Cleaning System

Abstract

To provide a washing system capable of reducing occurrence of a failure caused by inability of both each stage sensor and a rack detection sensor to detect a rack.SOLUTION: A washing system includes: each stage sensor for detecting presence or absence of a dish rack in each of a plurality of shelf parts; a wagon rack detection sensor for detecting presence or absence of the dish rack in a shelf part in which a lift device is to carry in the dish rack; a lift exit sensor for detecting that the dish rack is carried out of the lift device; and a main controller for controlling the lift device on the basis of detection results of each stage sensor and the wagon rack detection sensor, and carrying the dish rack in any one of the plurality of shelf parts. When the wagon rack detection sensor does not detect the dish rack when carrying-out of the dish rack is detected by the lift exit sensor, the main controller causes a lamp to notify a user of a fact that there is an abnormality in the wagon rack detection sensor.SELECTED DRAWING: Figure 11

Description

[Technical Field]

[0001] The present invention relates to a cleaning system. [Background technology]

[0002] A washing system is known that includes a loading device that loads racks containing dishes (items to be washed) into a washing machine, a washing machine that washes the dishes, a cart that is arranged vertically and has shelves that can store the racks, a lifting device that loads the dishes washed by the washing machine onto the shelves of the cart, and a carrying-out device that pushes the dishes out of the washing machine and loads them onto the lifting device. In this washing system, a series of operations can be fully automated, including loading the racks into the washing machine, washing the dishes in the washing machine, unloading the racks from the washing machine to the lifting device, and loading the racks from the lifting device onto the cart. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 3-41922 Summary of the Invention [Problem to be solved by the invention]

[0004] In this type of cleaning system, a tier sensor is provided to detect the presence or absence of a rack on each tier of the cart, and a rack detection sensor is provided on the lift to detect the presence or absence of a rack on the tier from which the lift is about to deliver. The lift is raised or lowered to a tier where the tier sensor detects that there is no rack on the tier from which the raised or lowered lift is about to deliver, and when the rack detection sensor detects that there is no rack on that tier, the lift delivers the rack to that tier. Through this control, a rack is carried into an empty tier where no rack exists.

[0005] However, if both the tier sensors and the rack detection sensor become unable to detect the rack due to dirt or broken wires, etc., there is a possibility that the rack will be sent to a tier where a rack is already present, which could result in a malfunction such as the racks colliding with each other and damaging dishes, etc.

[0006] Therefore, an object of the present invention is to provide a cleaning system that can reduce the occurrence of problems caused by the inability of both the individual stage sensors and the rack detection sensor to detect the rack. [Means for solving the problem]

[0007] The cleaning system of the present invention is a cleaning system comprising a cleaning machine that cleans items stored in a cleaning chamber, a cart with multiple shelves arranged vertically that can store items cleaned by the cleaning machine, and a lift device that transports the items to the cart by moving them vertically and horizontally as they are transported from the cleaning machine.The cleaning system comprises: each shelf sensor that detects the presence or absence of items to be cleaned on each of the multiple shelves; an item detection sensor that detects the presence or absence of items to be cleaned on the shelf to which the lift device is about to transport the items to be cleaned; a lift outlet sensor that detects that the items to be cleaned have been transported out of the lift device; and a control unit that controls the lift device based on the detection results of the each shelf sensor and the item detection sensor to transport the items to one of the multiple shelves.When the lift outlet sensor detects the removal of the item to be cleaned but the item detection sensor does not detect the item to be cleaned, the control unit alerts the alarm unit that there is an abnormality in the item detection sensor.

[0008] In a washing system configured as described above, when an object to be washed is transferred from the lift device to a wagon and the lift outlet sensor detects that the object has been transferred, both the object detection sensor and the rack sensor would normally detect the object. In contrast, in the washing system of the present invention, when an object to be washed is transferred from the lift device to a wagon and the lift outlet sensor detects that the object has been transferred, if the object is not detected by the object detection sensor, it is determined that there is an abnormality in the object detection sensor and the alarm unit is notified of the abnormality. This allows the operator to take some kind of action in response to the abnormality in the object detection sensor. As a result, it is possible to reduce the occurrence of malfunctions caused by the rack being unable to be detected by both the rack detection sensor and the rack sensor.

[0009] In the cleaning system of the present invention, the control unit may determine that there is an abnormality in each tier sensor when the tier sensor does not detect an object when the lift is moved to one of the multiple shelf sections based on the detection results of the tier sensors. In a cleaning system configured in this manner, when the lift moves to a shelf section determined to have no objects loaded based on the detection results of the tier sensors, the object detection sensor confirms that there are no objects loaded on the destination shelf section before loading the objects. In the cleaning system of the present invention, when the lift is moved to one of the multiple shelf sections based on the detection results of the tier sensors, if the object detection sensor detects an object, the control unit determines that there is an abnormality in the tier sensor and notifies the alarm unit of the abnormality. As a result, it is possible to more reliably reduce the occurrence of malfunctions caused by the inability of both the tier sensors and the rack detection sensor to detect a rack.

[0010] The cleaning system of the present invention is a cleaning system comprising a cleaning machine that cleans items stored in a cleaning chamber, a cart on which multiple shelves arranged vertically can accommodate items cleaned by the cleaning machine, and a lift device that transports the items to the cart by moving the items transported from the cleaning machine vertically and horizontally, and is also equipped with a respective shelf sensor that detects the presence or absence of items to be cleaned on each of the multiple shelves, a cleaning item detection sensor that detects the presence or absence of items to be cleaned on the shelf to which the lift device is to transport the items to, and a control unit that controls the lift device based on the detection results of the respective shelf sensors and the cleaning item detection sensor to transport the items to one of the multiple shelves, and when the control unit moves the lift to one of the multiple shelves based on the detection result of the respective shelf sensors and the cleaning item detection sensor does not detect the items to be cleaned, it causes the alarm unit to alert that there is an abnormality in the respective shelf sensor.

