AUTONOMOUS CAR WASHING SYSTEM

WITH WATER RECYCLING

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Abstract—This paper presents the development of an
automatic car washing system with integrated water
coagulation technology for sustainable water management.
Leveraging Programmable Logic Controllers (PLCs), the
system employs sensors and various cleaning mechanisms to
optimize efficiency and reduce time consumption. Water
coagulation technology purifies and recycles water, minimizing
environmental impact and promoting resource conservation.
Through theoretical background, methodology description,
and analysis of results, the study highlights the system's
effectiveness in improving efficiency and sustainability in the
car washing industry.
I. Introduction
The proliferation of vehicles worldwide has led to an increased
demand for efficient car washing solutions. In response to this
need, advancements in technology have paved the way for
automated car washing systems, offering benefits such as time
efficiency, labor reduction, and improved cleaning quality. This
paper explores the development and implementation of an
automatic car washing system, utilizing Programmable Logic
Controllers (PLCs) and water coagulation technology for
sustainable water management. By integrating sensors, conveyor
belts, and various cleaning mechanisms, the system streamlines the
car washing process while minimizing water consumption and
environmental impact. This introduction provides an overview of
the research topic, highlighting the significance of automated car
washing systems and their potential to enhance efficiency and
sustainability in the automotive industry.
Literature Review
The literature on car washing systems encompasses
various approaches, from traditional manual methods to
modern automated solutions. This section reviews existing
research on car washing technologies, with a focus on the
evolution of automation and the integration of sustainable
practices such as water coagulation.
Historically, car washing was primarily conducted manually,
either by vehicle owners themselves or by manual labour at
car wash facilities. These methods often involved significant
time and labor, with variable results in terms of cleaning
quality. However, the introduction of automated car washing
systems revolutionized the industry, offering faster, more
efficient, and consistent cleaning processes.
Automation in car washing began in the early 20th century,
with the development of rudimentary conveyor-based
systems. The first automatic conveyor car wash was
introduced in Hollywood, California, in 1940, featuring a
winch system that pulled cars through a tunnel while
attendants manually washed and dried them. Subsequent
advancements, such as the invention of semi-automatic
systems with conveyor belts and overhead sprinklers in the
1940s, paved the way for fully automated car washing
systems by the 1950s.
Today, automated car washing systems utilize advanced
technologies such as Programmable Logic Controllers
(PLCs) [1](Ragini Gaikwad et al) to control various stages of
the washing process. PLCs offer flexibility, reliability, and
ease of programming, making them ideal for industrial
control applications like car washing. Research by Simpson
(1946) and the Anderson brothers in Seattle (1951)
contributed to the development of fully hands-free automatic
car washes, where machines perform all cleaning tasks
without human intervention[2](Amir Hossein et al 2013)
In recent years, there has been a growing emphasis on
sustainability in the car washing industry. Water
conservation, in particular, has become a pressing concern
due to increasing water scarcity and environmental
regulations. One innovative approach to address this issue is
the integration of water coagulation technology into car
washing systems. Water coagulation involves the use of
chemicals to aggregate and remove impurities from
wastewater, allowing it to be reused for cleaning purposes.
Coagulation technology is an economical and simple water
treatment technology widely employed at domestic and
mass-scale and has been one of the primary purification
treatments of water supply. Coagulation is a general term for
the two processes of coagulation and flocculation [3]
(Yongjun Sun et al., 2019). It is the aggregation process of
microscopic suspensions of colloidal particles in water [4]
(Dina T Moussa et al 2016). Aggregation induces the loss of

