Abstract:
A system to produce a high pressure stream of deionized water, for cleaning vehicle bodies, comprising, in combination, first and second deionization beds within first and second vessels, a first conduit or conduits to conduct non-deionized water at a relatively low pressure or pressures to pass through the first bed to deionize the water, a primary sensor to measure the deionization level of water that has passed through the first bed, a second conduit or conduits to conduct water from the first bed to the second bed to further deionize the water, if required, a pump to receive water that has passed through the first bed, or through the first and second beds, and to pressurized said received water to a level of at least about 1,200 PSI, and a nozzle connected to the pump to dispense a high pressure stream of the water.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to wash systems, such as systems relating to vehicle washing; more particularly it concerns method and apparatus for such washing, employing deionized water. 
     As is known, very large numbers of vehicles such as trucks, automobiles, and boats are hand washed frequently, employing tap water at city pressure below 100 psi, and/or soaps, and/or detergents. This results in required use of millions of gallons of tap water, and tons of soaps and detergents, frequently entering storm sewer systems and water bodies receiving flow from such sewer systems. 
     Although efforts to reduce industrial pollution have been successful, the lack of a low cost convenient alternative to hand washing of vehicles has prevented or has limited success in this area. In fact, the lack of an acceptable alternative has been responsible for issuance of exemptions for residential vehicle washing. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide cleaning apparatus and methods, employing a high-pressure stream or streams of de-ionized water, used in ways providing a solution or solutions to the above described problems. The use of a stream or streams of high-pressure de-ionized water, directed at vehicle surfaces, accomplishes superior cleaning, eliminates need for soap and/or detergent, enables spot-free air drying of such surfaces, and provides a time-saving incentive for the user. In this regard, water at city pressure of 65 PSI and flow rate of 6 GPM represents 390 cleaning units. A low flow high-pressure system like the present system typically may have a cleaning unit rating of 2520, or about 6 times the cleaning potential. This also helps to eliminate the need for soap and contributes to the water usage savings associated with the present system. 
     Basically, the improved system to produce a high pressure stream of deionized water, for cleaning vehicle metal bodies, comprises, in combination: 
     a) first and second deionization beds within first and second vessels, 
     b) a first conduit or conduits to conduct non-deionized water at a relatively low pressure or pressures to pass through the first bed to deionize the water, 
     c) a primary sensor to measure the deionization level of water that has passed through the first bed, 
     d) a second conduit or conduits to conduct water from the first bed to the second bed to further deionize the water, if required, 
     e) a pump to receive water that has passed through the first bed, or through the first and second beds, and to pressurize said received water to a level above about 1,200 PSI, 
     f) and a nozzle connected to the pump and operable to controllably dispense a high pressure stream of the water, for vehicle cleaning. 
     In one example, when operated with a credit card or token, the unit operates by passing water through two deionizing beds and then to a high-pressure pump. Water is dispensed through a hose and hand-held wand. Typically, automobile complete cleaning time is about 50 to 100 seconds, with a water usage of about 2 to 3 gallons, total. 
     A further object is to provide a by-pass conduit to return water from-the pump to one of the vessels when flow of water from the nozzle is interrupted, whereby the apparatus then operates at an idle level. 
     A yet further object is to provide valving controlled by the primary sensor to alter flow of water via the second conduit or conduits to the second bed, in response to detection by the primary sensor of an ionization level that is insufficiently low. 
     An additional object is to provide a data card reader, and control means responsive to operation of that reader to control flow of water in the system. In this regard, a chamber is typically provided in which the dionization vessels, conduits and pump are located, the nozzle located outside that chamber, the reader carried by the chamber to read information on a data card presented at a reading zone accessible at the exterior of the chamber. 
     Another important object is to provide control means includes circuitry responsive to reading of both valid and invalid data cards to effect flow of water to the beds. Such data cards typically comprise plastic credit cards. 
     A yet further object is to provide a means responsive to determination of a non-neutral pH level or unacceptable mineral content of water that has passed through at least one of the beds to effect all of the following: 
     i) shut down of water flow through the beds and pump 
     ii) energizing of a message display 
     iii) energizing of a display lamp 
     iv) message transmission to a control center. 
