.  
     
     
         12 . A vehicle wash system for washing a vehicle positioned within a wash bay, the system comprising: 
 an overhead gantry movable along the length of the vehicle, the overhead gantry including a spray arch for washing the vehicle positioned within the wash bay;    a front sensor array positioned to detect the front end of the vehicle as the vehicle enters the wash bay; and    a control unit coupled to the front sensor array to receive an indication of the presence of the vehicle from the front sensor array;    wherein the control unit generates a signal to direct the position of the vehicle based upon the signal from the front sensor array.    
     
     
         13 . The system of  claim 12  wherein the front sensor array includes a first front sensor and a second front sensor each operable to detect the presence of the vehicle, wherein the control unit signals the proper positioning of the vehicle when only the first sensor detects the front of the vehicle and the control unit signals the improper positioning of the vehicle when both the first front sensor and the second front sensor detect the presence of the vehicle.  
     
     
         14 . The system of  claim 12  wherein both the first front sensor and the second front sensor are through-beam sensors.  
     
     
         15 . The system of  claim 13  further comprising an electronic sign positioned within the wash bay and coupled to the control unit, wherein the control unit operates the sign to indicate the proper and improper positioning of the vehicle within the wash bay.  
     
     
         16 . The system of  claim 12  further comprising an overhead sensor mounted to the overhead gantry, the overhead sensor being operable to determine the distance from the overhead sensor to the top of the vehicle positioned in the wash bay.  
     
     
         17 . The system of  claim 16  wherein the overhead sensor is an ultrasonic proximity sensor.  
     
     
         18 . The system of  claim 17  wherein the overhead sensor makes multiple measurements during relative movement between the overhead gantry and the vehicle such that the overhead sensor generates a top profile of the top surface of the vehicle.  
     
     
         19 . The system of  claim 18  wherein the overhead sensor is connected to the control unit such that the control unit operates the overhead gantry and the spray arch based upon the detected distance between the overhead sensor and the top of the vehicle.  
     
     
         20 . A vehicle wash system for washing a vehicle positioned within a wash bay, the system comprising: 
 an overhead gantry movable along the longitudinal length of the vehicle when the vehicle is positioned within the wash bay, the overhead gantry including a spray arch operable to wash the vehicle within the wash bay;    a control unit for controlling the movement of the overhead gantry and operation of the spray arch during washing of the vehicle;    a first vehicle position sensor operable to determine the distance from the first vehicle position sensor to a first side of the vehicle as the vehicle enters into the wash bay, the first vehicle position sensor being connected to the control unit;    a second vehicle position sensor operable to determine the distance from the second vehicle position sensor to a second side of the vehicle as the vehicle enters into the wash bay, the second vehicle position sensor being connected to the control unit;    an overhead sensor mounted to the overhead gantry, the overhead sensor being operable to determine the distance from the overhead sensor to the top of the vehicle positioned within the wash bay, the overhead sensor being coupled to the control unit; and    a first front sensor and a second front sensor spaced from each other and connected to the control unit, the first and second front sensors being operable to detect the presence of the vehicle, wherein the control unit signals the proper positioning of the vehicle when only the first front sensor detects the vehicle and the control unit signals the improper positioning of the vehicle when both the first front sensor and the second front sensor detect the presence of the vehicle;    wherein the control unit controls the operation of the overhead gantry and the operation of the spray arch based upon the sensed distance of the vehicle from the first vehicle position sensor, the sensed distance of the vehicle from the second vehicle position sensor, and the sensed distance of the top of the vehicle from the overhead sensor.    
     
     
         21 . The system of  claim 20  wherein the first vehicle position sensor and the second vehicle position sensor are ultrasonic proximity sensors.  
     
     
         22 . The system of  claim 20  wherein the first vehicle position sensor and the second vehicle position sensor make multiple measurements as the vehicle enters the wash bay such that the control unit receives multiple measurements of the distance between the vehicle and the first and second vehicle position sensors such that the control unit can develop a profile of the side surfaces of the vehicle.  
     
     
         23 . The system of  claim 20  wherein the overhead sensor is an ultrasonic proximity sensor.  
     