[0011] In a cleaning system configured as described above, when the lift moves to a shelf section determined to have no items loaded thereon based on the detection results of the tier sensors, the object detection sensor confirms that no items are loaded thereon before the items are loaded into the destination shelf section. In the cleaning system of the present invention, when the lift moves to one of multiple shelf sections based on the detection results of the tier sensors, if the object detection sensor detects an item, it determines that there is an abnormality in the tier sensor and causes the alarm unit to notify the abnormality. As a result, it is possible to reduce the occurrence of malfunctions caused by the inability of both the tier sensors and the rack detection sensor to detect the rack.

[0012] The washing system of the present invention further includes an alarm unit that notifies the user of an abnormality and a wagon detection sensor that detects whether a wagon is secured to the lift device. The control unit may set the alarm unit to an abnormality alarm state when it determines that an abnormality exists, and may cancel the abnormality alarm state when the wagon detection sensor detects that the wagon has been removed from the lift device. The washing system manual, etc., describes that when the alarm unit notifies the user of an abnormality, the user should remove the wagon from the lift device and clean the tier sensors and the object detection sensor. Therefore, when the alarm unit notifies the user of an abnormality, the user should remove the wagon from the lift device and clean the tier sensors and the object detection sensor. In the configuration of the present invention, the alarm unit automatically cancels the alarm state when the wagon is removed from the lift device, even if the user does not turn off the alarm state by turning off the power to the washing system or pressing the abnormality reset button. This reduces the user's workload. [Effects of the Invention]

[0013] According to the present invention, it is possible to reduce the occurrence of malfunctions in both the individual stage sensors and the rack detection sensor. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view showing the entire cleaning system according to one embodiment. [Figure 2] FIG. 2(A) is a front view of the carry table, and FIG. 2(B) is a plan view of the carry table. [Figure 3] FIG. 3 is a cross-sectional view showing a schematic configuration of the dishwasher. [Figure 4] FIG. 4 is a perspective view showing the lift device. [Figure 5] FIG. 5(A) is a side view of the lift device as seen from the wagon side, and FIG. 5(B) is a side view of the lift device as seen from the dishwasher side. [Figure 6]6 is a perspective view of the lift device with the panel removed. [Figure 7] FIG. 7 is a rear view of the dishwasher and lifting device. [Figure 8] FIG. 8 is an enlarged perspective view of the vicinity of the slider of the lift device. [Figure 9] FIG. 9 is a perspective view of a bracket provided on the slider of FIG. [Figure 10] FIG. 10 is a perspective view showing a wagon. [Figure 11] FIG. 11 is a functional block diagram showing the functional configuration of the cleaning system. [Figure 12] FIG. 12 is a flowchart illustrating the flow up to anomaly detection. [Figure 13] Fig. 13(A) is a diagram showing an example of an operation unit, and Fig. 13(B) is a diagram explaining a method for detecting an abnormality in a sensor. DETAILED DESCRIPTION OF THE INVENTION

[0015] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In the description of the drawings, identical or corresponding elements are designated by the same reference numerals, and duplicate explanations will be omitted. The dimensional ratios of the drawings do not necessarily match those in the description. In the following description, the directions (up-down direction, front-rear direction, left-right direction) defined in FIG. 1 will be used for explanation.

[0016] 1, the washing system 1 includes a carry table 3, a dishwasher (washing machine) 4, a lift device 5, a cart 6, and a carry-out device 90. In the washing system 1, the carry table 3 and the dishwasher 4 are arranged side by side in the front-to-back direction, and the dishwasher 4, the lift device 5, and the cart 6 are arranged side by side in the left-to-right direction. That is, in the washing system 1 of this embodiment, the carry table 3, the dishwasher 4, the lift device 5, and the cart 6 are arranged in an L-shape in a plan view so that a dish rack R that stores dishes (items to be washed) moves from the front to the rear and then moves from the right to the left.

[0017] The carry table 3 transports the dish rack R to the dishwasher 4. As shown in Figures 1, 2(A) and 2(B), the carry table 3 has a base 10, four legs 19 that support the base 10, a transport mechanism 11, a table rack detection sensor 14, a main controller (control unit) 12 and an arm detection sensor 13.

[0018] Base 10 is a table on which dish rack R is placed. Base 10 has mounting surface 10a on which dish rack R is placed. Base 10 is provided with sliding portion 16, which protrudes from mounting surface 10a and extends along the conveyance direction of dish rack R, allowing dish rack R to slide. Sliding portion 16 is configured as a plate-shaped member made of, for example, polyacetal resin, fixed to mounting surface 10a with screws or the like. Sliding portion 16 can be made of any material as long as it provides good sliding properties for dish rack R, and can also be made of materials other than polyacetal resin.

[0019] The transport mechanism 11 moves the dish rack R on the base 10. The transport mechanism 11 has an arm member 11A, a support portion 11B, a chain 11C, sprockets 11D, 11D, and a table drive portion 11E. The transport mechanism 11 is housed in a housing 17. When the carry table 3 is viewed from the front, the housing 17 is disposed behind the base 10 and protrudes above the mounting surface 10a of the base 10.

[0020] The arm member 11A is a member that pushes out the dish rack R and is supported by a support portion 11B so as to be rotatable on the placement surface 10a. The support portion 11B is provided so as to be movable in the front-rear direction along a guide rail (not shown) arranged parallel to the chain 11C, and is fixedly connected to a part of the chain 11C. The chains 11C, 11C are wound around two sprockets 11D, 11D. The table driving portion 11E is, for example, a gear motor. One of the sprockets 11D is supported on the rotation shaft of the table driving portion 11E.

