Patent Publication Number: US-2022234169-A1

Title: Automated vehicle component cleaning system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 62/849,539, filed on May 17, 2019, incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to cleaning systems for vehicle components, and more specifically to an automated vehicle component cleaning system using a cleaning agent. 
     BACKGROUND OF THE DISCLOSURE 
     During manufacturing of a vehicle, a cleaning system is used to pre-clean one or more vehicle components of the vehicle before performing a physical vapor deposition (PVD) process. The PVD process is used to transfer a coating material at an atom or molecule level on the vehicle components and to provide pure and high-performance coatings. Such coatings are highly resistant to tarnishing and corrosion, and therefore render the vehicle components highly resistant to scratches and scrapes. Typically, the vehicle components are pre-cleaned with a cleaning liquid (e.g., water) and/or a solvent (e.g., a hydrocarbon solvent) to prepare for the PVD process. Surface roughness, texture, and component cleanliness are all critical parameters for achieving a proper PVD coating performance from an adhesion perspective. However, achieving a uniform coating thickness on the vehicle component can be difficult when the vehicle component includes a complicated geometry, such as a small bore. 
     Referring now to  FIG. 1 , during the PVD process, a coating layer  10  is applied onto an outer surface of a substrate  12  of the vehicle component. Often, even after the pre-clean process, one or more unwanted particles or other contaminants  14  can remain on the outer surface of substrate  12 . For example, a pilot valve seat (PVS) of a fuel injector in the vehicle includes a small outlet opening connected to a fuel passageway. Due to complex internal geometries, unwanted particles or contaminants  14  can be trapped in the outlet opening and the fuel passageway. Trapped particles or contaminants  14  can be baked onto substrate  12  during the PVD process causing undesirable results. Various residues from the cleaning liquid, an environment (e.g., dust), and/or a rust preventative fluid may cause further accumulation of unwanted particles or contaminants  14  on the outer surface of substrate  12 . Moreover, a manual handling of the vehicle component with a contaminated hand can leave the residues on the outer surface of substrate  12 . 
     Such various contaminations may result in a poor coating adhesion between substrate  12  and coating layer  10 , and cause unnecessary delays and increased operating costs during a manufacturing process of the vehicle. Accordingly, it is desirable to develop an enhanced cleaning system that eliminates or alleviates one or more operational disadvantages described above. 
     SUMMARY OF THE DISCLOSURE 
     In one embodiment, the present disclosure provides a system for performing a cleaning process of a component of a vehicle. The system includes a first cleaning applicator configured to deliver a cleaning agent to a first surface of the component of the vehicle, a second cleaning applicator configured to deliver the cleaning agent to a second surface of the component of the vehicle, a third cleaning applicator configured to deliver the cleaning agent to a third surface of the component of the vehicle, and a control unit configured to instruct the first cleaning applicator to project the cleaning agent onto the first surface of the component for a first predetermined period, the second cleaning applicator to project the cleaning agent onto the second surface of the component for a second predetermined period, and the third cleaning applicator to project the cleaning agent onto the third surface of the component for a third predetermined period. The first, second, and third applicators are instructed to project the cleaning agent in a predetermined sequence. 
     In another embodiment of the present disclosure, a cleaning method is provided for performing a cleaning process of a component of a vehicle. The method includes delivering a cleaning agent to a first surface of the component of the vehicle using a first cleaning applicator, delivering the cleaning agent to a second surface of the component of the vehicle using a second cleaning applicator, delivering the cleaning agent to a third surface of the component of the vehicle using a third cleaning applicator, instructing, using a processor, the first cleaning applicator to project the cleaning agent onto the first surface of the component for a first predetermined period, the second cleaning applicator to project the cleaning agent onto the second surface of the component for a second predetermined period, and the third cleaning applicator to project the cleaning agent onto the third surface of the component for a third predetermined period, and instructing the first, second, and third applicators to project the cleaning agent in a predetermined sequence. 
     While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features of this disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of embodiments of the present disclosure taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a schematic illustration of exemplary contamination on a vehicle component during a physical vapor deposition process; 
         FIGS. 2 and 3  are schematic illustrations of exemplary contamination on a pilot valve seat used in a vehicle; 
         FIG. 4  is a schematic illustration of an automated vehicle component cleaning system in accordance with embodiments of the present disclosure; and 
         FIG. 5  is a flow chart of an exemplary cleaning process using the cleaning system of  FIG. 4  in accordance with embodiments of the present disclosure. 
     
    
    
     While the present disclosure is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the present disclosure to the particular embodiments described. On the contrary, the present disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the present disclosure is practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure, and it is to be understood that other embodiments can be utilized and that structural changes can be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims and their equivalents. 
       FIGS. 2 and 3  show an illustrative vehicle component, such as a solenoid seat  16  used in a vehicle (not shown). Exemplary vehicles include land mobile machines, railed vehicles, marine vehicles, aircraft, spacecraft, or any motored machines that drive forces for movement. In one example, an engine can be a fuel injection engine operated by liquid or gaseous fuel, such as gasoline, diesel, or gas (e.g., LPG). Other suitable types of engines using gaseous fuels, such as liquefied hydrogen, propane, or other pressurized fuels, are also contemplated to suit different applications. In fuel injected engines, fuel is supplied to the engine using solenoid seat  16 . In one example, solenoid seat  16  can be a pilot valve seat (PVS) of a fuel injector (not shown). 