     An additional object is to provide a low pressure manifold structure including first and second manifold sections, valving blocking communication between the sections, the first section communicating with an inlet or inlets to at least one of the vessels, and the second section communicating with an outlet or outlets from at least one of said vessels, whereby water flows from the manifold first section to the manifold second section via a bed or beds in at least one of the vessels. 
     A further object is to provide an assembly operatively connected between the pump and nozzle and including 
     i) a regulator valve 
     ii) a first sensor comprising a flow pressure sensor at the downstream side of the regulator valve, 
     iii) and a second sensor comprising a flow sensor at the downstream side of the regulator valve, 
     iv) a by-pass conduit or conduits is connected between the regulator valve and the intake side of one of said deionization bed vessels, and 
     v) control means responsive to operation of the sensors, 
     whereby in the event of no-flow as sensed by the second sensor, and of high pressure as sensed by the first sensor, the control means operates to open the regulator valve to by-pass the flow to the intake side of the deionization vessel or vessels, and whereby in the event of high flow as sensed by said second sensor and very low pressure as sensed by said first sensor, the control means operates to shut down the system; and whereby, in the event of predetermined acceptable flow as sensed by the second sensor, and predetermined acceptable high flow pressure, the control means will allow the regulator valve to continue to pass the flow from the pump to the nozzle. 
     Additional objects concern provision of system control circuitry or software and methods of control for controlling operation (including business methods) of the apparatus in different modes, as will be seen, and basically including. 
     a) a wash station including water flow deionizing and delivery elements, and having at least two deionizing treatment beds, 
     b) computer apparatus associated with said station, and including circuitry, 
     c) said circuitry having first means for sensing an operating input by a user at said station, and to produce an output, 
     d) the circuitry also having 
     i) second means responsive to said output to initiate operation with flow to said deionizing and delivery elements, 
     ii) third means responsive to composition of said flow to control water flow through one or more of said beds, 
     e) and there being fourth means responsive to pressure of said flow to effect a change in said flow when said flow pressure changes relative to a predetermined limit or limits. 
    
    
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
     DRAWING DESCRIPTION 
     FIG. 1 is an elevation showing a washing station, and equipment, as during washing; 
     FIG. 2 is a view like FIG. 1, but showing the station with a washing nozzle in stored position; 
     FIG. 3 is an elevation showing the rear side of the station seen in FIG. 2; 
     FIG. 4 is a view like FIG. 3, but enlarged having the rear side of the container broken away, to illustrate interior details; 
     FIG. 5 is a view like FIG. 2, enlarged and having the front wall and doors broken away to illustrate interior details; 
     FIG. 6 is an enlarged view of the cabinet lower interior, to show interior details; 
     FIG. 7 is a block diagram showing system components in schematic form; 
     FIGS.  8 ( a )- 8 ( d ) are block diagrams showing status, of system components during is different flow, no-flow and high and low pressure conditions; 
     FIGS. 9-14 are block diagrams labeled for showing operation sequencing and functioning, as controlled by associated software means or elements. 
    
    
     DETAILED DESCRIPTION 
     In the drawings, a container  10  has side walls  11  and  12 , end walls  13  and  14 , a top  15 , and a perforated bottom panel  16  to enable inflow of cooling air, and drainage of water from the container interior  17 . Referring to FIG. 5, there are two inlets to the container wall  13 , inlet  20  for supply water as from city mains, at pressure for example between 60 psi and 70 psi, and electrical inlet  21  for a cable or cables. 
     Located within the container are a low water pressure manifold assembly  22 , as seen in FIG. 5, a high water pressure manifold assembly  23 , as seen in FIGS. 4 and 6, a back-flow prevention assembly  24  as seen in FIG. 6, and two vertically elongated deionization tanks  25  and  26  as best seen in FIG.  5 . The latter figure also shows piping connections between the low water pressure manifold ducting  30  which is shown as extending horizontally above the levels of the two tanks  25  and  26 , and the two tanks  25  and  26 . Also located within the container as seen in FIG. 4 are high-pressure pump  32 , and a hose reel  33 , from which hose  34  extends at the tank exterior to a nozzle unit  35 . That unit contains a valve  38  for delivering water as a high-pressure spray  39  for cleaning the surface of a vehicle by high-pressure spray impact see FIG. 1, showing a vehicle at  36 . 
