Abstract:
A vehicle wash system includes a track system positioned above a wash area and a movable body coupled to the track system. The movable body is movable along at least two axes and includes a gripping mechanism to selectively hold and release one or more wash tools.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/764,618 entitled “Robotic Vehicle Wash System,” filed Feb. 14, 2013. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates in general to automatic carwashes, such as in-bay automatic car washes commonly called rollovers. 
       BACKGROUND 
       [0003]    In-bay automatic washes are designed to wash a vehicle after it has stopped within the wash bay rather than being pulled through the bay as is the case in a tunnel wash. In-bay automatic washes are typically installed at gas station convenience stores in conjunction with self-serve wash sites, lube centers or at car dealerships. About half of these machines installed are “touch-free” so that a chemical and high pressure water spray are used to wash the vehicle without the need for workers to touch the vehicle. The other machines are friction washes that use either a bristle brush, cloth pads or closed cell foam material to wipe away dirt off the vehicle surface. There are advantages and disadvantages to each of these machines and their associated process. As such, wash customers or operators typically have a definite preference as to which process type they prefer. Many customers will not use a friction wash if they prefer touch-free, and customers that prefer a friction wash will often not use a touch-free wash. Thus, washes that employ only one of these wash techniques (i.e., only touch-free wash or only friction wash) are often limited in the number of customers that will use their washes. 
       SUMMARY 
       [0004]    A highly flexible and programmable vehicle wash and dry system is described wherein, in some embodiments, an overhead wash robot or a portion of the robot may move longitudinally, laterally, and rotationally to carry out wash and dry functions to the vehicle. In some embodiments, the wash robot is able to contour the front, rear, and sides of a vehicle to be washed by longitudinal, lateral, and rotational motion commonly referred to X, Y, and Z, or “theta,” motion. The robot may have grippers, commonly referred to as effectors, for attaching washing tools such as brushes, rinse manifolds, sprayers, dryers, etc. In some embodiments, one effector may be located for vehicle top washing tools and the other for side washing tools. These grippers may be stored in respective docking stations out of the wash area until the controller determines a particular attachment is required for the next wash cycle or portion of a wash cycle. The robot, or a portion of the robot, may then move to the docking stations and attach the required wash attachments to carry out the appropriate wash functions with the corresponding wash attachments. 
         [0005]    A vehicle washing system is described that includes a washing bay for accommodating a vehicle to be washed and an overhead track system that may include a transversely spanning bridge supported on and guided by the track system for longitudinal reciprocal forward and backward movement over the wash bay. This forward and backward movement may be along an x-axis and a y-axis. In some embodiments, a servomotor is mounted on the bridge and/or track system with timing belts such that the servo motor selectively propels the unit forward and backward along the overhead track the length of the vehicle for y-axis travel. The bridge may have a shuttle unit mounted thereon that is adapted for lateral reciprocal motion thereupon over the width of the vehicle along the x-axis. A second servomotor with a timing belt may be mounted on the shuttle and may selectively propel the shuttle laterally overhead the vehicle for the x-axis. The shuttle may have several load bearing guiding idler wheels to engage the bridge guiding surfaces. The shuttle may support, and may be rotationally coupled to, a vertical bearing shaft through the center by which a frame, or theta body, hangs thereunder. In some embodiments, a third servomotor is mounted onto the shuttle and rotates the theta body about a third, vertical axis for “theta” motion. A side effector may be located at one end of the theta body and an upper effector may be located on the upper back of the theta body. The theta body may include other effectors on other portions of the theta body and the system may include other effectors on other portions of the system. In some embodiments, due to the fact that the theta body is relatively wide and attaches the wash tools to effectors on one of the distal ends, the theta body may have increased reaching capability relative to the overall size of the system. Even though the length of travel of the theta body in the lateral direction on the bridge may be shorter than the total width of the car washing system, side wash tools can be coupled to the support frame perimeter to extend the reach of the theta body. The wash robot may also have a sensor to pick up the vehicle contours, such as, for example, the front, back and side edges of the vehicle. The robot may include drying blower motors and fans for precise drying control during a dry cycle. The drying blower motors and fans may be located on and movable with the theta body or may be located elsewhere on the robot. 
         [0006]    The aforementioned robot effectors may have pickup alignment or stab shafts to guide the robot into the wash tools on respective docking stations and to align the robot with respect to the wash tools Likewise, the wash tools may have tapered, hollow guide features to help locate the alignment shafts. Pneumatic actuators located within the guide features or otherwise associated with the guide features may help lock the robot to the wash tools. The actuators, or other locking devices, may keep the respective wash tool locked into either the docking station or the assigned robotic effector, depending on where the system is in a particular wash cycle. Upon the event that the chosen tool is a side brush, upon engagement, a motor may be magnetically coupled to the brush for powered rotation to scrub the sides of the vehicle to be washed. The motor may be part of the theta body or may be located elsewhere on the robot or system. Upon the event that the chosen tool is a pressure washing arm, the stab shafts are locate into the tool head and are forced into sealing glands to allow for water or other fluids to be transferred to the washing arm. In this way, liquids can be transferred from a remote pumping system, through the robot, into the wash arm, and out onto the vehicle during a wash cycle. The side effector may have a built in breakaway knuckle mechanism to prevent vehicle or system damage during an impact to the side attachment. Once the obstacle is removed, the knuckle can automatically center itself back to the original position. 