[0021] Arm member 11A is fixed to support portion 11B via a torsion spring (not shown) so that the tip of arm member 11A can rotate between a state in which it faces toward dishwasher 4 (rear side) and a state in which it faces toward the front side (left side) of carry table 3. The torsion spring biases arm member 11A in a counterclockwise (left-handed) direction in a plan view. That is, the torsion spring biases arm member 11A in a direction in which it advances from housing 17. Due to the action of the torsion spring, arm member 11A advances to an advance area on placement surface 10a, which is outside housing 17, unless it comes into contact with a regulating member such as a shutter (not shown). Arm member 11A is movable between an advance area overlapping placement surface 10a in a plan view and a retreat area retreated from placement surface 10a. When not pushing out dish rack R, arm member 11A is retreated to the retreat area.

[0022] Arm member 11A rotates left and right when viewed from the front of carry table 3 by moving in conjunction with sprocket 11D and chain 11C driven by table drive unit 11E. Arm member 11A advances from within housing 17 onto placement surface 10a when transporting dish rack R, and retreats into housing 17 when in a standby state. More specifically, arm member 11A advances onto placement surface 10a when table rack detection sensor 14 detects the movement of dish rack R on placement surface 10a toward dishwasher 4, or when start button B1 on operation unit 18 is pressed.

[0023] Arm member 11A pushes out dish rack R towards dishwasher 4. A bearing (not shown) may be provided at the tip of arm member 11A, i.e., the portion that abuts against dish rack R. Once arm member 11A transports dish rack R to dishwasher 4 (i.e., when it reaches the pushing position where it pushes out dish rack R), it returns to a standby position that is part of the retraction area inside housing 17.

[0024] Arm member 11A extends leftward from the right side as a base point in the left-right direction. In this embodiment, the left end of arm member 11A is located to the right of the center position CL of mounting surface 10a in the left-right direction. Note that the left end of arm member 11A may also extend leftward from the center position CL from the right side as a base point. In this case, arm member 11A can contact a portion of dish rack R placed on mounting surface 10a to the left of the center position in the left-right direction and push it toward dishwasher 4.

[0025] The main controller 12 controls the overall operation of the washing system 1, including the carry table 3. The main controller 12 includes an input / output interface for inputting and outputting signals to and from the outside, a storage medium such as a read-only memory (ROM) storing programs and information for various processes, a random access memory (RAM) for temporarily storing data, a central processing unit (CPU), and a communication circuit. Based on signals output by the CPU, the main controller 12 stores input data in the RAM, loads programs stored in the ROM into the RAM, and executes the programs loaded into the RAM to perform various processes. The main controller 12 controls, for example, the operation of the carry table 3, the opening and closing of the door 23 of the dishwasher 4, the operation of the discharge device 90, the operation of the lift device 5, and the like. The main controller 12 is housed, for example, in a housing 17.

[0026] As shown in Figure 11, the main controller 12 is communicatively connected to the table drive unit 11E, the arm detection sensor 13, the table rack detection sensor 14, the operation unit 18, the washer controller 35, the door drive unit 70, the discharge device 90, the lift drive unit 42C, the belt drive unit 43C, the lift entrance sensor 44A, the lift exit sensor 44B, the wagon rack detection sensor (item to be washed detection sensor) 44C, and the respective tier sensors 45A, 45B, 45C, and 45D.

[0027] 2 and 13(A), the operation unit 18 is disposed on a part of a panel forming the housing 17. The operation unit 18 has a start button B1 for starting the operation of the transport mechanism 11, an abnormality stop button B2 for emergency stopping the operation of the transport mechanism 11, a lamp L1 for indicating whether the power to the cleaning system 1 is ON or OFF, a lamp (alarm unit) L2 for indicating that an abnormality has occurred in the wagon rack detection sensor 44C or each stage sensor 45A, 45B, 45C, 45D, and a lamp L3 for indicating that the cleaning system 1 is in a stopped state due to the abnormality stop button B2 being pressed.

[0028] Returning to Fig. 2, arm detection sensor 13 detects that arm member 11A has moved to a predetermined position. In this embodiment, arm detection sensor 13 is positioned so as to detect the position of arm member 11A when arm member 11A completes carrying in dish rack R into washing chamber 21 of dishwasher 4. In other words, arm detection sensor 13 detects that carrying in dish rack R into washing chamber 21 of dishwasher 4 has been completed. The detection result of arm detection sensor 13 (rack carrying-in completion notification) is acquired by main controller 12.

[0029] As shown in Fig. 1, the dishwasher 4 is disposed adjacent to the carry table 3 on the rear side thereof. The dishwasher 4 washes dishes stored in a dish rack R. As shown in Figs. 1 and 3, the dishwasher 4 has a washing machine main body 20 covered with a stainless steel panel. The washing machine main body 20 is divided into an upper part 20A in which a washing chamber 21 is formed, and a lower part 20B in which a machine chamber 22 is formed.

[0030] A box-shaped door 23 for opening and closing the cleaning chamber 21 is provided on the upper portion 20A of the washer main body 20. The door 23 is connected to a connecting member 74 (see FIGS. 5(A) and 5(B)), which will be described in detail later. The connecting member 74 is driven by a door drive unit 70 (see FIG. 5(B)), which is controlled by the main controller 12. The door 23 is driven by the door drive unit 70 to move between a closed position (position shown in FIG. 4) where the door 23 is located at the lowest height position in the vertical direction and closes the cleaning chamber 21, and an open position (position shown in FIG. 1) where the door 23 is located at the highest height position in the vertical direction and opens the cleaning chamber 21. Although not provided on the door 23 in this embodiment, the door 23 may be provided with a handle for manually opening and closing the door 23.