     In the illustrated embodiment, solenoid seat  16  of the fuel injector in the vehicle includes an outlet opening  18  connected to a fuel passageway  20  ( FIG. 3 ). Due to complex internal geometries (or small sizes) in outlet opening  18  and fuel passageway  20 , unwanted particles or contaminants  14  can be trapped in outlet opening  18  and/or fuel passageway  20 . Most unwanted particles or contaminants  14  are found near an outlet portion  22  of solenoid seat  16 . For example, unwanted particles or contaminants  14  can be found in or near a conical region of outlet opening  18 . However, due to an uneven surface roughness or texture of an outer surface  24  ( FIG. 2 ) of solenoid seat  16 , some residual unwanted particles or contaminants  14  can also be found near outlet portion  22  of solenoid seat  16 . Although solenoid seat  16  is shown for illustration purposes, any other vehicle components with complex internal or external geometries (e.g., surfaces or orifices) and/or small sizes are contemplated to suit different applications, for example, diesel vehicle components or electronic parts (e.g., a wire harness or cable assembly). Examples of such other vehicle components include tappets integrated in internal combustion engines, fuel pumps such as piston-type and plunger-type pumps, and injection plug pins or needles for use in injector nozzles, among others. 
       FIG. 4  shows an illustrative cleaning system  100  configured to automatically clean one or more vehicle components, such as solenoid seat  16  (e.g., PVS), using a control unit  102 . A power source  104 , such as a battery or an electric outlet, is electrically connected to control unit  102  to deliver electric power. Control unit  102  is configured to control an overall operation of one or more cleaning nozzles or applicators  106 A,  106 B,  106 C during a cleaning process of solenoid seat  16 . Although three nozzles  106 A,  106 B,  106 C are shown for illustration purposes, any number of nozzles is contemplated to suit the application. 
     In the illustrated embodiment, an annular heated jacket  108  is mounted near a distal portion of nozzle  106 A to heat the distal portion of nozzle  106 A to a desired temperature. Each nozzle  106 A,  106 B,  106 C is fluidically connected to a pump  110  configured to deliver a cleaning agent, such as hot and/or pressurized air, an alcohol, or a carbon dioxide (CO 2 ). In one embodiment, a replenished CO 2  is selected as the cleaning agent to utilize a green technology without an application of other chemicals, such as rust preservatives. 
     In embodiments, the CO 2  is stored in a CO 2  reservoir or tank  112  and the alcohol is stored in an alcohol reservoir or tank  114 . In one embodiment, control unit  102  instructs pump  110  to deliver the CO 2  from CO 2  tank  112  to nozzles  106 A,  106 B,  106 C via one or more conduits  116 . For example, each nozzle  106 A,  106 B,  106 C is configured to project or spray small sized pellets of dry ice out of a corresponding nozzle together with compressed air onto an outer surface of solenoid seat  16  for cleaning. Dry ice for blasting can be produced by a controlled expansion of liquid CO 2  into dry ice snow or crystals. In some embodiments, additives can be added to the liquid CO 2  before the expansion of the liquid CO 2  into dry ice snow, or the additives can be sprayed onto the surfaces of dry ice snow (e.g., CO 2  based solvents). Although embodiments of the present disclosure are not limited to particular temperature or pressure values for maintaining the liquid CO 2 , the liquid CO 2  is typically maintained at a temperature of approximately −60 degree Celsius (−60° C.) at a pressure of approximately 5.11 atmospheric pressure (approximately 0.52 MPa). The blasting or spraying of the CO 2  may be performed at a higher pressure than the pressure in which the pressure which the liquid CO 2  is maintained. Furthermore, in some examples, air may be used to clean the surface. The air may be delivered at a high pressure (for example, at a pressure that is above 5 MPa, 10 MPa, 20 MPa, or 50 MPa, etc., as suitable for the component to be cleaned) and/or a high temperature (for example, at a temperature that is above 70° C., 100° C., 150° C., or 200° C., etc., as suitable for the component to be cleaned). 
     A viewing device  118 , such as a camera, is communicably connected to control unit  102  via a communication link  120 . In one embodiment, control unit  102  is configured to monitor a progress of the cleaning process using viewing device  118  that transmits one or more images (or videos) of solenoid seat  16 . In another embodiment, control unit  102  receives one or more images of the outer surface of solenoid seat  16  from viewing device  118  to detect the presence of unwanted particles or contaminants  14 . Further, control unit  102  can be configured to detect a wet condition or a dry condition of the outer surface of solenoid seat  16 . As such, viewing device  118  can be used by control unit  102  before, during, and after the cleaning process as desired. 