         [0007]    In some embodiments, the system support frame has four support legs mounted on the wash bay floor that extend upward toward the ceiling for supporting an overhead structure. The system support may encompass a wash area in which an automobile is located to be washed. For example, the system support may encompass an area that is slightly larger than a vehicle and the vehicle may be driven into this area prior to commencement of a wash cycle. Two crossbeam headers at each end of the system support frame are supported by two respective legs, and two structural  3   d  trusses spanning the length of the support frame are supported from the headers and also serve as the track for the carriage and theta body. Each of the trusses may be independently rigid in a vertical and horizontal plane to support the weight of the robot, carriage and/or theta body. Each truss also serves as structural reinforcement laterally due to the side to side motion of the robot on the frame. The driver&#39;s side truss may have two docking stations for retaining side tools, such as a side brush and a pressure wash arm, while the passenger&#39;s side truss may have one docking station for the top wash tool, such as a mitter curtain. Other configurations and locations are possible for the docking stations and any number of docking stations may be included in the system. In some embodiments, many more than three wash tools could be utilized by the system. For instance, the system may include a top wash tool that is a high pressure wash bar or a rotating top brush with some adaptations to the robot. The side tools could also include a rocker panel blaster arm or a rotary wheel scrub brush with no modification to the robot. 
         [0008]    In some embodiments, during a touch free wash cycle, presoak soap and high pressure wash, water is fed from a remote off-board pumpstation into the robot. High pressure nozzles, preferably turbo-nozzles, may be located on a top spray bar permanently attached to the theta body or other portion of the robot, and then a separate spray bar may be incorporated into a side tool high pressure arm that can be attached to the theta body. Similarly, touch-free application soaps may be fed through a second spray bar next to the high pressure bars. The robot may apply the presoak first and then the high pressure rinse thereafter. In both instances, the robot controls the arm around the periphery of the vehicle so as to circumscribe the entire perimeter of the vehicle on each respective cycle while maintaining an optimal distance of approximately 16 inches away from the vehicle. 
         [0009]    In some embodiments, the system is controlled by a logic controller and at least one motion controller. Servomotors may be connected to amplifiers and motion controllers to determine where the robot and/or theta body are in the wash bay with great accuracy. The servomotors may be closed loop with encoders providing positioning. 
         [0010]    Other aspects of the system will now be generally described. In one aspect, the system has docking stations in the wash bay corners that are somewhat cloaked by the wash bay entrance wall and not readily visible to the vehicle driver. As described above, the robot may have the ability to grip and attach whatever wash attachment is desired during the wash process, whether it be a touch free arm, a set of brushes, or a mitter curtain. If a customer selects a touch free wash, the customer may not see any brushes on the robot during operation and will likely not notice the brushes in the docking stations, thereby removing concerns about a brush touching the customer&#39;s vehicle. 
         [0011]    In another aspect, the system uses a single sensor to detect the positioning of the vehicle. This may simplify the amount of vehicle detection sensors, and thereby reduce the cost to manufacture the system and increase the reliability of the system. Additionally, the sensor may be mounted on the robot or theta body thereby giving multiple measurement points and flexibility depending on wash requirements. For example, the sensor may be mounted on the theta body so that the sensor can be moved by the theta body to different positions with respect to the vehicle. As such, a single sensor may be used to locate a front, rear and side edges of the vehicle. The robot may measure out all vehicle dimensions on an initial scan pass without any wash apparatus attached to the robot. 
         [0012]    In another aspect, the system may include a blower unit that is movable with the theta body in an X, Y, and Theta coordinate system to provide a customized dry process to the vehicle. The dry process may be customized according to the vehicle size, shape, and position in the wash bay. 
         [0013]    In another aspect, after the wash process and prior to the drying process, the wash robot may drop off the wash attachments. This way, wash tools such as dripping brushes are stored off the robot and away from the dry process. Additionally, without any attachments hanging below, the robot can position the dryers laterally and angularly in any position desired for optimal drying and shedding water off the vehicle. 
         [0014]    In another aspect, the robot has three constant torque high speed permanent magnet servo motors with closed loop feedback encoding to determine the position, speed, and torque of the positioning motors. Thus, in some embodiments, the robot needs no proximity switches to determine machine positions. The servomotor motion controller detects home and end of travel positions by means of hard stops during power up and then retains all positions in memory. This can reduce proximity switch count by 5 or 6 switches increasing reliability and easing troubleshooting. The robot or a portion of the robot, such as the theta body, may travel on an X-Y coordinate in the wash bay and may rotate about a theta axis for orienting the robot into the correct position. This way the robot can operate whatever wash device in any angular position and any location within the wash area. This provides an increased capability to wash vehicles of all different shapes and sizes with much greater flexibility. 
         [0015]    In a further aspect, there is provided a vehicle wash system that includes a track system positioned above a wash area and a movable body coupled to the track system. The movable may be movable along at least two axes and may include a gripping mechanism to selectively hold and release one or more wash tools. 