     LOW PRESSURE MANIFOLD AND PIPING 
     Turning to FIGS. 5 and 6, entering water is first delivered upwardly in pipe  40  to the back-flow prevention assembly  24 , and then upwardly in pipe  40   a  to the left end  41   a  of manifold duct  30 , for rightward flow in the “in” or left section  30   a  of the manifold, located to the left of a valve  43 . That valve closes off communication between the left section  30   a  of the manifold and the “out” or right section  30   b  of the manifold duct. See also the FIG. 7 diagram, showing the manifold duct section  30   b  delivering water via line  44  at low pressure to the pump  32 . 
     Connected in parallel branch relation to the manifold “in” section  30   a  are two solenoid controlled valves  50  and  51 . When valve  50  is open, water flows via line  52  to top inlet  53  of first deionizor tank  25 , then downward in that tank and back upward, through deionizing beds  54 , and then to the tank outlet  55 . From outlet  55 , deionized water flows via piping  56 ,  57  and  58  to the top inlet  59  of second deionizer tank  26 . Water flows downwardly in that tank and back upwardly, through deionizer beds  60 , and then to the outlet  61  of the tank  26 . From outlet  61 , water flows in duct or pipe  62  to an inlet  63  to the manifold duct “out” section  30   b . From that section, water flows (at inlet pressure less any pressure drops) to the inlet  65  of pump  32 , via line  64  from filter  65 , as seen in FIGS. 4 and 5. 
     Referring to FIG. 5, it will be understood that the second solenoid valve  51  can be opened to deliver inlet water via line  66  to piping  57  and then via pipe  58  to tank  26 . In this regard, a solenoid valve  50  in pipe  52  can be closed, isolating tank  25  from pipe  57 , and tank  25  can then be removed, and a replacement “new” tank with a fresh deionizer bed can be substituted; or, the system can be shut down, and tank  26  put in the position of first tank  25 , and the “new” tank installed in the second tank position. The tank in the position of tank  25  normally removes 100% of the ionic material to be removed from the water flow, so the tank  26  functions mainly as a back-up in case the bed or beds in tank  25  are filled with removed solid material (for example, calcium, magnesium, aluminum, and their salts such as carbonates, sulfates, etc.). Ultra pure water (0-10 parts per million dissolved solids) is thereby delivered to the nozzle assembly, enabling provision of a soapless, high effective, high pressure wash system, for vehicles. High pressure (1,000-1,200 psi) at the nozzle provides a high velocity spray, for superior cleaning effect. 
     Various sensors are positioned along the water flow path to detect parameters. For example, referring to FIGS. 1 and 7, pressure sensing switch  50 ′ is connected into manifold section  30   a  and another pressure sensing switch  51 ′ is connected into manifold section  30   b . If the water pressure in either section is below a predetermined level, the switch connected to that section will signal the master control, such as computer  100 , as via lines  50   a  and  51   a  and the computer will shut down the system, including shutting off inlet valves  50  and  51 . A total dissolves solids (TDS) detector  70  installed in line  56  operates to detect the total dissolve solids in the flow from tank  25 , and if that level is too high, it will signal the computer  100  via line  71 , and the computer is programmed to by-pass tank  25 . A second TDS sensor  70   a  is shown as installed at manifold section  30   b . A pH detector  72  is connected to manifold section  30   b . pH level and total dissolved solids in the deionized flow to the pump are thereby detected. The computer circuitry will shut-down the system if these levels are abnormal. Note line  72   a  to the computer. A line  74  to drain is connected to manifold section  301 , in series with a manually operated valve  75 , and a sight glass  76 . At start-up, valve  75  is opened by hand, and flow in section  30   b  is tapped via  75  and  74 , and bi-pass flow visually monitored via glass  76  for pressence of air bubbles. When bubbles in the flow cease, valve  75  is closed. Pressure relief valve  77  is connected to manifold  306  to relieve pressure exceeding approximately 150 psig. This condition may occur for example if the unit is heated by the sun during non-operation, causing water in the manifold and tanks to expand. 