[0031] Rack rails 24 on which dish racks R are placed are detachably disposed within washing chamber 21. Dish racks R carried from carry table 3 to dishwasher 4 are pushed onto rack rails 24. Upper washing nozzle 26A consisting of three radially extending arms and upper rinsing nozzle 27A consisting of two arms are rotatably disposed at the top of washing chamber 21. Similarly, lower washing nozzle 26B consisting of three radially extending arms and lower rinsing nozzle 27B consisting of two arms are rotatably disposed at the bottom of washing chamber 21. Washing water is sprayed from above and below by upper washing nozzle 26A and lower washing nozzle 26B onto dishes arranged on dish rack R, and rinsing water is sprayed from above and below by upper rinsing nozzle 27A and lower rinsing nozzle 27B.

[0032] A cleaning pump 29 is connected to the cleaning water tank 28 via a cleaning water suction port. A cleaning water discharge pipe 30 is connected to the discharge port of the cleaning pump 29. The cleaning water discharge pipe 30 branches into a first cleaning water discharge pipe 30A and a second cleaning water discharge pipe 30B, with the first cleaning water discharge pipe 30A being connected to the upper cleaning nozzle 26A and the second cleaning water discharge pipe 30B being connected to the lower cleaning nozzle 26B.

[0033] A rinsing water tank 31 is disposed within the machine room 22, to which rinsing water is supplied from the outside via a water supply pipe (not shown). A rinsing pump 33 is connected to the rinsing water tank 31 via a rinsing water suction pipe 32. A rinsing water discharge pipe 34 is connected to the discharge port of the rinsing pump 33. The rinsing water discharge pipe 34 branches into a first rinsing water discharge pipe 34A and a second rinsing water discharge pipe 34B, with the first rinsing water discharge pipe 34A connected to the upper rinsing nozzle 27A and the second rinsing water discharge pipe 34B connected to the lower rinsing nozzle 27B. The first rinsing water discharge pipe 34A is disposed within the first cleaning water discharge pipe 30A. In other words, the first cleaning water discharge pipe 30A and the first rinsing water discharge pipe 34A form a double-pipe structure.

[0034] The machine compartment 22 contains an electrical box (not shown) that houses a washer controller 35 that controls the overall operation of the dishwasher 4. The washer controller 35 outputs a wash completion signal to the main controller 12 of the carry table 3, indicating that washing has finished.

[0035] Dishwasher 4 is equipped with a heat exchange unit 36. Heat exchange unit 36 ​​condenses water vapor discharged from washing chamber 21 of washer body 20 and discharges air with a reduced amount of water vapor to the outside. Dishwasher 4 is equipped with four legs 37 that support washer body 20.

[0036] As shown in FIG. 1, the lift device 5 is disposed adjacent to the dishwasher 4 on the left side thereof. The lift device 5 transfers the dish rack R removed from the dishwasher 4 to a predetermined position on the cart 6. As shown in FIGS. 4 to 6, the lift device 5 includes a main body 40, a lift 41, a lift drive mechanism 42, a lift entrance sensor 44A, a lift exit sensor 44B, a cart rack detection sensor 44C, individual level sensors 45A, 45B, 45C, and 45D, a cart detection sensor 46, and a door drive mechanism 7.

[0037] The main body 40 includes a frame 40A, a pair of front and rear portions 40B and 40C facing each other in the front-to-rear direction, a right side portion 40D, a left side portion 40E, a ceiling portion 40F, a bottom portion 40G, and legs 40H. The pair of front and rear portions 40B and 40C are panel-like members made of stainless steel or the like. The main body 40 is open on both sides in the horizontal direction perpendicular to the opposing direction of the pair of front and rear portions 40B and 40C. The right side portion 40D is a panel-like member that covers a portion of the upper side of the opening on the dishwasher 4 side (right side). The left side portion 40E is a panel-like member that covers a portion of the upper side of the opening on the cart 6 side (left side).

[0038] The ceiling portion 40F is a panel-like member that covers the upper portion of the main body 40. The ceiling portion 40F has a top plate portion 40Fa that forms the upper surface of the lift device 5 and a bent portion 40Fb that is bent from the top plate portion 40Fa to the left side portion 40E. The bent portion 40Fb is disposed on the left side and outside of the frame 40A disposed on the rear side and covers the frame 40A. In the lift device 5, the frame 40A on the wagon 6 side, in particular, the rear frame 40A, may be collided with by the wagon 6 when the wagon 6 is attached to or detached from the lift device 5, and this collision may cause deformation of the frame 40A. If such deformation of the frame 40A becomes too great, it may become impossible to attach or detach the wagon 6. In this regard, in the present embodiment, the bent portion 40Fb of the ceiling portion 40F covers the frame 40A on the wagon 6 side and the rear frame 40A, thereby reducing the possibility of deformation of the frame 40A due to a collision by the wagon 6. The ceiling portion 40F may be bent toward the front portion 40B, the rear portion 40C, and the right side portion 40D. The legs 40H are provided at the four corners of the bottom portion 40G.

[0039] The lift 41 receives the dish rack R transported from the dishwasher 4 at a vertical loading position (the height position of the lift 41 shown in Figure 4), moves vertically to an unloading position on the shelf section 53 of the wagon 6 where the dish rack R is not stored, transports the received dish rack R horizontally from the dishwasher 4 side to the wagon 6 side, and transports (transfers) the dish rack R onto the shelf section 53.

[0040] The lift 41 is supported by a lift support part 41A. The lift support part 41A is moved up and down (vertically) by a lift drive mechanism 42. This causes the lift 41 to move up and down. The lift drive mechanism 42 mainly includes a belt 42A, a pair of sprockets 42B, 42B, and a lift drive part 42C. The lift drive part 42C is, for example, a gear motor. The lift drive part 42C is, for example, disposed on the upper part of the lift device 5. The operation of the lift drive part 42C is controlled by the main controller 12 of the carry table 3. An output shaft of the lift drive part 42C is connected to one of the sprockets 42B. The lift 41 rotates in response to the rotation of the sprocket 42B via the belt 42A. The belt 42A is looped around the pair of sprockets 42B, 42B.