         [0016]    In some embodiments, the movable body is rotatable about a third axis that is perpendicular to the at least two axes. In another embodiment, the movable body includes a sensor for sensing a position of an automobile in or near the wash area. In certain embodiments, the sensor is movable with the movable body to sense a forward edge of the automobile and a rear edge of an automobile. In other embodiments, the movable body includes a blower for drying an automobile in or near the wash area and a motor for powering the blower. In another embodiment, the vehicle wash system includes a first motor for moving the movable body along a first axis of the at least two axes and a second motor for moving the movable body along a second axis of the at least two axes. In yet another embodiment, the first and second motors are coupled to an encoder and the encoder is coupled to a controller for determining the position of the movable body. In still another embodiment, the first motor is controllable independently of the second motor. In some embodiments, the one or more wash tools include one or more of a wash tool to wash a side surface of a vehicle, a spray bar to spray a liquid onto the vehicle and a blower for drying the vehicle. In another embodiment, the vehicle wash system includes a docking station to hold the one or more wash tools that are not in use. 
         [0017]    In another aspect, a vehicle wash system includes a support structure positioned over a wash area, a sensor movably coupled to the support structure, and a controller. The sensor may be positionable above a vehicle in the wash area to detect entry of the vehicle into the wash area. The controller may receive a signal from the sensor and to send a warning signal to a user interface if the signal from the sensor indicates that the vehicle has moved outside of the wash area. In certain embodiments, the vehicle wash system includes a movable body that is movably coupled to the support structure and is couplable to one or more washing tools. The sensor may be coupled to the movable body. In other embodiments, the sensor is positionable to detect a front edge, a rear edge and one or more side edges of the vehicle. In another embodiment, the sensor is directed downward. 
         [0018]    In another aspect, a vehicle wash system includes a support structure and a movable body that is coupled to the support structure. The movable body may be movable along a first, horizontal axis and may be rotatable about a second, vertical axis. The movable body may include a powered device for facilitating a vehicle wash, such as, for example, a motor, a wash tool, an actuator or any other powered device. In certain embodiment, the powered device is an arm that is foldable to position the arm adjacent to the movable body. In other embodiments, the powered device is an arm with rotatable scrubbers. 
         [0019]    In another aspect, there is described a method of washing an automobile. The method may include grasping a washing tool with a movable body that is movably coupled to a track system. The method may also include moving the movable body so that the washing tool washes the automobile and then placing the washing tool in a docking station. The method may include releasing the washing tool from the movable body. In some embodiments, the method includes grasping a second washing tool, moving the movable body so that the second washing tool washes the automobile, placing the second washing tool in a second docking station, and releasing the second washing tool from the moving body. In other embodiments, moving the movable body so that the washing tool washes the automobile includes washing a side surface of the automobile, moving the movable body around a perimeter of the automobile and washing an opposite side surface of the automobile. In another embodiment, moving the movable body so that the washing tool washes the automobile includes moving the movable body along a first axis, moving the movable body along a second axis and rotating the movable body about a third axis that is perpendicular to the first and second axes. In still another embodiment, the method includes sensing a position of the automobile with a sensor located on the movable body. 
         [0020]    In another aspect, a vehicle wash system includes a track system positioned above a wash area, a movable body coupled to the track system and a sensor for sensing a location of a side surface of the vehicle. The movable body may include a blower for drying a vehicle and the movable body may be movable along an axis to position the blower adjacent to a sensed location of the side surface of the vehicle. In some embodiments, the sensor senses a location of a second side surface of the vehicle that is opposite from the first side surface. The movable body may be movable along the axis to position the blower adjacent to a sensed location of the second side surface of the vehicle. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a perspective view of one embodiment of a wash system with a vehicle positioned within the wash bay. 
           [0022]      FIG. 2A  is a perspective view of one embodiment of the robot theta body with the pressure wash arm tool attached and having protective covers installed. 
           [0023]      FIG. 2B  is a perspective view of one embodiment of the robot theta body with the side brush tool and mitter curtain tool attached. 
           [0024]      FIG. 3  is a perspective view of one embodiment of the wash robot unit showing Y axis bridge structure and the X axis shuttle frame. The theta body is also shown with protective panels removed from the theta body for clarity. 
           [0025]      FIG. 4A  is a detail perspective view of one embodiment of the X axis shuttle with Theta drive components included. 
           [0026]      FIG. 4B  is partially sectioned perspective view of one embodiment of the X axis shuttle with Theta drive components included. 
           [0027]      FIG. 5  is a rear detail perspective view of one embodiment of the theta body and on-board blower incorporated therein. 
           [0028]      FIG. 6  is a perspective view of one embodiment of the system support frame with Y axis support beams. 
           [0029]      FIG. 7A  is a cropped perspective view from below of one embodiment of the side effector shown in the theta body of  FIG. 3  and  FIG. 5  and engaging one of the side docking stations of  FIG. 1 . The side wash tool is hidden, while showing the lock mechanism and how it engages the side effector and docking station stab shafts during docking. 
           [0030]      FIG. 7B  is a further detailed view of one embodiment of the lock and stab shafts and illustrates the engagement between locking elements. 
           [0031]      FIG. 7C  is a detailed view of a one embodiment of a lock. 
           [0032]      FIG. 8A  is a cropped exploded view of one embodiment of the side effector shown in the theta body of  FIG. 3  and  FIG. 5 . and engaging the pressure wash tool docking station of  FIG. 1 . Details of one embodiment of the pressure wash tool is shown as well. 
           [0033]      FIG. 8B  is a cropped view of one embodiment of the side brush tool while locked into the side effector. 
           [0034]      FIG. 8C  is a detail exploded view one embodiment of the side brush tool. 