     In another embodiment, a protective enclosure  122  at least partially surrounds one or more of solenoid seat  16 , nozzles  106 A,  106 B,  106 C, and viewing device  118  to reduce the risk of external or cross contamination from its surrounding environment. For example, the cross contamination can be caused by various oils, fingerprints, or non-organic substances, such as debris, during the manufacturing process of the vehicle. In one embodiment, robotic arms, grippers, or actuators controlled by control unit  102  can be used in protective enclosure  122  to selectively move or operate solenoid seat  16 , nozzles  106 A,  106 B,  106 C, and viewing device  118 . As such, a minimal user contact is required to avoid potential handling contamination. 
       FIG. 5  shows an exemplary cleaning process  200  using cleaning system  100 . Although the following steps are primarily described with respect to the embodiments of FIGS.  1 - 4 , it should be understood that the steps within the method may be modified and executed in a different order or sequence without altering the principles of the present disclosure. Although cleaning process  200  is shown using the CO 2 , the process  200  can be similarly applied to another cleaning method using a different cleaning agent, such as the alcohol. 
     The method begins at step  202 . In step  202 , control unit  102  instructs a first or top nozzle  106 B to project the dry ice pellets for a first predetermined period (e.g., 5-10 seconds). In one example, each nozzle  106 A,  106 B,  106 C projects the dry ice pellets in a constant stream for 5 seconds. In another example, each nozzle  106 A,  106 B,  106 C projects the dry ice pellets in a pulsed pattern for 10 seconds. Any combination of these projection techniques can be used to suit different applications. In one embodiment, top nozzle  106 B is configured to clean an upper surface of solenoid seat  16 . For example, the upper surface includes the conical region of outlet opening  18  and the outer surface  24  of solenoid seat  16  ( FIG. 2 ). Also, the dry ice pellets can be blasted downwardly into fuel passageway  20  of solenoid seat  16  for cleaning internal portions of solenoid seat  16 . 
     In step  204 , control unit  102  instructs a second or bottom nozzle  106 C to project the dry ice pellets for a second predetermined period (e.g., 5-10 seconds). Bottom nozzle  106 C is configured to clean a lower surface of solenoid seat  16 . Also, the dry ice pellets can be blasted upwardly into fuel passageway  20  of solenoid seat  16  for cleaning. 
     In step  206 , control unit  102  instructs again first or top nozzle  106 B to project the dry ice pellets for the first predetermined period (e.g., 5-10 seconds). Any number of repetitive projections using any of three nozzles  106 A,  106 B,  106 C is contemplated to suit different applications. 
     In step  208 , control unit  102  instructs a third or lateral nozzle  106 A to project the dry ice pellets for a third predetermined period (e.g., 5-10 seconds). In one embodiment, lateral nozzle  106 A is configured to clean a side surface of solenoid seat  16 . For example, the dry ice pellets are blasted horizontally onto the side surface of solenoid seat  16  using lateral nozzle  106 A. During the cleaning process, solenoid seat  16  can be rotated or moved in any desired direction using an indexing table or a robotic arm to clean all outer surfaces of solenoid seat  16 . It is to be understood that the aforementioned steps in the cleaning process  200  may be applied to any combination of different surfaces including but not limited to: side surfaces, upper surfaces, lower surfaces, internal surfaces, or passageways of the component to be cleaned, for example. In some examples, the passageways (or fluid passageways) are orifices which may fluidly couple two different surfaces, such as an internal surface and an external surface. 
     An exemplary total duration of the cleaning process ranges between approximately 20-100 seconds depending on an amount of unwanted particles or contaminants  14  detected by viewing device  118 . More specifically, the exemplary total duration is approximately 85 seconds. As described above, unwanted particles or contaminants  14  are effectively removed from solenoid seat  16  using cleaning system  100 , subsequently improving the coating adhesion between substrate  12  and coating layer  10  of solenoid seat  16  during the PVD process. 
     The method ends at step  208  which may include a return to step  202 . Any of steps  202 - 208  can be repeated as desired. 
     The above detailed description and the examples described therein have been presented for the purposes of illustration and description only and not for limitation. For example, the operations described can be done in any suitable manner. The methods can be performed in any suitable order while still providing the described operation and results. It is therefore contemplated that the present embodiments cover any and all modifications, variations, or equivalents that fall within the scope of the basic underlying principles disclosed above and claimed herein. 
     Embodiments of the present disclosure are described by way of example only, with reference to the accompanying drawings. Further, the following description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. As used herein, the term “unit” or “module” refers to, be part of, or include an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor or microprocessor (shared, dedicated, or group) and/or memory (shared, dedicated, or group) that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. Thus, while this disclosure includes particular examples and arrangements of the units, the scope of the present system should not be so limited since other modifications will become apparent to the skilled practitioner. 
     Furthermore, while the above description describes hardware in the form of a processor executing code, hardware in the form of a state machine, or dedicated logic capable of producing the same effect, other structures are also contemplated. Each unit or component can be operated as a separate unit from control unit  102 , and other suitable combinations of sub-units are contemplated to suit different applications. Also, although the units are illustratively depicted as separate units, the functions and capabilities of each unit can be implemented, combined, and used in conjunction with/into any unit or any combination of units to suit different applications. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. For example, it is contemplated that features described in association with one embodiment are optionally employed in addition or as an alternative to features described in associate with another embodiment. The scope of the present disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.