     
         24 . The system of  claim 23  wherein the overhead sensor makes multiple measurements during relative movement between the overhead gantry and the vehicle such that the control unit can determine a top profile of the vehicle.  
     
     
         25 . The system of  claim 24  wherein the spray arch includes a top arm and a side arm, wherein the control unit controls operation of the top arm and the side arm based upon the top profile of the vehicle.  
     
     
         26 . The system of  claim 20  wherein the first front sensor and the second front sensor are through-beam sensors.  
     
     
         27 . A method of controlling the operation of an overhead gantry and a spray arch of a vehicle wash system, the method comprising the steps of: 
 determining the position of a first side of the vehicle as the vehicle enters into the wash bay;    determining the position of a second side of the vehicle as the vehicle enters into the wash bay; and    operating the overhead gantry and the spray arch based upon the position of the first side of the vehicle and the position of the second side of the vehicle within the wash bay.    
     
     
         28 . The method of  claim 27  further comprising the steps of: 
 detecting the position of the front end of the vehicle in the wash bay; and  
 signaling to an operator of the vehicle to move the vehicle to a selected position in the wash bay based upon the detection of the position of the front end of the vehicle.  
 
     
     
         29 . The method of  claim 28  further comprising the steps of: 
 detecting the height of the vehicle in the wash bay; and  
 operating the overhead gantry and the spray arch based upon the height of the vehicle within the wash bay.  
 
     
     
         30 . The method of  claim 27  wherein the step of determining the position of the first and second side of the vehicle includes the steps of: 
 positioning a first vehicle position sensor near the entry of the wash bay;  
 positioning a second vehicle position sensor opposite the first vehicle position sensor near the entry to the wash bay;  
 operating the first vehicle position sensor to determine the distance from the first vehicle position sensor to the first side of the vehicle as the vehicle enters into the wash bay;  
 operating the second vehicle position sensor to determine the distance from the second vehicle position sensor to the second side of the vehicle as the vehicle enters into the wash bay; and  
 receiving the measured distances from the first vehicle position sensor and the second vehicle position sensor in a control unit, wherein the control unit controls the operation of the overhead gantry and the spray arch based upon the detected distances.  
 
     
     
         31 . The method of  claim 30  wherein both the first vehicle position sensor and the second vehicle position sensor are ultrasonic proximity sensors.  
     
     
         32 . The method of  claim 31  wherein the first vehicle position sensor and the second vehicle position sensor are each operated at predetermined intervals such that the first vehicle position sensor and the second vehicle position sensor generate multiple distance measurements as the vehicle enters into the wash bay such that the control unit can generate a side profile for each side of the vehicle.  
     
     
         33 . The method of  claim 28  wherein the step of detecting the position of the front end of the vehicle includes the steps of: 
 positioning a first front sensor within the wash bay, the first front sensor operable to detect the presence of the vehicle;  
 positioning a second front sensor within the wash bay, the second front sensor being operable to detect the presence of the vehicle, wherein the front sensor is spaced from the first front sensor;  
 coupling the first front sensor and the second front sensor to a control unit; and  
 signaling the proper positioning of the vehicle when only the first front sensor detects the vehicle and signaling the improper position of the vehicle when both the first front sensor and the second front sensor detects the presence of the vehicle.  
 
     
     
         34 . The method of  claim 33  wherein the first front sensor and the second front sensor are through-beam sensors.  
     
     
         35 . The method of  claim 29  wherein the step of determining the height of the vehicle in the wash bay includes the steps of: 
 positioning an overhead sensor on the overhead gantry, the overhead sensor being operable to determine the distance from the overhead sensor to the top of the vehicle; and  
 coupling the overhead sensor to a control unit such that the control unit can determine the height of the vehicle based upon the sensed distance from the overhead sensor to the top of the vehicle.  
 
     
     
         36 . The method of  claim 35  wherein the overhead sensor is an ultrasonic proximity sensor.  
     
     
         37 . The method of  claim 36  wherein the overhead sensor makes multiple distance measurements during movement of the overhead gantry relative to the longitudinal length of the vehicle, such that the control unit can generate a top profile based upon the multiple distance measurements.