           [0035]      FIG. 8D  is a cropped view of one embodiment of the mitter curtain tool while locked into the top effector. 
           [0036]      FIG. 9  is a schematic view of one embodiment of the robot motion control system. 
           [0037]      FIGS. 10A and 10B  are top and side schematic illustrations of one embodiment of a vehicle driven into the wash bay and breaking the laser beam during initial vehicle position detection in the wash bay. 
           [0038]      FIGS. 10C and 10D  are top and side schematic illustrations of one embodiment of the robot theta body indexed with the laser beam clearing the vehicle leading edge during initial vehicle position detection in the wash bay. 
           [0039]      FIG. 11  is a top schematic path-of-travel diagram for one embodiment of the laser sensor during vehicle dimension scanning. 
           [0040]      FIG. 12A  is an entrance schematic view of one embodiment of the wash robot adjusting to map the side position of the vehicle. 
           [0041]      FIG. 12B  is an entrance schematic view of one embodiment of the wash robot adjusting the theta body and side tools according to vehicle size or position. 
           [0042]      FIG. 13  is a top schematic path-of-travel diagram for one embodiment of the side wash tool and theta axis during a wash cycle. 
       
    
    
     DETAILED DESCRIPTION 
       [0043]    In the description which follows like parts are marked throughout the specification and drawing with the same reference numerals respectively. The drawing figures are not necessarily to scale and certain features may be shown in generalized or schematic form in the interest of clarity and conciseness. 
         [0044]      FIG. 1  shows one embodiment of a vehicle wash system  100  with a vehicle  29  located in the vehicle wash system  100  on a wash bay floor  21  and stopped at a nominal washing position according to the instructions of traffic light  122  located at the wash bay exit area. An elevated, generally rectangular support structural frame  20  covers the wash area in a horizontal plane, spans across and extends along the majority of the wash bay floor and is supported at each respective corner with vertical support corner stanchions  37 . Two spaced apart, opposed, independent longitudinal box beams  40  are supported within the frame and extend the length of the frame  20 . A vehicle wash robot is generally indicated with the reference numeral  30  and is supported on the frame  20 . On each side of the wash bay area and hanging down below the frame  20  are attachable wash tools  26 ,  27 , and  28 . Each respective wash tool  26 ,  27  and  28  is retained within a respective docking station  22   a,    22   b,  and  163 . On the driver&#39;s side, wash tools  27  and  28  are retained in respective docking stations  22   a  and  22   b,  and on the vehicle passenger&#39;s side of the wash area wash tool  26  is retained in docking station  163 . The support frame  20  has four vertical support legs or stanchions  37 , each respectively supporting a corner of the frame  20 . 
         [0045]    Briefly referring to  FIG. 2A , the theta body  53  is here shown with pressure wash attachment  27  locked into the robot theta body  53 . The theta body  53  is shown with protective covers  124  shrouding the theta body  53 . Likewise protective covers  77  shroud the pressure wash attachment  27 . 
         [0046]      FIG. 2B  shows the theta body  53  adapted for friction washing with mitter curtain tool  26  and side brush tool  28  locked into the wash robot  30 . 
         [0047]      FIG. 3  is a perspective view of one embodiment of the wash robot  30  showing Y axis movement structure  500  and the X axis movement structure  502 . The theta body  53  is also shown with protective panels  124  removed from the theta body  53  for clarity. Referring now to  FIG. 3 , the wash robot  30  has three independent stages of motion: motion in the x-axis, motion in the y-axis and rotational motion around the z-axis. The axes of motion are characterized by a moveable bridge  52  which travels along a Y axis  300  of motion, a shuttle unit  51  which travels along an x-axis  302  of motion by laterally traversing on the bridge  52  along the x-axis  302 , and a theta body  53  which is supported by and rotationally coupled to the shuttle unit  51 . 
         [0048]    The bridge shuttle  52  has a simple structural frame  54  with two spaced apart parallel box beams  59  oriented perpendicular to the support beams  40  and spanning a distance between the support beams  40  over and across the wash bay area (not shown). The structural frame  54  includes an end plate  61   a  capping the beams on the drivers side of the frame and an end plate  61   b  capping the beams on the opposite end of the frame. Together, these four elements (the parallel box beams  59  and the end plates  61   a  and  61   b ) form a basic rectangular frame  54  that is movable in the y-axis along the support beams  40 . Each end plate  61   a  and  61   b  has a pair of idler axes or pins  63   a  mounted perpendicular to the surface of the end plate  61   a  or  61   b  and having idler wheels  62   a  rotationally mounted for rolling along support beams  40 . End plate  61   a  has a cutout relief wherein a channel  164  is welded in through the plate  61   a  in addition to the two spaced apart idler axles  63   a  with the guide wheels  62   b  rotationally mounted thereupon. The guide wheels  62   a  straddle and roll against drivers side support beam  40  thereby laterally constraining the bridge shuttle  52  as it rolls along the support beams  40 . 
