Abstract:
Movable spray nozzle side and overhead supports are moved by actuators to preprogrammed locations in a body leak tester enclosure to adapt the apparatus to various body configurations of automotive vehicles by a central controller. Control valves operated by the central controller may also be shut down flow to unneeded spray nozzles for smaller vehicle configurations.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority of provisional application 60/074,803, filed on Feb. 16, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention concerns leak testing of automotive vehicles to detect body seal or body fit deficiencies which will allow rain water penetration into the passenger compartment. 
     Such tests are commonly conducted on prototype vehicles to detect design problems as well as on production vehicles as a quality control measure. 
     The standard method involves directing a powerful spray of water at vulnerable areas on the vehicle exterior, and detecting any leakage by observations made from inside the vehicle. Spray nozzles are typically arranged on an arched framework into which the vehicle is driven. 
     Each spray nozzle framework arrangement is dedicated to vehicles having the same approximate body size such that either the spray nozzle arrangement be manually changed or a different frame work used, requiring considerable time for changeover. 
     Often, less than optimum spray nozzle patterns are relied on where a single installation is used for many body sizes, reducing the reliability of the test. 
     It is the object of the present invention to provide a body leak detection method and apparatus which accommodates a great number of body shapes and sizes without compromising the effectiveness of the leak testing. 
     SUMMARY OF THE INVENTION 
     The above object as well as others which will become apparent upon a reading of the following specification and claims are achieved by providing an array of spray nozzles mounted on three movable structures arranged to enclose an intermediate region into which a vehicle may enter, each structure mounted for in and out movement with respect to the location where at the vehicle is to be driven. The spray nozzle arrays are juxtaposed to each of the vehicle sides and the top of the vehicle body to enable a water jet spray pattern to be directed at the sides and top of the vehicle. In addition, a fixed spray nozzle array is disposed at the bottom to direct upward water sprays at the vehicle underbody. 
     Actuator devices are provided for each of the movable structures, enabling in and out movement of the structures juxtaposed adjacent to the vehicle sides, and up and down movement of the overhead structure positioned over the vehicle. 
     A central controller operates the actuators to position movable spray nozzle arrays at preprogrammed positions corresponding to a vehicle body type to be tested, to appropriately space the nozzles from the vehicle body surfaces to obtain effective spray coverage of the areas vulnerable to leakage. 
     In addition, the central controller opens or closes valves controlling the flow of water to individual nozzles or grouping of nozzles to provide complete coverage of the vehicle body while not unnecessarily operating nozzles not required for a particular vehicle configuration. 
     The vehicle may be accurately located with respect to the spray nozzle arrays in a test enclosure by sensors such as optical beam devices notifying a tester when a vehicle has been driven to the correct point, or alternatively locator bars may be used. A mechanical sensor arm may be used to detect the side to side relative location of the vehicle with respect to the spray nozzles, and causing the side nozzle mounting structures to be correspondingly moved, or a simple target may be employed on which the test driver sights when driving the vehicle into the test enclosure. 
     The nozzles may be supplied with water via flexible hoses connected to fixed manifolding the hoses accommodating the in and out or up and down movement of mounting structures. Alternatively, the manifolding, valves and spray nozzles may all be mounted to a movably mounted support structure, with flexible water supply hoses to the manifolding and electrical cables to the valves. 
     There may also be provided swinging or tilting nozzle supports at the front and rear to place spray nozzle arrays in position to direct water sprays at the sloping windshield or rear body portions of the vehicle for more effective spray coverage. 
     The movable nozzle support structure may be mounted to slide in ways lined with low friction bearing material or suspended from frame members with slidable walls. 
     During testing, the vehicle rests on a gridwork overlying a pit collecting water runoff, water in the pit recirculated with a pump supplying pressurized water to the spray nozzle. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a diagrammatic representation of the basic apparatus according to the invention. 
     FIG. 2 is a side elevational view of a full size vehicle in a test enclosure equipped with the nozzle supports according to the present invention. 
     FIG. 3 is an end elevational view of the full size vehicle in the enclosure shown in FIG.  2 . 
     FIG. 4 is a plan view of the full size vehicle and test enclosure shown in FIGS. 2 and 3. 
     FIG. 5 is a side elevational view of a mid sized vehicle in the test enclosure shown in FIG.  2 . 
     FIG. 6 is a side elevational view of a compact vehicle in the test enclosure shown in FIGS. 2-5. 