[0041] The lift 41 activates the belt drive mechanism 43 to pull the dish rack R into the lift device 5 and transport the dish rack R to the cart 6. The belt drive mechanism 43 mainly includes a pair of conveyor belts 43A, 43A, two pairs of sprockets 43B, 43B around which the pair of conveyor belts 43A, 43A are respectively wound, and a belt drive unit 43C. Each of the pair of conveyor belts 43A, 43A is an endless belt that is stretched over a pair of sprockets 43B, 43B. The pair of conveyor belts 43A, 43A are arranged to face each other in the width direction (front-back direction) perpendicular to the conveyance direction (left-right direction) of the dish rack R. Each of the pair of conveyor belts 43A, 43A is arranged to support the dish rack R near both ends in the width direction from below.

[0042] Conveyor belt 43A is provided with protrusions 43Aa. Protrusions 43Aa are members that hook onto latching portions formed on dish racks R. The latching portions of dish racks R are portions that latch onto protrusions 43Aa, such as the edge of dish rack R (the frame-shaped portion that comes into contact with conveyor belt 43A when dish racks R are placed on conveyor belt 43A in the normal state) and recesses formed on the bottom surface of dish rack R. Protrusions 43Aa are provided at predetermined intervals along the longitudinal direction (left-right direction) of conveyor belt 43A.

[0043] A pair of sprockets 43B, 43B are provided at both ends of the dish rack R in the conveying direction and are wound around the conveyor belt 43A. One sprocket 43B is provided with a rotating shaft, and is configured to be able to transmit power from the belt drive unit 43C via a chain, belt, etc. The other sprocket 43B is rotated by being driven by the conveyor belt 43A. The belt drive unit 43C is, for example, a gear motor. The operation of the belt drive unit 43C is controlled by the main controller 12 of the carry table 3.

[0044] The lift entrance sensor 44A detects when a dish rack R enters the lift device 5 (lift 41) from the dishwasher 4. The detection result of the lift entrance sensor 44A is acquired by the main controller 12. The lift entrance sensor 44A is provided, for example, at the end of the lift 41 on the dishwasher 4 side. The lift entrance sensor 44A is, for example, a reflective photoelectric sensor.

[0045] The lift exit sensor 44B detects that the dish rack R has been transported to a predetermined position downstream in the transport direction of the conveyor belts 43A from the detection position of the lift entrance sensor 44A. The detection result of the lift exit sensor 44B is acquired by the main controller 12. The lift exit sensor 44B is provided, for example, at a position near the end of the lift 41 on the wagon 6 side, and is attached, for example, to the frame 40A via a bracket or the like.

[0046] The wagon rack detection sensor 44C is, for example, a reflective photoelectric sensor. The wagon rack detection sensor 44C detects the presence or absence of a dish rack R on the shelf portion 53 of the wagon 6 located on the left side of the lift 41 (the position where the dish rack R is supported by a pair of support rails 53A, 53B). In other words, it detects the presence or absence of a dish rack R on the shelf portion 53 of the wagon 6 that the lift 41 is about to transfer. The detection result of the wagon rack detection sensor 44C is acquired by the main controller 12. The wagon rack detection sensor 44C is, for example, a reflective photoelectric sensor.

[0047] Each of the shelf sensors 45A, 45B, 45C, and 45D detects the presence or absence (vacancy status) of a dish rack R on each of the four (plural) shelves 53 of the cart 6. The detection results of each of the shelf sensors 45A, 45B, 45C, and 45D are acquired by the main controller 12. Each of the shelf sensors 45A, 45B, 45C, and 45D is provided corresponding to each of the four shelves 53 of the cart 6. Each of the shelf sensors 45A, 45B, 45C, and 45D is provided on the frame 40A adjacent to each of the four shelves 53. Each of the shelf sensors 45A, 45B, 45C, and 45D is, for example, a reflective photoelectric sensor. Each of the shelf sensors 45A, 45B, 45C, and 45D may be covered by a cover 40I made of a flexible and heat-insulating material. The detection range of each of the stage sensors 45A, 45B, 45C, and 45D is appropriately set or the performance is selected so that objects other than the dish rack R are not detected.

[0048] Furthermore, each of the shelf sensors 45A, 45B, 45C, and 45D may be provided inside the frame 40A, and the detection light may be emitted from a square hole or the like formed in the frame 40A. A transparent resin plate or the like may be attached to the square hole. Each of the shelf sensors 45A, 45B, 45C, and 45D may be provided above or below the main body 40, and may be arranged so that the detection light is emitted toward each of the shelves 53.

[0049] The wagon detection sensor 46 detects that the wagon 6 is fixed to the lift device 5. The wagon detection sensor 46 is, for example, a reflective photoelectric sensor. The detection result of the wagon detection sensor 46 is acquired by the main controller 12.

[0050] As shown in Figures 5(A), 5(B), and 7, the door drive mechanism 7 drives the door 23 of the dishwasher 4 to a closed position and an open position. The door drive mechanism 7 includes a door drive unit 70, a pair of sprockets 71A, 71B, a chain 72, a slider 73, a connecting member 74, and a bracket 76. The door drive mechanism 7 is provided on the rear side of the lift device 5. More specifically, the door drive mechanism 7 is fixed to the rear side portion 40C. Although the pair of sprockets 71A, 71B and the chain 72 are shown in Figure 7, they may be covered with a cover or the like.