         [0049]    Additionally, servomotor  31   a  is suitably mounted into endplate  61   a  with timing drive pulley  35  coupled to the motor drive shaft by means of a taperlock bushing. The bridge y-axis drive shaft  34  spans the bridge shuttle  52  and has supporting flange bearings  36  bolted into the endplates  61   a  and  61   b  on each end. Inboard of the drive shaft passenger&#39;s side distal end is a relatively large gearing reducer timing pulley  32  is coaxially located, and inboard of each end bearing of the drive shaft  34  is a y-axis linear timing belt pulley  36  having timing belts  33  drivingly wrapped around the belt pulleys on each end of the bridge shuttle  52 . Referring to  FIG. 6 , the timing belts  33  (not shown) are each terminated with the support frame  20  at an entrance terminating clamp point  161  and an exit terminating clamp point  162 . Referring again to  FIG. 3 , the timing belt idlers  136  are rotationally secured into each end plate  61   a  and  61   b  as well. Each y-axis linear timing belt  33  is routed from an entrance clamp point  161  ( FIG. 6 ), around a timing pulley  36 , back-bended around an idler pulley  136 , and then terminated at an exit clamp  162  ( FIG. 6 ) forming an elongated Z shape routing form in each y-axis timing belt  33 . A timing belt  46  is drivingly coupled between the servomotor pulley  35  and the reducer timing pulley  32 . In this way, each end of the bridge shuttle  52  has a linear timing belt  33  drivingly engaged with the drive shaft  34  for stable reciprocal motion along the y-axis of travel. 
         [0050]    Referring to  FIGS. 3 and 4A , an x-axis shuttle  51  is shown, adapted for linear reciprocal motion on the bridge beams  59  of the bridge shuttle  52 . The x-axis shuttle  51  has a simple aluminum welded frame  55  with two side plates  70   a  and  70   b  connected together with a top plate  67  and a bottom plate  68  forming a generally box type construction with two open ends. Each side plate  70   a  and  70   b  has two horizontally extending idler wheels  69   a  to support the shuttle on beams  59  of the bridge shuttle  52  and also has a lower guide idler  69   b  underneath idler wheel  69   a.  Top plate  67  extends beyond the bridge beams  59  with four vertically oriented guiding idlers  69   b  constrained therein and guidingly engaging both sides of bridge beams  59 . 
         [0051]    Further detail on the x-axis and theta axis power transmission components of the x-axis shuttle  51  can be seen in  FIGS. 3 and 4B . The x-axis shuttle servomotor  64   a  is bolted into top plate  67  ( FIG. 4A ). Similarly, the x-axis drive jack shaft  154  has flange bearings  153   a  and  153   b  on each end bolted into the top and bottom plates  67  ( FIG. 4A) and 68  respectively, and driven timing gear  152  coaxially constrain thereon as well. A driver pulley  74  on the end of the servomotor  64   a  shaft is coupled to the timing gear  152  by means of a timing belt  157 . The jack shaft  154  also has a timing belt pulley  152  coupled to it below timing gear  152 . A timing idler pulley  75  is mounted to the bottom plate  68 . Referring specifically to  FIG. 3 , on each end of the bridge shuttle  52  a suitable timing belt termination clamp  60   a  and  60   b  is located: a first clamp  60   a  on the driver&#39;s side and a second terminating clamp  60   b  on the passenger&#39;s side. An x-axis timing belt  66  is routed from the second clamp  60   b,  around drive pulley  152  ( FIG. 4B ), then backbending around idler pulley  75  ( FIG. 4B ), then terminating at clamp  60   a,  forming a generally elongated Z formation along its path. 
         [0052]    The theta steering gear  73  of the x-axis shuttle  51  is also shown in  FIG. 4B . A vertically oriented jackshaft  151  supported by a rotational bearing  147   a  at the top and  147   b  at the bottom, with the top bearing bolted into cover  124  ( FIG. 2A ) and the bottom bearing bolted into lower support channel  168 . A timing pulley  72  is coaxially mounted onto the jackshaft  151  with a smaller driver pulley  146  mounted just above. Theta servomotor  71   a  is bolted onto the shuttle weldment  55  by means of support bracket  140  ( FIG. 4A ). Driver timing pulley  78  is mounted onto the servomotor drive shaft. A timing belt  143  is coupled between the pulley  78  and the larger timing pulley  72 . Within the center shuttle frame, a relatively large, vertically oriented tube  81  is welded in as part of the frame  55 , and houses theta body bearings  80   a  and  80   b  ( FIG. 5 ) when the theta body  53  is fully assembled with the x-axis shuttle  51 . The aforementioned large Theta steering pulley  73  is coupled to the driver timing gear  146  by means of a timing belt  79 . 
         [0053]    Briefly referring now to  FIGS. 4B and 5 , theta body  53  is axially secured into the x-axis shuttle  51  with a radial array of bolts (not shown) secured through bolt holes  400  in the steering gear  73  and into mounting holes  402  of the rotation tube  76  of the theta body  53 . In this way, the theta body  53  is rotationally coupled to the servomotor  71   a  through the power transmission gearing. Vertically spaced apart support bearings  80   a  and  80   b  are fitted onto the rotation tube  76 . 