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stability of the colloid in the water after the addition of the
coagulant. The colloidal particles agglomerate with each
other, resulting in the formation of numerous small flowers
or globules, known as flocs [5](Sillanpaa et al., 2018). Large
flocs formed during the coagulation process by adsorption,
bridging, electric neutralization, and net-sweeping [6](Sharp
et al., 2006).
Overall, the literature highlights the evolution of car washing
systems from manual methods to automated solutions, with a
growing emphasis on sustainability and water conservation.
The integration of technologies such as PLCs and water
coagulation has the potential to further enhance efficiency
and environmental sustainability in the car washing industry,
offering benefits for both businesses and the environment.
Objectives
The primary objective of this research paper is to design,
implement, and evaluate an automatic car washing system
that incorporates advanced technologies, including
Programmable Logic Controllers (PLCs) and water
coagulation technology. Through this system, we aim to
achieve the following specific objectives:
Optimize Efficiency: Develop an automated car washing
system that streamlines the vehicle cleaning process, reduces
time consumption, and minimizes labor requirements
compared to traditional manual methods.
Reduce Water Consumption: Integrate water coagulation
technology into the car washing system to purify and recycle
water, thereby minimizing freshwater usage and promoting
sustainable water management practices.
Promote Environmental Sustainability: Assess the
environmental impact of the automatic car washing system
and evaluate its potential to reduce water consumption,
wastewater discharge, and overall environmental footprint in
the automotive industry.
Evaluate Performance: Conduct comprehensive testing and
evaluation of the automated car washing system to assess its
effectiveness, reliability, and cleaning quality compared to
conventional car wash methods.
Provide Insights for Future Development: Generate valuable
insights and recommendations for further research and
development in automated car washing technologies, PLC
programming, and sustainable water management practices
in the automotive industry.
By addressing these objectives, this research paper aims to
contribute to the advancement of automated car washing
systems while promoting sustainability and environmental
responsibility in the automotive sector.
II. METHODOLOGY AND BLOCK DIAGRAM
The Automatic Car Washing System is entirely governed by
a preprogrammed device, specifically a Programmable Logic
Controller (PLC), in conjunction with various sensors. These
sensors transmit signals to the PLC, prompting it to activate
different components within the system. Here's an
elaboration of the provided information:
The workflow of the Proximity Sensor-based Automatic Car
Washing System begins with a 230V AC power supply,
which is inputted into the Switched-Mode Power Supply
(SMPS). The SMPS converts this voltage into 24V DC, as
PLCs typically operate at this voltage. Terminal Blocks are
utilized to facilitate multiple inputs and outputs within the
system.
Communication between a Personal Computer (PC) and the
PLC occurs via an RS-232 cable, enabling the transfer of
ladder logic programs. This ensures seamless programming
and monitoring of the PLC's operations.
The movement of the vehicle through the washing process is
facilitated by a conveyor belt, which is driven by a DC motor
operating at 100 rpm. Proper alignment of all system
components is crucial for accurate sequencing and operation.
Additionally, precise placement of the car's wheels on the
conveyor track is essential to prevent unnecessary
displacement.
The washing process involves the use of brushes, which are
typically constructed from dirt-proof and waterproof
materials, such as cloth. This ensures that the brushes do not
damage the car's fixed or painted finishing while providing a
gentle polishing effect, resulting in a shinier paint finish.
Soap solution and water are sprayed onto the vehicle to clean
hard-to-reach areas effectively. Finally, hot steam or fans are
employed to dry the car thoroughly.
The construction of the system can vary based on its intended
use, whether for domestic or commercial purposes. The
system's design must align with specific requirements and
considerations, such as throughput capacity, water
consumption, and space constraints.
After the car washing process, the wastewater is directed into
a tank equipped with a level sensor mounted on a float. This
sensor continuously monitors the water level in the tank.
When the water level surpasses a predefined threshold,
indicating that the tank is nearing full capacity, an alarm is
triggered to alert the operator.
To treat the wastewater, a water coagulation process is
employed. Solar energy is utilized to supply electricity for
this purpose, ensuring an environmentally friendly and
sustainable approach to water treatment. The solar energy
provides the necessary power to initiate and sustain the water
coagulation process.
Once the wastewater tank reaches full capacity and the alarm
is activated, it indicates the need for wastewater treatment. At
this point, the full tank is replaced with an empty one,
allowing the wastewater treatment process to commence. The
wastewater in the newly installed tank undergoes purification
through water coagulation, effectively removing impurities
and contaminants.
This cyclical process ensures that wastewater generated from
the car washing system is efficiently treated and managed.
By incorporating solar energy and automated water level
sensing and alarm systems, the overall efficiency and
sustainability of the wastewater treatment process are
maximized, contributing to environmental conservation
efforts.
The overall process can be explained properly by this block
diagram which represents the entry of vehicle through the
entry sensor where it will be detected by input proximity
sensor and it will be initiate the operation of conveyor belt
and will further initiates the process which is accurately
categorised as different stages of the process.
 Figure 1: work flow
A) Ladder Logic of the plc used
let's break down the provided process into a step-by-step
explanation:
Instruction list
Figure 2: Instructions used for different inputs
Ladder logic for whole operation
Figure 3: Ladder logic
1. Conveyor Belt Activation:
 Upon detection by the entry sensor, the conveyor
belt is turned ON. This action initiates the
movement of the car into the washing station.
2. Soapy Water Sprinkler Activation (Stage 1):
 Once the car reaches stage 1 of the washing station, a
sensor detects its presence.
 This detection triggers the activation of the soapy
water sprinkler.
 The sprinkler applies soapy water to the car's surface
for a predetermined amount of time, effectively
starting the cleaning process.
3. Brusher Activation (Stage 2):
 As the car progresses to stage 2, sensors in this area
detect its presence.
 Upon detection, the brusher is activated to scrub and
clean the car's surface.
 The brusher operates for a specific duration to
ensure thorough cleaning.
4. Clean Water Sprinkler Activation (Stage 3):
 After passing through the brushing stage, the car
moves to stage 3.
  Sensors in this area detect the car's presence and Proximity sensors are used in.
trigger the activation of the clean water sprinkler.
 Detection of Vehicle Presence
 The sprinkler rinses off the soapy residue, leaving
 Triggering System Operations
the car's surface clean.
5. Dryer Activation (Stage 4):  Precision and Reliability