[0051] The door drive unit 70 is, for example, a gear motor. The door drive unit 70 is, for example, disposed on the upper part of the lift device 5. The operation of the door drive unit 70 is controlled by the main controller 12 of the carry table 3. The door drive unit 70 is not provided with a braking mechanism (brake). That is, when an external force is applied to the output shaft of the door drive unit 70, the output shaft rotates. The sprockets 71A and 71B are disposed at a predetermined interval in the vertical direction. The output shaft of the door drive unit 70 is connected to the sprocket 71A. The sprocket 71B rotates in response to the rotation of the sprocket 71A via a chain 72. The chain 72 is stretched around the pair of sprockets 71A and 71B.

[0052] The slider 73 is connected to the chain 72. The slider 73 moves up and down in accordance with the movement of the chain 72. The slider 73 is connected to a guide rail 75 extending in the up and down direction, and moves along the guide rail 75. An upper sensor (not shown) and a lower sensor (not shown) are provided within the movement range of the slider 73. The upper sensor is located above the lower sensor. The upper sensor is located at a position where it detects the slider 73 when the door 23 of the dishwasher 4 reaches the open position. The upper sensor outputs the detection result to the main controller 12 of the carry table 3. The lower sensor is located below the upper sensor. The lower sensor is located at a position where it detects the slider 73 when the door 23 of the dishwasher 4 reaches the closed position. The lower sensor outputs the detection result to the main controller 12 of the carry table 3.

[0053] The connecting member 74 is connected to the box-shaped door 23 (see FIG. 3) for opening and closing the washing chamber 21. The bracket 76 connects the slider 73 and the connecting member 74. The connecting member 74 is arranged on the dishwasher 4 side (right side) of the lift device 5. The bracket 76 extends in the front-to-rear direction. One end of the bracket 76 is fixed to the slider 73, and the other end of the bracket 76 is connected to the connecting member 74.

[0054] 8 and 9, the bracket 76 of this embodiment is fixed to the slider 73 and also to the chain 72. The bracket 76 has a main surface portion 76a, a door fixing portion 76b, a chain fixing portion 76c, and bent portions 76d, 76d. The main surface portion 76a, the door fixing portion 76b, the chain fixing portion 76c, and the bent portions 76d, 76d of the bracket 76 are formed by bending.

[0055] The main surface portion 76a is a portion that is fixed to the slider 73. The main surface portion 76a and the slider 73 are fixed with bolts or the like. The door fixing portion 76b is a portion that is bent from the main surface portion 76a and fixed to the connecting member 74. The door fixing portion 76b and the connecting member 74 are fixed with bolts or the like. The chain fixing portion 76c is a portion that is bent from the main surface portion 76a and fixed to the chain 72. The bent portions 76d, 76d are bent from the chain fixing portion 76c and are interposed between the chain 72 and the slider 73, with one end contacting the chain 72 and the other end contacting the slider 73.

[0056] Conventionally, the chain 72 and the connecting member 74 have been connected by two members: a first member connecting the slider 73 and the connecting member 74, and a second member connecting the chain 72 and the slider 73. In this configuration, repeated starting and stopping of the chain 72 causes rotational forces to act between the slider 73 (or the connecting member 74) and the first member and between the chain 72 (or the slider 73) and the second member, which tends to cause rattling (vibration), and there is a risk that the screws securing the slider 73 (or the connecting member 74) to the first member and the screws securing the chain 72 (or the slider 73) to the second member may come loose.

[0057] In contrast to such a conventional configuration, the configuration of this embodiment includes a bracket 76 that integrally fastens the connecting member 74, slider 73, and chain 72. This eliminates rattle between the bracket 76 or chain 72 and the slider 73, as well as between the slider 73 and the bracket 76 or connecting member 74. Furthermore, by using bolts instead of screws to fasten the bracket 76 and the slider 73, the distance between the bolts can be increased. This reduces rattle in the rotational direction of the bracket 76. Furthermore, the single-member bracket 76 allows the chain fixing portions 76c to be parallel, so that vibrations generated when the chain 72 starts and stops can be absorbed by the chain fixing portions 76c and 76c, effectively reducing rattle. Furthermore, the bracket 76 having bent portions 76d, 76d, allows the end faces of the bracket 76 to contact the side surfaces of the slider 73, thereby suppressing vibrations generated when the chain 72 starts and stops.

[0058] As shown in FIG. 1, the wagon 6 is disposed adjacent to the lift device 5 on the left side thereof. The wagon 6 can store multiple (four in this embodiment) dish racks R. The wagon 6 stores the dish racks R by the lift device 5. The wagon 6 is detachably mounted on the lift device 5. As shown in FIG. 10, the wagon 6 has a main body 50.

[0059] The main body 50 has a frame 50A, a pair of front and rear portions 50B and 50C arranged opposite each other in the front-to-rear direction, a ceiling portion 50F, and a bottom portion 50G. The pair of front and rear portions 50B and 50C are panel-like members made of stainless steel or the like. The main body 50 is open on both sides in the horizontal direction perpendicular to the opposing direction of the pair of front and rear portions 50B and 50C.

[0060] A pair of support rails 53A, 53B are provided on the inner surfaces of the pair of front and rear portions 50B and 50C, respectively, at positions facing each other. The pair of support rails 53A, 53B support a dish rack R. The pair of support rails 53A, 53B form a shelf portion 53 in the wagon 6 that stores the dish rack R. A plurality of support rails 53A, 53B are arranged at predetermined intervals in the vertical direction. Operation handles 54A, 54B that can be gripped by an operator are provided on the outer surface of the front portion 50B. The bottom portion 50G is provided with four rollers 55A, 55B, 55C, and 55D that allow the wagon 6 to move freely when the wagon 6 is removed from the lift device 5, and installation mechanisms 56A and 56B that install (fix) the wagon 6 when the wagon 6 is attached to the lift device 5.