         [0054]    In  FIG. 5  the theta body  53  is shown without protective panels  124 . The theta body  53  has a welded aluminum frame  156  having a horizontal elongated box beam  84  with a clearance hole (not shown) into which the structural rotation tube  76  is welded. The majority of the length of the rotation tube  76  is protruding out the top face of the beam  84  thereby allowing a suitable pair of spaced apart bearings  80   a  and  80   b  to be installed over the beam  84 . A connecting bar  86  is welded to the bottom side of each end of the beam  84 . The connecting bars  86  extend downward to connect to a lower horizontal beam  85  thereby forming the basic frame structure of the theta body  53 . Tubular standoffs  88   a  and  88   b  welded at each end of the box beam  84  extend outwardly along a horizontal plane. An auxiliary connector  89  is welded between the standoffs  88   a  and  88   b  that is parallel to and spaced apart from the box beam  84 . At a distal end of the standoff  88   a,  a horizontal flat plate  94   a  is welded for securing a retaining block  92  and an effector stab shaft  95   a.  The effector stab shaft  95   a  includes a point at the distal end for engaging a mitter curtain tool  26  ( FIG. 2B ), as will be described in more detail below. Likewise, at the end of standoff  88   b  includes a horizontal flat plate  94   b,  a retaining block  92  and an effector stab shaft  95   b.    
         [0055]    In the center of connector  89 , an adjustable plate  90  in bolted for supporting and providing strain relief to cables (not shown). At one end of the lower beam  85 , an end plate  87  is welded for bolting on an effector breakaway block to support a side effector  57 . Also welded to the frame is a channel  165  that holds a laser sensor  117  so that the laser beam  139  is pointed downward toward the vehicle or wash bay floor (not shown). The theta body  53  also includes a blower unit  58  that is coupled to the weldment  156 . Two motor mounting plates  166  are located below box beam  84  for holding blower motors  83 . 
         [0056]      FIG. 6  provides greater detail as to the elements of the system support frame  20 . Two welded structurally rigid trusses  39   a  and  39   b  provide gravitational support as well as lateral stability from the acceleration and deceleration forces generated from the dynamic movement of the wash robot  30 . Both trusses  39   a  and  39   b  have a generally triangular cross sectional profile with an upper structural beam  49   a  and a lower structural beam  49   b  connected together by an array of vertical connectors  41 , forming a basic rail shape. Also incorporated into the truss  39   a  and  39   b  is a travel support beam  40 , which is parallel and spaced apart from the structural beams  49   a  and  49   b.  Connecting beam  40  to beam  49   a  is an array of horizontal members  44 , and connecting lower beam  49   b  to beam  40  are diagonal connectors  45 . Spaced apart parallel trusses  39   a  and  39   b  are connected together by means of entrance header  38   a  and exit header  37   b  forming the basic overhead frame system having four vertical support stanchions  37  to support the frame  20  above a vehicle. 
         [0057]    In  FIG. 7A , shows the side of the theta body  53  and the side attachment effector  57  with the side tool hidden for clarity. The theta body  53  is engaged with docking station  22 . The side tool docking station  22  is mounted onto the end of tubing stub  42  with a u-bracket  167 . The u-bracket  167  has four alignment isolators  150 , and a plate  144  bolted to the other side of the isolators. The plate  144  retains a pair of stab shafts  134  that protrude for engaging the selected side wash tool  27  or  28 . 
         [0058]    Referring now to the lower frame beam  85  of the theta body  53 , at the end of the theta body lower frame beam  85  there is an attachment plate  87  for mounting a side effector breakaway v-block  159 .  FIG. 8A  shows an upper view of the breakaway v-block  159 . The breakaway v-block  159  has a close tolerance clearance hole (not shown) provided with an axially and radial moveable shaft  113  mounted therethrough. The outboard end of the shafts  113  has a crosspin shaft  109  welded to form a t-shaped connector for two axis of rotational controlled motion for the breakaway function of the v-block  159 . Referring specifically to  FIG. 7A , the shaft  113  has screw threads cut therein for tightening a hex nut  615 . The hex nut  615  moves thrust washer  112 , which in turn, compresses spring  110 , which thereby pulls the shaft  113  and crosspin  109  to draw the side effector thrust rollers  108  ( FIG. 7B ) into the v-block  159  forcing alignment to the robot  30  during a normal operational condition, while allowing for two axis of breakaway motion. A closer detail of the side effector, locking pin  109 , and stab shafts  104  is shown in  FIG. 7B . The side effector  57  is a rigid structure with a machine block  158  to house and tightly control alignment of stab shafts  104  fitted into a side face and extending outwardly from the robot  30  to engage selected side tools  27  or  28  and are each ported to channel fluid from the robot into the pressure wash side tool  27 . A pair of spaced apart plates  106  are welded on the opposite block face and facing inwardly toward the theta body  53 . Each plate  106  has a roller  108  rotatably secured for engaging the v-block  158 . At one end of the block  158 , plate  97  is welded for bolting side tool lock pneumatic actuator  114 . On the other end of block  158 , a flange ring  103  ( FIG. 8A ) is welded to support motor  102 . A pair of compression springs  148   b  are bolted in between the stab shafts  104  and pocketed into the block  158  for bias pressure locking side tools therein. An angle bracket  50  ( FIG. 7A ) is mounted on actuator  114  to hold lock shift guide pin  48 , which upon side tool engagement sides into side tool lock block  47  so the actuator  114  can shift the lock for selectively locking the side tool into either the side effector, or into the docking station as required by the system.  FIG. 7C  shows the baseplate  91   a,  the effector lock pin  91   b  mounted on the baseplate  91   a,  and a docking lock pin  91   c  mounted on the baseplate  91   a.  Each lock pin  91   b  and  91   c  has respective reliefs  132  and  133  machined that serve as clearances for the respective stab shafts  104  and  134  to pass through when the appropriate side tool is slid into or pulled out of the side effector or docking station as needed. The stab shafts  104  and  134  each have respective reliefs for engaging or clearancing the respective pins  91   c  and  91   b  as needed as well. 