     FIG. 7 is a side elevational view of a mid sized vehicle in the test enclosure shown in FIGS. 2-5. 
     FIG. 8 is a plan view of a typical bottom/top spray pattern. 
     FIG. 9 is a view of a fragmentary position of a floor grid showing an opening in which an upwardly aligned spray nozzle is disposed. 
     FIG. 10 is a fragmentary view of the floor grid showing a fragmentary portion of a spray nozzle support received in a guiding slide. 
     FIG. 11 is an end view of a fragmentary portion of a floor grid showing a position sensor arm in engagement with the side wall of a vehicle tire. 
     FIG. 12 is a side view of a nozzle side support and manifold. 
     FIG. 13 is a detail view of a spray nozzle mounting. 
     FIG. 14 is a detail of a spray nozzle valving mounting. 
     FIG. 15 is an end view of a full size vehicle in a test enclosure having water spray apparatus according to a second embodiment of the invention. 
     FIG. 16 is an end view of a mid size vehicle in the test enclosure of FIG.  15 . 
     FIG. 17 is a side elevational view of the test enclosure and apparatus of FIGS. 15 and 16. 
     FIG. 18 is a floor plan view of the test enclosure and apparatus of FIGS. 15-17. 
     FIG. 19 is a top plan view of the test enclosure and apparatus of FIGS.  15 - 18 . 
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims. 
     FIG. 1 comprises a conceptual diagram of the arrangement  10  according to the present invention. 
     A test enclosure  12  has a series of movable spray valve arrays  14 ,  16 ,  18  and a fixed bottom spray nozzle array  20 . 
     Each of the movable spray nozzle arrays  14 ,  16 ,  18  are arranged in groupings of two sides and a top around an intermediate region, so as to define a “tunnel” space into which a vehicle  36  may be moved. 
     The fixed bottom spray array  20  lies beneath the floor approximately aligned with the top array  16  to complete spray coverage of the vehicle  36  to be leak tested. 
     A programmable industrial central controller  22  controls actuators  24 ,  26 ,  28  to cause the movable arrays  14 ,  18  to be moved in and out, and top nozzle array  16  to be moved up and down to be positioned at a particular distance during the test with respect to the side walls and top of vehicle  36  depending on its size. 
     The central controller  22  also controls water flow to the spray nozzle arrays  14 ,  16 ,  18 , which may also change the spray pattern by shutting off flow to individual spray nozzles or groupings of spray nozzles, during the test particularly for smaller vehicle sizes. 
     FIGS. 2 and 3 show a first embodiment of a body leak test apparatus according to the invention. 
     The apparatus includes a test enclosure  30  installed over a floor pit  32  covered by a floor grid  34  capable of supporting the weight of a vehicle  36  driven into the enclosure. 
     At least four generally planar spray nozzle arrays  38 ,  40 ,  42  and  44  are arranged around an intermediate region  46  defined within the enclosure  30 . Spray nozzle supports  48 ,  50  are movably mounted on either side of the region  46  so that actuators  52 ,  54  (such as power cylinders) can slide the supporting structures  48 ,  50 ,  56  for the side spray nozzle arrays  38 ,  42  in and out to be spaced a greater or lesser distance apart, to be matched to wider or narrower body sizes respectively. 
     The top spray nozzle array  40  is mounted on a support structure  56  to be movable up and down by actuators  58 . 
     Spray nozzle array  44  extends beneath the top array  40 , fixed to a supply manifold  60  located beneath the floor grid  34 . 
     Control valves  62  allow flow shut off of water flow to selected spray nozzles. Flexible hoses  70  connect the valves  62  to accommodate the movement of the support structures  48 ,  50 ,  56 . 
     Fixed plates  72  mount one end of the flexible hoses  70  and anchor the actuators  52 ,  54 ,  58 . 
     A pump  64  recirculates water collected in pit  32 , directing flow through piping  66  and manifolds  68  to the various spray nozzle arrays. 
     Swing down spray nozzle arrays  76  (FIG. 2) can optimally be provided for the windshield area, as well as swing in arrays  76  (FIG. 4) for the rear of the vehicle  36 . 
     Vehicle entry and exit roll up doors  78 A,  78 B can optionally be provided for the enclosure  30 , as well as doors  82 ,  84  for personnel access. A single draped plastic sheeting or strips may suffice for entry and exit doors. 