[0061] The discharge device 90 discharges a dish rack R from the dishwasher 4 to the lift device 5. As shown in FIG. 1, the discharge device 90 is provided at the front of the right side of the dishwasher 4. The discharge device 90 has an arm 91. The arm 91 rotates around a rotation axis extending in one direction as a rotation center, thereby pushing out the dish rack R placed on the rack rail 24 (see FIG. 3) in the washing chamber 21 to the lift device 5. The dish rack R pushed out by the arm 91 slides along the rack rail 24 and is discharged from the dishwasher 4 to the lift device 5.

[0062] Next, the operation of the lift device 5 will be described with reference to FIG. 12. When the dishwasher 4 completes washing, the lift 41 waits at the same height (origin position) as the rack rail 24 (see FIG. 3) of the dishwasher 4. When the discharge device 90 discharges the dish rack R from the dishwasher 4 and the lift entrance sensor 44A detects that a portion of the dish rack R is positioned on the lift 41 (step S01), the lift 41 starts operating the conveyor belts 43A, 43A (step S02). That is, the main controller 12 controls the belt drive unit 43C. As a result, the dish rack R is pulled to a predetermined position on the lift 41 (the position detected by the lift exit sensor 44B) with the protrusions 43Aa of the conveyor belts 43A, 43A hooked.

[0063] Here, when the lift outlet sensor 44B detects the dish rack R (step S03: YES), the lift 41 retracts the dish rack R to the predetermined position and begins to rise or fall so that the dish rack R is at the same height as the shelf sections 53 on the cart 6 that do not contain the dish rack R (empty shelf sections 53) (step S04). That is, the main controller 12 controls the lift drive section 42C. The main controller 12 determines the vacancy status of each shelf section 53 based on the detection results of the respective shelf sensors 45A, 45B, 45C, and 45D. In this embodiment, when multiple empty shelf sections 53 are detected, the lift 41 rises or falls so that the dish rack R is loaded in order (priority) starting from the upper shelf section 53.

[0064] Lift 41 stops rising or falling when it reaches the same height as empty shelf section 53 (step S05). Next, conveyor belts 43A, 43A start to rotate (step S06) to load dish rack R onto empty shelf section 53. When dish rack R is loaded from lift 41 onto shelf section 53 of wagon 6 and lift exit sensor 44B detects that dish rack R has been loaded, both wagon rack detection sensor 44C and sensors 45A, 45B, 45C, 45D for each shelf into which dish rack R was loaded enter a detection state.

[0065] When the dish rack R is transferred from the lift 41 to the shelf 53 of the wagon 6 and the lift exit sensor 44B detects that the dish rack R has been transferred, if the dish rack R is not detected by the wagon rack detection sensor 44C, the main controller 12 determines that there is an abnormality in the wagon rack detection sensor 44C and turns on or blinks lamp L2. Possible abnormalities in the wagon rack detection sensor 44C include dirt, a broken wire, or a malfunction of the wagon rack detection sensor 44C.

[0066] Furthermore, after step S03, when the lift 41 ascends or descends to a shelf 53 determined to have no dish rack R based on the detection results of the shelf sensors 45A, 45B, 45C, and 45D, the tray rack detection sensor 44C confirms that the dish rack R is not present on the shelf 53 before the dish rack R is delivered to the destination shelf 53. In this embodiment, when the lift 41 moves to one of the shelves 53 based on the detection results of the shelf sensors 45A, 45B, 45C, and 45D, if the tray rack detection sensor 44C detects a dish rack R, it determines that there is an abnormality in the shelf sensors 45A, 45B, 45C, and 45D, and turns on or flashes the lamp L2. Possible abnormalities in the shelf sensors 45A, 45B, 45C, and 45D are, like those in the tray rack detection sensor 44C, dirt, broken wires, or a malfunction of the tray rack detection sensor 44C.

[0067] When an abnormality is detected in the wagon rack detection sensor 44C or each tier sensor 45A, 45B, 45C, 45D and lamp L2 is turned on or flashing, when the dish rack R is removed, i.e., when the wagon detection sensor 46 no longer detects the wagon 6, lamp L2 stops flashing or turning on.

[0068] If the lift entrance sensor 44A detects a dish rack R in step S01 and then detects that 20 seconds have elapsed (step S11: YES), the rotation of the conveyor belts 43A, 43A is stopped (step S12). Next, the detection by the lift entrance sensor 44A is stopped (step S13), and the main controller 12 determines that there is an abnormality in the lift entrance sensor 44A and turns on or blinks the lamp L2. Note that even if the main controller 12 determines that there is an abnormality in the lift entrance sensor 44A, the conveyor belts 43A, 43A may be rotated to allow the washing operation to continue when the dish rack R is automatically carried from the carry table 3 to the dishwasher 4. Furthermore, if the detection of the dish rack R by the lift entrance sensor 44A is confirmed after step S13, the blinking or lighting of the lamp L2 may be stopped.

[0069] When the dish rack R is transported by the lift device 5, the protrusions 43Aa on the conveyor belts 43A may not catch properly on the dish rack R, and the lift entrance sensor 44A may repeatedly detect and not detect (ON and OFF) (section E) as shown in FIG. 13(B). In this case, the trigger for starting the abnormality determination in step S11 after 20 seconds has elapsed may be the timing T2 when the sensor last turned ON, rather than T0. Note that while FIG. 13(B) illustrates an example in which one detection and non-detection occurs, this may occur two or more times. Furthermore, if such detection and non-detection are repeated ten times, for example, the main controller 12 may determine that the dish rack R is caught and stop the operation of the lift device 5.

[0070] The effects of the washing system 1 of the above embodiment will be described. In the washing system 1 of the above embodiment, when a dish rack R is transferred from the lift device 5 to the wagon 6 and the lift exit sensor 44B detects that the dish rack R has been transferred, if the wagon rack detection sensor 44C does not detect the dish rack R, it determines that there is an abnormality in the wagon rack detection sensor 44C and causes the lamp L2 to indicate the abnormality. This allows the operator to take some action in response to the abnormality in the wagon rack detection sensor 44C. As a result, it is possible to reduce the occurrence of malfunctions caused by the inability of both the individual tier sensors 45A, 45B, 45C, 45D and the wagon rack detection sensor 44C to detect the dish rack R.