 Once the car enters stage 4, sensors detect its  Non-contact Sensing
presence.  Integration with Control Systems
 This detection signals the activation of the dryer, Solenoid Valve:
which blows air to dry the car.
 The dryer operates for a predetermined period,
ensuring the car is completely dried before exiting
the washing station.
6. Water Overflow alarm:
 As the water level reaches the apex level in the west
water tank an alarm starts which indicates that tank
is full.
III. COMPONENTS USED
A. Conveyor Belt

Figure 6: Solenoid valve

Solenoid valves are essential components in a car washing
system, responsible for controlling the flow of various fluids
such as water, detergents, and cleaning solutions. Here's an
elaboration on their usage within the system.
Solenoid valve are used in.
 Fluid Control
 Activation by Sensors
 Sequential Operation
 Precise Control

Figure 4: conveyor belt DC Motor

In a car washing system, the conveyor belt serves as the

backbone of the entire operation, facilitating the movement
of vehicles through each stage of the cleaning process. Here's
a detailed explanation of its usage.

B. Unitech Inductive Proximity Sensor

Figure 7: DC Motor

DC motors serve various purposes within a car washing

system, providing the necessary mechanical motion and
power for different components.
DC motors are used in.
 Conveyor Belt Propulsion
Figure 5: proximity sensor  Brush and Scrubber Actuation
The Unitech Inductive Proximity Sensor serves as a critical  Sprayer and Nozzle Control
component within a car washing system, enhancing its  Drying System Operation
automation, efficiency, and safety.