     FIG. 5-7 show various sizes of vehicles  36 A,  36 B,  36 C in place in the test enclosure  30 , with the top spray nozzle array  40  moved closer according to the control program. The side spray nozzle arrays would also be moved closer by signals generated by the central controller  22 . 
     As a further feature, many of the spray nozzles in each of the arrays could be shut off for shorter vehicles  36 B, as indicated in FIG.  6 . 
     FIG. 8 shows the top and bottom spray patterns  40 ,  44  in which the spray nozzles  88  are in staggered rows, defined by supply pipes  90  to provide complete coverage. 
     FIG. 9 shows a detail of a flow spray nozzle  88  projecting up through an opening  92  provided in floor grid  34 . 
     FIG. 10 shows a detail of a movable spray nozzle support structure  48 , in which the bottom is slidable in a guide channel  96 , with a Teflon® slide bearing  98  also provided. 
     FIG. 11 shows an optional side position sensor, in which a tube  100  on each side are each advanced as with a power cylinder  102  to engage a vehicle tire  104  to detect the lateral location of the vehicle  36  (FIG.  4 ). The central controller can cause corresponding position adjustment of the side spray nozzle arrays  38 ,  40 . 
     FIGS. 12-14 shows details of installations of the ball joint spray nozzles  80 , hoses  70 , valves  62 . 
     FIGS. 15-19 show an alternate embodiment of the apparatus according to the invention. 
     A test enclosure  100  defines a region  102  configured to allow entry of the vehicles  36 - 36 C of various sizes shown in FIGS. 5-7. A pit  104  is covered with an open grid  106  supporting the vehicle  36 , allowing water runoff to be collected and recirculated with a pump  108 . 
     A programmed central controller  110  operates valves  150  (FIG. 17) and actuators  122 ,  124  (FIG. 15,  16 ) as in the previously described embodiment. 
     In this embodiment, the manifolds, valves, and spray nozzles for the top spray nozzle array  112  and side arrays  114  are moved together as an assembly. 
     The manifolds  116 ,  116 A are constructed of a lightweight plastic piping to reduce weight. 
     The side manifolds  116  are suspended by strut members  118  held on a linear slide  120  allowing in and out movement, actuator cylinders  122  causing the movement when operated by the central controller  110 . 
     The top manifold  116 A is movable up and down by a pair of actuator cylinders  124 . 
     The pump  108  supplies water under pressure to distribution mains  126  which are connected to the manifolds  116 ,  116 A by flexible hoses  128  to accommodate the in and out and up and down movement as described. 
     A bottom manifold  130  is fixed and supplied via connection  132 . 
     The wiring to the control valves  150  will also have dropped sections to accommodate the movement of the nozzle arrays. 
     As seen in FIG. 19, an optical beam generator and sensor units  134 A,  134 B detect when the vehicle  36  is driven to line  138 , and a light is turned on when the vehicle moves to that line to indicate to the driver that the vehicle  36  is in proper fore and aft position. A simple target can enable the drive to correctly position the vehicle laterally. 
     Optical sensors (not shown) for determining vehicle type and various safety conditions will also typically be provided. 
     An exhaust fan hood  140  is provided. 
     An operating procedure is as follows: 
     Operator pulls vehicle into booth. Center with plumb bob/O.K. light when pulled into proper position. 
     Operator exits booth and closes vehicle doors. 
     Photo cells check vehicle model with model programmed by operator. 
     Operator starts test by auto sequence: side and top spray racks index to vehicle. Nozzle control valves go to position. Test in progress light starts. Pump and exhaust fan start, beginning test. 
     Monitor points: water flow, air flow, doors closed, filter pressure sensor, pit liquid level, test time. 
     Test fault conditions: Booth door opened (with alarm horn-test terminates spray racks return to home). Pit liquid low level. Pit liquid high level. Filter pressure drop high. Spray racks move during test (with alarm horn-test terminates spray racks return to home). Air flow fails. Operator manual stop (spray racks return to home). 
     Test complete: Pump stops, ending test. Exhaust fan runs for two minutes, after pump stop. Spray racks return to home. Door opens. Operator backs vehicle out of booth. Test in progress light stops. Vehicle guide bars index to home. Personnel door switches disengaged. 
     Conditions not allowed: Personnel doors opened with test in progress. Spray rack movement other than that specified for test. Testing of a vehicle other than programmed for. Any doors opened with spray racks not in home position. 
     Options: manual programming of system (password coded as necessary). Test status remote reporting. Booth temperature control (35° F. to 95° F.).