     Barrier valve  43  between  30   a  and  30   b  can be opened, if desired, and valves  50  and  51 , closed, enabling flow of untreated supply water to the pump and spray nozzle unit  35 , as during system maintenance and calibration. 
     HIGH PRESSURE MANIFOLD ASSEMBLY AND PIPING 
     Referring now to FIGS. 4,  6 ,  8 ( a ),  8 ( b ),  8 ( c ) and  8 ( d ), the high pressure manifold assembly  23  and its operation will now be described. It receives high pressure inflow of deionized water from the pump  32 , via line  80 . The assembly includes a flow unloader or regulator valve  81 , a relief valve  82 , a pressure indicating gage  83 , a pressure sensor  84  at the downstream side of the regulator, and a flow sensor  84   a  at the downstream side of the regulator. The following contingencies are monitored and handled, 
     a) pump discharge pressure exists at  80 , and discharge flow at  85  is blocked, as by turn-off of cleaning nozzle (see FIG.  8 ( a )), 
     b) pump discharge pressure exists at  80 , and discharge flow at  85  to cleaning nozzle is controlled with trigger operated valve  38 . (See FIG.  8 ( b )), 
     c) pump discharge pressure exists at  80 , but there is open (i.e. unrestricted) flow at  85 , due for example to inadvertent removal of nozzle unit  38  off hose  34 . (See FIG.  8 ( c )), 
     d) flow sensor  84   a  indicates no flow to nozzle, but pressure sensor  84  indicates high pressure. (See FIG.  8 ( d )). 
     Under condition a), the sensor  84  senses high pressure, and sensor  84   a  senses no flow, and their outputs operate via the computer to cause the regulator valve  81  to by-pass the flow via by-pass line  87  back to the pipe  88  connecting  51  to line a  57 , seen in FIG.  5 . The by-passed hi-pressure deionized water then flows back to join the deionized water stream from the two tanks  25  and  26 . This allows pump  32  to continue to operate. 
     Under condition b) the outputs from the sensors  84  and  84   a  operate via the computer to cause the regulator valve to pass water to the cleaning nozzle unit  38 . Excess pressure, should it occur, is relieved via the by-pass  87 , as described. If pressure exceeds, say, 1,500 psi (a pre-set high emergency level) relief valve  82  opens to discharge water into the interior of the container  10 , to drain out the bottom at  16 . 
     Under condition c), flow sensor  84   a  senses very high flow, and pressure sensor  84  senses very low pressure, and these signals are recognized as indicative of a failed or missing hose, trigger operated valve, and/or nozzle, and processed by the computer which then shuts down the water supply (closes valves  50  and  51 , and disconnects electrical power to the pump). 
     Under condition d), sensor  84   a  senses no flow, but sensor  84  senses high pressure. These signals are recognized by the computer as indicative of a failed regulator valve  81 . The computer shuts down the system and calls home. See FIG. 14 for the call home office software operation sequence. 
     Referring now to FIGS. 9-14, they show, in function-labeled block form, the operational sequencing of the apparatus controls, as during various modes of operation. Various blocks also define means responsive to outputs of prior sequence blocks to perform functions, as stated. 
     FIG. 1 also shows a credit card or token acceptor  110  on the front face  111  of the unit, as well as a start button  112  and card insert slot  113  for card (credit or account) reading. A status or instruction display is indicated at  114 . FIG. 10 shows the steps and means for start up, including unit run and start indication at  115 - 117 . In the event of attempted use of an invalid credit card, the programming allows unit start-up, but the home office is notified. Subsequent use of the invalid card does not permit start-up. See FIG. 10 a.    
     FIG. 1 also shows a holder  120  for the nozzle  35 , located at wall  12 . 