Fan
Figure 8: Fan
Fans are commonly used in car washing systems for drying
vehicles after the cleaning process.
Fans are used in.
 Air Drying.
 Integration with Control System
 High-Velocity Airflow
 Quick Drying Time:
PLC
Figure 9: PLC
PLCs (Programmable Logic Controllers) are integral to
the automation and control of car washing systems, offering
a centralized platform for managing and coordinating the
operation of various components. Here's how PLCs are
utilized in such systems.
Functions of PLC
 Sequence Control
 Sensor Integration
 Fault Detection and Alarm Handling
 Variable Speed Control
 Recipe Management
 Data Logging and Reporting
WATER RECYCLING
The world is currently facing a significant challenge with
water scarcity due to the increasing global population and
rising rates of water consumption. To address this issue,
there is a growing interest in developing wastewater
treatment technologies that are both cost-effective and
environmentally friendly. These technologies aim to treat
and recycle the large volumes of wastewater generated by
various industries.
While there are several existing wastewater treatment
methods, many of them rely heavily on energy derived from
carbon-based sources. This reliance on non-renewable
energy contributes to carbon dioxide emissions,
exacerbating environmental concerns such as climate
change. Therefore, there is a need for more sustainable and
energy-efficient approaches to wastewater treatment that
minimize environmental impact while meeting the growing
demand for water resources.
A standard wastewater treatment facility employs a variety
of methods, including physical, chemical, and biological
processes, to eliminate various pollutants from wastewater.
Physical unit operations focus on separating pollutants from
the water without altering its chemical or biological
properties significantly. This means that these processes
primarily rely on physical methods such as filtration,
sedimentation, and screening to remove solid particles,
debris, and other contaminants from the wastewater.
Essentially, physical unit operations involve techniques that
physically isolate or separate pollutants from the water
without causing any significant changes to its chemical
composition or biological characteristics.
electrocoagulation (EC) is an innovative water and
wastewater treatment technology that combines aspects of
coagulation, flotation, and electrochemistry. Both
coagulation/flocculation and EC methods aim to remove
suspended particles from wastewater by destabilizing their
repulsive forces, allowing them to agglomerate and settle
out of the water more easily. However, the key difference
lies in the generation of coagulants: while traditional
coagulation relies on chemical additives like metal salts or
polymers, EC generates coagulants in situ through the
electrolytic oxidation of an appropriate anode material. This
results in significantly less sludge production compared to
chemical coagulation/flocculation processes.
One of the primary advantages of EC over conventional
methods is its ability to effectively treat oily water. In EC,
the presence of electric current facilitates electrocoagulation,
causing oil droplets to merge and form larger aggregates that
can be easily separated from the water. This is particularly
beneficial for addressing tight emulsions commonly
encountered in industries such as Oil and Gas, where fine
water droplets are dispersed in oil or vice versa, as in the
case of produced water. Electrocoagulation has been
demonstrated as an effective means of treating these
challenging emulsions, offering a promising solution for oily
water treatment.
ELECTROCOGULATION
Electrocoagulation is an electrochemical water treatment
process that utilizes an electric current to remove
contaminants from water. It involves the use of electrodes,
typically made of materials like aluminum or iron, which are
immersed in the wastewater to facilitate the coagulation and
precipitation of impurities. Here's a detailed explanation of
electrocoagulation.
1. PRINCIPLE OF OPERATION
The principle of operation of electrocoagulation (EC) in
water recycling involves the application of an electric
current to destabilize contaminants and facilitate their
removal from water. This process begins with electrodes,
typically made of materials like aluminium or iron,
immersed in the wastewater. When a direct current is
applied, metal ions are released from the anode into the
water, reacting with water and hydroxide ions to form metal
hydroxide precipitates. These precipitates act as coagulants,
neutralizing the charges on suspended particles and colloids
in the water. As a result, the particles agglomerate to form
larger flocs, which can then be separated from the water
through sedimentation, flotation, or filtration. The efficiency
of electrocoagulation depends on factors such as the type
and concentration of contaminants, electrode material,
current intensity, and treatment duration. Overall,
electrocoagulation offers a sustainable and effective solution
for water recycling by utilizing electrochemical processes to
produce clean and reusable water resources.
2. ELECTRODES
In electrocoagulation (EC) for water recycling, electrodes
play a crucial role in facilitating the removal of
contaminants from wastewater. These electrodes, typically
made of materials such as aluminum, iron, or other reactive
metals, are immersed in the wastewater and subjected to an
electric current. During the EC process, metal ions are
released from the anode into the water, while hydrogen gas
is generated at the cathode through electrolysis. The metal
ions released from the anode react with water and hydroxide
ions present in the solution, leading to the formation of
metal hydroxide precipitates. These precipitates act as
coagulants, neutralizing the charges on suspended particles
and colloids in the water, thereby promoting their
agglomeration and eventual removal. The choice of
electrode material can influence the effectiveness and
efficiency of the EC process, with factors such as electrode
surface area, conductivity, and durability being important
considerations. Overall, electrodes in electrocoagulation
systems play a critical role in initiating coagulation reactions
and facilitating the removal of contaminants, contributing to
the production of clean and reusable water resources in
water recycling applications.
3. COAGULATION AND PRECIPITATION
Coagulation and precipitation are fundamental processes in
water recycling, essential for removing suspended particles,
colloids, and dissolved contaminants from wastewater.
Coagulation involves the addition of chemical coagulants,
such as aluminum sulfate (alum) or ferric chloride, to the