[0071] In the washing system 1 of the above embodiment, when the lift 41 is moved to one of the shelves 53 based on the detection results of the shelf sensors 45A, 45B, 45C, and 45D, if the trolley rack detection sensor 44C detects a dish rack R, it is determined that there is an abnormality in the shelf sensors 45A, 45B, 45C, and 45D, and lamp L2 is activated to notify the abnormality. As a result, it is possible to more reliably reduce the occurrence of malfunctions caused by the inability of both the shelf sensors 45A, 45B, 45C, and 45D and the trolley rack detection sensor 44C to detect the dish rack R.

[0072] In the washing system 1 of the above embodiment, when an abnormality is detected in the washing system 1, the lamp L2 enters an abnormality alarm state (in this embodiment, it lights up or flashes) indicating the abnormality. Furthermore, in the washing system 1 of the above embodiment, the abnormality alarm state is canceled when the cart 6 is removed from the lift device 5, i.e., when the cart detection sensor 46 detects that the cart 6 has been removed from the lift device 5. The washing system 1 manual, etc., states that when an abnormality is alarmed by the lamp L2, the cart 6 should be removed from the lift device 5 and the cart rack detection sensor 44C and the individual shelf sensors 45A, 45B, 45C, and 45D should be cleaned. In the washing system 1 of the above embodiment, the abnormality alarm state of the lamp L2 is automatically canceled when the dish rack R is removed from the lift device 5 and the cart 6. This eliminates the need to turn off the power to the washing system 1 or turn the abnormality stop button B2 to cancel the abnormality alarm state of the lamp L2, thereby reducing the operator's workload.

[0073] Although one embodiment has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention.

[0074] In the washing system 1 of the above embodiment, an example has been described in which an abnormality is determined in the wagon rack detection sensor 44C and also in the individual tier sensors 45A, 45B, 45C, and 45D, but it may be possible to determine only that an abnormality exists in the individual tier sensors 45A, 45B, 45C, and 45D and have the lamp L2 notify the abnormality in the individual tier sensors 45A, 45B, 45C, and 45D. Even in this case, it is possible to reduce the occurrence of malfunctions caused by the inability of both the individual tier sensors 45A, 45B, 45C, and 45D and the wagon rack detection sensor 44C to detect the dish rack R.

[0075] In the cleaning system 1 of the above embodiment or modified example, the shelf sensors 45A, 45B, 45C, and 45D are disposed on the frame 40A as sensors used to determine the availability of each of the four shelves 53. However, the present invention is not limited to this configuration. For example, the sensors may be disposed on the ceiling 40F or the bottom 40G above or below the lift device 5, instead of on the frame 40A.

[0076] In the washing system 1 of the above embodiment or modified example, an example has been described in which lamp L2 issues an alert when it is determined that there is an abnormality in wagon rack detection sensor 44C or each stage sensor 45A, 45B, 45C, 45D, but for example, the alert may be issued on a mobile terminal carried by an operator, or on a server or the like that centrally manages washing system 1. Furthermore, the alert unit that issues an alert may not only be provided in washing system 1 as lamp L2, but also as a speaker that emits an alarm, for example. [Explanation of symbols]

[0077] 1...Cleaning system, 3...Carry table, 4...Dishwasher (washing machine), 5...Lift device, 6...Wagon, 7...Door drive mechanism, 12...Main controller (control section), 40A...Frame, 40F...Ceiling section, 40Fa...Top plate section, 40Fb...Bending section, 41...Lift, 42...Lift drive mechanism, 43...Belt drive mechanism, 44A...Lift entrance sensor, 44B...Lift exit sensor, 44C...Wagon rack detection sensor sensor (sensor for detecting items to be washed), 45A, 45B, 45C, 45D...each stage sensor, 46...wagon detection sensor, 50A...frame, 53...shelf portion, 70...door drive portion, 72...chain, 73...slider, 74...connecting member, 75...guide rail, 76...bracket, 76a...main surface portion, 76b...door fixing portion, 76c...chain fixing portion, 76d...bending portion, L2...lamp (alarm portion), R...dish rack (rack).

Claims

1. A washing system comprising: a washing machine that washes objects stored in a washing chamber; a cart having a plurality of shelves arranged vertically that can accommodate the objects washed by the washing machine; and a lift device that transports the objects from the washing machine into the cart by moving the objects vertically and horizontally; a shelf sensor for detecting the presence or absence of the object to be cleaned on each of the plurality of shelves; a sensor for detecting the presence or absence of the object to be cleaned on the shelf to which the lift device is to transfer the object to be cleaned; a lift outlet sensor that detects that the object to be cleaned has been transported from the lift device; a control unit that controls the lift device based on the detection results of the each shelf sensor and the object detection sensor to load the object onto one of the plurality of shelf units; the control unit notifies the notification unit that there is an abnormality in the object detection sensor when the object detection sensor does not detect the object when the lift outlet sensor detects the removal of the object, A cleaning system in which, when the control unit moves the lift device to one of the multiple shelf sections based on the detection results of the each tier sensor, if the item to be cleaned is detected by the item to be cleaned detection sensor, the control unit notifies the alarm unit that there is an abnormality in the each tier sensor.

2. the notification unit that notifies the user that an abnormality has occurred; a wagon detection sensor that detects that the wagon is fixed to the lift device, The cleaning system of claim 1, wherein the control unit, when determining that an abnormality exists, causes the alarm unit to enter an abnormality alarm state indicating that an abnormality exists, and cancels the abnormality alarm state when the wagon detection sensor detects that the wagon has been removed from the lift device.

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