     Summary and Operation 
     (Typical Example) 
     The wash system consists of 5 sub-systems. These include: 
     1. control and monitoring system 
     2. communication system 
     3. deionizing system 
     4. high pressure delivery system 
     5. back flow prevention system 
     All sub-systems are contained within a vandal resistant steel housing. Advertising copy, operating instructions, warnings, credit card or token acceptor and hose outlet are located on the front face of the unit. Service access and deionizing bed-loading provisions are on the sides. Service connections consisting of potable water, electrical input and optional telephone are located at the rear of the unit. 
     When operated with a credit card or token, the apparatus operates by passing water through two deionizing beds and then to a high-pressure pump. Water is dispensed as for example through a 50-foot hose and a hand-held wand. Typical automobile cleaning time is about seventy-five seconds, with a water usage of about 2.5 gallons. 
     The control and monitoring system are contained within an electronics bay, a watertight steel box  125  within the outer housing. Basic control is through the use of a computer  126 , typically equipped with additional circuit cards that enable the computer to interface with various sensors and controls. 
     A watchdog system requires the computer to check-in at one-minute intervals. If a check-in is missed, the watchdog circuit communicates with head quarters by hard-wired telephone or cellphone, and indicates the machine location and nature of the problem. Technicians can then re-boot or, attempt to restore normal computer functions. If these attempts fail, a service call is made to the unit where by the problem is remedied. 
     Monitoring devices within the unit consists of two total dissolved solids (TDS) sensors, one pH sensor, three pressure switches and one flow switch. Data from these sensors is fed to the computer and logged and periodically transmitted via the Internet to head quarters. Deionizing bed selection, as well as unit shutdown decisions, are made by the computer based on data received from these sensors. 
     Software installed in each unit typically consists of a Windows 98 operating system. Unit control functions and transactions in Visual Basic™ monitoring and remote control of each unit from head quarters is accomplished through PC ANYWHERE™. 
     Under normal operating conditions, all data is reported as a text file that is converted to a database. This database provides credit card transaction data to Visa supplied Point of Sale (P.O.S.) software, which then transmits credit card activity data to Visa for payment processing. The database also supplies information for routine service requests and provides monitored data in report form. 
     Various options, such as evening shutdown periods, sensor normalization periods, displayed messages, etc. are also accessible for each unit. 
     The communication system allows monitored data to be viewed by company personnel, it provides verification of proper computer operation, and it transmits all transaction data. The system includes two independent communication devices. Primary communication takes place through the computer and sends encrypted data via the Internet. The second communication system utilizes a pre-programmed telephone dialer and operates in a direct dial-up mode with headquarters and through a dedicated pager system. This system communicates if a computer system failure occurs. This system is also used to interrupt power to the computer to permit the computer to re-start if required. Communication method is installation dependent and is either by cellphone or hardwired telephone connection. 
     The deionization system normally consists of between two and six deionization beds, sensors, valves and other components necessary to allow water to flow through the selected bed or beds and to verify proper operation of those beds. 
     The described low-pressure manifold, sensors, valves, hose connections, etc. in addition to their primary duties, also permit bleeding air from the system, allow for relief of high-pressure that can occur with changes in ambient temperature when the unit is not in use. The deionizing beds also serve as a heat sink to allow re-circulation of water when the pressure pump is operating but the wand is not in use. 
     In operation, the deionizing bed system will not significantly change the pH of the incoming or supply water but will reduce total dissolved solids (T.D.S.) to a value less than 10 parts per million. 
     The high-pressure delivery system includes the motor pump for increasing water pressure to 1200 psi, the high-pressure manifold, the hose reel, the hose, and the trigger operated wand. 
     The high-pressure manifold, contains an un-loader valve set at 1200 psi, a pressure-switch, flow-switch, pressure gage, and a high-pressure relief valve set at 1500 psi. These devices allow the computer to monitor pump conditions, hose conditions and also allow the computer to assign either run-rate charges or idle rate charges against the operators credit card. 