         [0059]    In  FIG. 8A  shows the pressure wash arm side wash tool  27  aligned with the side effector  57  and the docking station  22 , and shows the basic elements of the tool  27  starting with the head block  111 . The head block  111  is fitted with a set of gland seals  160  to receive the effector stab shafts  104  such that a pressure seal is made and wash fluids can be transferred from a remote source through the robot  30  and into the tool  27  as required. Two pipes  145   a  and  145   b  serve as liquid dispense manifolds due to generally equally spaced out tapped holes for even distribution, and high and low pressure nozzles  23   b  and  23   a  respectively screwed into the tapped holes for dispensing wash fluids onto the vehicle. The pipes  145   a  and  145   b  have a common flange welded to them on the upper terminating end for securing to the head block  111 , and flexible hoses  149  for porting the fluids out of each respective seal gland  160  to the respective pipe in fluid communication with it. 
         [0060]    In  FIG. 8B , the side brush washing tool  27  is shown attached to the robot theta body  53  by means of the side effector  57 . A head stab block  141  having close tolerance clearance holes to accept stab shafts and a clearance hole through the center top to bottom is fitted on top with an adapter plate  142  ( FIG. 8C ) so as to accept a hollow bore right angle worm gear style speed reducer  137  by means of bolted fasteners. The reducer  137  has an input shaft with a rare-earth magnetic coupler  105   b  affixed to it. A rotary cleaning brush  127  having a drive shaft  138  ( FIG. 8C ) is mounted into the speed reducer  137 . A lock  107  ( FIG. 8C ) with a predetermined amount of axial freedom of movement is permanently retained within the head stab block  141  for selectively engaging a docking station  22  or the robot side effector  57  as required. Similarly, a rare-earth magnetic rotary power transmission coupler  105   a  is mounted onto the end of drive motor  102  such that when the side brush wash tool  28  is locked into the robot, rotational power can be transmitted from the motor  102 , through magnetic couplers  105   a  and  105   b , and into the side brush for scrubbing the vehicle. 
         [0061]    Referring to  FIG. 8D , the mitter curtain wash tool  26  is shown in attached to the robot theta body  53  to carry out cleaning of the vehicle top surfaces. The mitter curtain wash tool  26  has a sheetmetal frame  128  with an array of angular crossmembers  131  welded to it for strengthening the frame  128  and to secure the upper end of cloth strips  129  hanging down underneath for cleaning the vehicle top surfaces. Plastic engaging stab blocks  116   a  are bolted onto the frame  128  as a point for the theta body  53  to secure the tool  26 , and to locate the wash tool  26  into a top wash tool docking station, not shown in detail. A pair of stab shafts  95   a  extending out from the theta body  53  engage and then are locked into the mitter curtain stab blocks  116   a  by means of a locking shaft  98   b  which is retained within the mitter curtain tool  26  and is actuated by pneumatic cylinder  93  to slide the locking pin to a position for locking the mitter curtain tool  26  into either the theta body  53  or into the docking station. A rectangular machined block  98   a  is welded to locking shaft  98   b  with a guide pin  98   d  protruding out of one face for linear engagement with a plate  123  mounted to the actuator  93 . Another pin  98   c  is welded into the block  98   a  to keep the lock shaft  98   b  in the optimal angular orientation. 
         [0062]    Referring to  FIGS. 9 , one example embodiment of the operation of the wash system  100  will be described. The system  100  overall control is determined by a programmable logic controller  600 . Specific wash site parameters are selected or adjusted within the controller  600  by means of an operator interface  602 . Selectable parameters include, but are not limited to, wash cycle speed, sensor calibration, robot training parameters, errors, maintenance, etc. Additionally, the logic controller  600  also receives commands by way of a customer personal interface  604 . The controller  600  may have an analog, digital, and discreet input/output in addition to a multi-axis motion controller utilizing software such as G-Code or an advanced form of C. The wash robot  30  is capable of three axis of motion: x-axis  302  linear motion, y-axis  300  linear motion, and theta axis  304  rotational motion (i.e., rotation about the theta axis  304 ). The motion controller controls three motors  64   a,    31   a,  and  71   a  by means of an amplified three phase PWM power wave to each motor  64   a,    31   a,  and  71   a.  The power wave provides adjustable torque, speed, and position. Likewise, the respective motors utilize encoders  64   b,    31   b , and  71   b  to feedback positioning to the motion controller  606 . The motion controller  606  sends the motion status to the logic controller  600 . Each axis  300 ,  302  and  304  includes a home position point established by way of engaging a hard stop  118 ,  119  or  120  at the end of a travel limit. The x, y and theta axes utilize respective hard stops  119 ,  118 , and  120 . Upon a maintenance event or a power failure, the logic controller  600  will signal the motion controller  606  to locate the positioning of the robot  30  by means of jogging each axis of motion  300 ,  302 ,  304  to the respective hard stop  118 ,  119  or  120 . The system  100  rotates motors  64   a,    31   a,  and  71   a  until each motor  64   a,    31   a,  and  71   a  is stopped because the respective drive system encounters the dedicated hard stop  118 ,  119  or  120 , the motion controller  606  detects that the encoder has stopped advancing, and motor amperage has spiked. From these encoder positions, the motion controller  606  can move all three robot axis  300 ,  302  and  304  without concern of a collision. The positioning of the robot  30  allows for proper engagement with the docking stations  22  and wash tools  27  or  28  ( FIG. 13 . Proper alignment into the tool  27  or  28  and docking stations  22  may prevent a crash, and proper depth engagement into the tool  27  or  28  and docking station  22  by the robot  30  allows the locks to be freed so they can be actuated into the proper position. For this reason, upon system  100  installation prior to system wash cycling, the robot  30  docking station positions are entered into the logic controller  600  and motion controller  606  and stored into non-volatile memory. This is accomplished by manually or automatically jogging the robot  30  axis of motion  300 ,  302  and  204  to each desired position and manually or automatically inputting the positions using the operator interface. Close tolerance timing of the mechanical drive system may be maintained without excessive backlash by means of high performance timing belting and timing pulleys. 