water. These coagulants neutralize the charges on suspended
particles through charge neutralization or sweep coagulation
mechanisms, causing them to aggregate into larger flocs.
Precipitation occurs as these flocs settle out of the water due
to their increased size and weight, aided by gravity or the
addition of flocculants to enhance settling. During
precipitation, the flocs form a sediment layer at the bottom
of the treatment tank, which can be separated from the
clarified water through sedimentation, flotation, or filtration
processes. Coagulation and precipitation are highly effective
in removing a wide range of contaminants, including
suspended solids, turbidity, pathogens, and some dissolved
pollutants, thus producing clean and reusable water suitable
for various applications in water recycling systems.
4. PH ADJUSTMENT:
The pH level of wastewater plays a significant role in the
efficiency of electrocoagulation processes.
Electrocoagulation typically functions optimally under
slightly acidic to neutral pH conditions, as this range
promotes favorable metal hydroxide precipitation. However,
if the pH of the wastewater falls outside this optimal range,
adjustments may be necessary to ensure effective treatment.
In such cases, pH adjustment can be achieved by adding
acidic or alkaline chemicals to the wastewater as needed.
Acidic chemicals, such as sulfuric acid or hydrochloric acid,
can be introduced to lower the pH, while alkaline chemicals,
like sodium hydroxide or lime, can be used to raise the pH.
By fine-tuning the pH level to fall within the ideal range, the
electrocoagulation process can be optimized for enhanced
contaminant removal and overall treatment efficiency in
water recycling systems.
5. FACTORS AFFECTING THE EFFICIENCY OF
ELECTROCOAGULATION PROCESS
Several factors can influence the efficiency of the
electrocoagulation process in water treatment. These factors
include.
Electrode Material
The choice of electrode material can significantly impact the
efficiency of electrocoagulation. Materials such as
aluminum, iron, or other reactive metals are commonly
used. The composition and surface characteristics of the
electrodes influence the generation of coagulants and the
overall effectiveness of contaminant removal.
Electric Current
The intensity and duration of the electric current applied to
the electrodes affect the rate of coagulant generation and the
extent of contaminant removal. Proper control of current
parameters is essential to optimize treatment efficiency
while minimizing energy consumption.
pH Level
The pH of the wastewater plays a crucial role in
electrocoagulation efficiency. The process typically operates
best under slightly acidic to neutral pH conditions, where
metal hydroxide precipitation is most favorable. pH
adjustment may be necessary to ensure optimal treatment
performance.
Water Chemistry
The composition of the wastewater, including its ionic
strength, conductivity, and presence of complexing agents or
organic matter, can influence electrocoagulation efficiency.
Certain contaminants may require specific treatment
conditions or additional pre-treatment steps to achieve
effective removal.
Temperature
Temperature can affect the rate of chemical reactions and
the solubility of contaminants in water, thereby impacting
electrocoagulation efficiency. Higher temperatures may
accelerate the coagulation process but can also increase
energy consumption.
Electrode Configuration
The design and arrangement of electrodes within the
electrocoagulation system can influence treatment
efficiency. Factors such as electrode spacing, surface area,
and configuration (parallel, series, bipolar) affect the
distribution of electric current and coagulant generation in
the wastewater.
Treatment Time
The duration of electrocoagulation treatment can impact its
efficiency in contaminant removal. Longer treatment times
may be necessary to achieve desired water quality standards,
particularly for complex or highly contaminated wastewater
streams.
Contaminant Characteristics
The type, concentration, size, and charge of contaminants
present in the wastewater influence electrocoagulation
efficiency. Certain contaminants may require specific
operating conditions or additional treatment steps to achieve
effective removal.
In summary, electrocoagulation is an electrochemical water
treatment process that offers an effective and
environmentally friendly solution for removing
contaminants from water. It is widely used in various
industrial, municipal, and environmental applications,
offering advantages such as effective contaminant removal,
reduced chemical usage, and flexibility in system design and
operation. However, careful consideration of system design,
operating parameters, and maintenance requirements is
necessary to ensure the successful implementation of
electrocoagulation for specific water treatment needs.
CONCLUSION
In conclusion, this research has demonstrated the feasibility
and effectiveness of implementing an automatic car washing
system controlled by Programmable Logic Controllers
(PLCs) and sensors. The integration of PLCs and sensors has
facilitated efficient and synchronized operation, resulting in a
streamlined car washing process. Additionally, the
incorporation of water treatment technologies, such as water
coagulation powered by solar energy, underscores the
system's commitment to sustainability and environmental
responsibility. Overall, this study highlights the potential of
automation and renewable energy in enhancing car washing
operations while minimizing environmental impact. Further
research and development in this area could lead to even
more advanced and sustainable solutions for the automotive
industry.
REFERENCES
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“PLC-based automatic car washing system using proximity sensors”
IEEE International Conference on power, control, signals and
Instrumentation Engineering (ICPCSI-2017)
[2] Amir Hossein, Daei Sorkhabi “Manufacturing of full automatic
carwash using with intelligent control algorithms” IEEE, Vol:7 No:3,
2013
[3] Yongjun Sun a,, Shengbao Zhou A, Pen-Chi Chiang B, Kinjal J. Shah
“Evaluation and optimization of enhanced coagulation process: Water
and energy nexus” Water energy-nexus, Volume 2, Issue 1, June 2019
[4] Dina T. Moussa, Muftah H. El-Naas, Mustafa Nasser, Mohammed J.
Al-Marri “A Comprehensive review of electrocoagulation for water
treatment: potential and challenges” Journal of Environmental
Management-2016
[5] Mika Sillanppa et al. “Removal of natural organic matter in drinking
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volume 190 Jan-2018
[6] Sharp, E.L., Parson, S.A., Jefferson, B., 2006. Coagulation of NOM:
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