     The back-flow prevention system, is as required by all local water districts. In the event of a reduction in municipal water pressure, this system will prevent the flow of water from the deionizing beds or plumbing within the unit from entering the municipal water system. 
     FIGS. 9-14 are block diagram labeled for showing operation sequencing and functioning, as controlled by associated software means, or elements. 
     With reference to FIG. 9, and from what has been described, computer apparatus  100 , as referred to, is associated with the vehicle wash station. The system includes: 
     a) a wash station including water flow deionizing and delivery elements, and having at least two deionizing treatment beds, 
     b) computer apparatus associated with the station, and including circuitry, 
     c) the circuitry having first means for sensing an operating input by a user at the station, and to produce an output, including start-up (see  150 ), 
     d) the circuitry also having 
     i) second means responsive to said output to initiate operation of water flow to the deionizing and delivery elements, 
     ii) third means responsive to composition of the flow to control water flow through one or more of the beds, (see bed-selection sequence  151 ), 
     e) and there being fourth means responsive to pressure of the flow to effect a change in the flow when the flow pressure changes relative to a predetermined limit or limits. 
     The said fourth means typically includes at least one of the following: 
     x 1 ) a low pressure sensor (see block  152 ) 
     x 2 ) a high pressure sensor (see block  153 ) 
     X 3 ) both low pressure and high pressure sensors. 
     Also, and with regards to FIGS. 9,  11  and  13 , the fourth means typically includes a means to shut-down said flow in response to one of the following: 
     y 1 ) sensed flow pressure above a predetermined limit (see  154 ) 
     y 2 ) sensed flow pressure below a predetermined limit (see  155 ) 
     The circuitry also includes fifth means responsive to manual operation to shut-down operation of the system. (See block  156 ) 
     With reference to FIGS. 1 and 10, the first means typically includes one or more of the following to response to said operating input: 
     iii) a token payment sensor (see  160 ) 
     iv) an account card reader (see  161 ) 
     v) a credit card reader (see  162 ) 
     Note also in FIG. 10 the provision for parity check at  164 , boxes and functions at  165 - 170 , including start-up. See also FIG. 10 a , and functions. 
     With reference to FIGS. 5 and 12, the third mentioned means, which is responsive to the flow composition, typically includes: 
     iii) a first TDS sensor located to sense total dissolved solids in the flow from a first one of the beds, and to produce a control output, (see block  171 ), 
     iv) means responsive to said control output of the first TDS sensor to enable water flow input to a second of the beds when said sensor total disclosed solids in the flow from the first bed exceeds a predetermined threshold, 
     v) a second TDS sensor located to sense total dissolved solids in the flow from the second bed, and to produce an output, (see block  172 ), 
     vi) means responsive to said output produced by the second TDS sensor to effect shut-down of water flow in the system when the total dissolved solids in water flow from the second bed exceeds a predetermined threshold. (See block  173 ). 
     Also, water pH is sensed, as indicated by block  173 ′, and if, acceptable the unit continues to run. See block  174 . If not acceptable, shut-down occurs. See block  175 , and auxiliary functions. 
     With reference to FIGS. 1,  11 ,  12  and  13 , the computer circuitry typically includes auxiliary means for 
     z 1 ) shutting-down system operation 
     z 2 ) and communicating the operating or shut-down status of the system to a remote control location. 
     The remote control location may be a home office or headquarter having operative communication with the referenced auxiliary means, at the wash station, whereby efficient business communication is established, and also with respect to FIG. 14 sequencing. 
     With regard to FIG. 14, the computer circuitry may also include auxiliary dialing circuitry, see  176 , characterized by 
     z 3 ) an automatic dialing mode, (see block  178 ) operable to communicate station computer disabled status, to said remote location 
     z 4 ) a user operated dialing mode, operable to communicate a coded message to said remote location. (See-block  178 ). 
     A modem may be provided (see block  179 ) to transmit at least one of the following: 
     z 5 ) a call from said remote location to said station (see block  180 ) 
     z 6 ) a dialed call in one of said dialing modes 
     z 7 ) a message from said station, indicating station location, and nature of a problem with operation of the system.