         [0063]    At the beginning of a wash cycle, the system  100  may be flagged to start in two manners. The first is a commonly used cash acceptance type kiosk which sends a signal to the controller  600  to arm the system  100 . A second method is to receive a signal from a mobile device such as a smart phone, mobile PC, or tablet. These mobile devices may be in communication with servers over public and private networks. The controller  600  may have a network connection to a server where the customer can set up an online account, make wash payment, or adjust the performance of the wash to the customer&#39;s preferences. At the wash bay entrance, the customer can scan a barcode into the mobile device and the controller  600  will be signalled to engage the customer through the mobile device or through audiovisual means such as an instruction sign  122 . During the wash process, the customer may adjust the wash and dry cycles, and at the end of the wash cycle a camera  125  located in the wash bay area may send an image to the customer so the customer can determine if the wash is satisfactory. The wash can then re-wash with adjustments if requested. 
         [0064]    As can be seen in  FIG. 10A  thru  10 D, an illuminated instruction stand  122  signals the customer to drive into the wash bay while the robot  30  is staged at the wash bay exit end with the x-axis shuttle  51  biased to the driver&#39;s side of the bridge shuttle  52  and the theta body  53  indexed such that the laser sensor  117  is extended out toward the passenger&#39;s side of the bay. The laser beam  139  may be pointed downward to detect the wash bay floor  21 . The vehicle  29  is driven forward until the front end breaks the laser beam  139  and laser sensor  117  signals the logic controller that the beam target distance has changed, indicating that the vehicle  29  has been detected. The instruction sign  122  changes from an “ENTER” instruction to a “STOP” instruction. After allowing a brief moment for the vehicle  29  to stop and settle, the robot indexes the theta body  53  counterclockwise from a plan view, approximately 20 degrees or 14 linear inches at the laser  139  point to verify the vehicle  29  has stopped within the specified range. If the laser sensor  117  does not detect the floor  21  again at the predetermined distance in the angular sweep, this indicated the instruction sign  122  displays “BACK UP” until the vehicle  29  is in proper position to start the wash processes. 
         [0065]    After the vehicle is determined to be in the correct position as is shown in  FIGS. 11 and 12A , the robot  30  carries out a vehicle mapping sequence to detect the sides, rear, and height of the vehicle  29  while utilizing the X, Y and Theta motion in conjunction with the laser sensor  117  mounted on the theta body  53 . At the start of the mapping sequence, the robot  30  is positioned at the exit of the wash bay and then travels toward the wash bay entrance. After the laser sensor  117  detects the vehicle, the robot  30  will continue in the same path for approximately 36 inches, or within the length of the shortest length vehicle  29  that could be washed, at which point the robot shuttle  51  advances toward the passenger&#39;s side of the wash bay until the floor  21  is detected at which point the vehicle  29  passenger&#39;s side position is stored into the motion controller memory. The robot  30  then makes an X, Y, and Theta coordinated move to travel the laser sensor  117  directly across the vehicle  29  laterally until the driver&#39;s side position is detected as well, and is stored into memory. At this point in the mapping sequence the theta body is indexed approximately 90 degrees out from where it started in the sequence. Thereafter, another robot  30  X, Y, and Theta coordinated move brings the laser  117  laterally to the center of the vehicle  29  with the theta body indexed to original angular position. Then, the robot travels toward the wash bay entrance until the vehicle  29  rear end is detected and the position stored into controller memory. 
         [0066]      FIG. 12B  illustrates in schematic form how a wash tool  27  can be adjusted to the optimal washing distance away from the vehicle  29  according vehicle dimensions and parked positions in the wash bay. In this illustration the wash tool is shown in relationship to the vehicle  29  passenger&#39;s side, however, this adjustment clearly can be made to all sides of the vehicle. 
         [0067]    Referring to  FIG. 13 , a selected side wash tool  27  or  28  is attached to the robot  30 , and utilizing the X, Y, and Theta coordinated motion, the vehicle  29  can be circumscribed with a wash tool  27  or  28 , while maintaining an optimal wash distance and desired wash trajectory angle the entire periphery of the vehicle  29  until the side wash tool is placed back into the appropriate docking station. This type of circumscribing path-of-travel is utilized for applying soaps to the vehicle  29 , washing the vehicle with high pressure water, and while carrying out a friction wash cycle. It should be noted however, that during any of these cycles additional moves for enhanced capability may be carried out.