Automated Cleaning Machine Short Cycle Mode for High-Volume Throughput
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Solution Overview
Problem
Automated cleaning machines in high-volume settings face inefficiencies due to longer cycle times required for effective cleaning and sanitizing under default settings, which hinder throughput during peak periods.
Innovation Solution
Implementing 'short' cleaning cycles with adjusted parameters such as higher wash and rinse water temperatures, shorter cycle durations, and increased detergent concentration, allowing the automated cleaning machine to switch between default and short cycle modes based on throughput thresholds or time periods to optimize cleaning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If default cleaning cycle parameters are used, then cleaning and sanitizing effectiveness is maintained, but cycle time is prolonged reducing throughput
Solution Approach 1:
The cleaning machine dynamically adjusts cycle parameters based on real-time conditions. The controller monitors whether to execute default or short cycles and switches between modes accordingly, making the system adaptive rather than static. This resolves the contradiction by allowing the system to maintain effectiveness when needed while maximizing throughput when conditions permit.
Solution Approach 2:
The patent changes multiple parameters simultaneously to achieve shortened cycles: reducing wash phase duration, reducing rinse phase duration, increasing wash water temperature, and increasing detergent concentration. These parameter changes allow the system to maintain cleaning effectiveness while significantly reducing cycle time, thereby increasing throughput.
2Productivity
If short cleaning cycle parameters are used, then throughput is increased, but cleaning and sanitizing effectiveness may be compromised
Solution Approach 1:
The short cycle parameters are specifically designed with increased wash water temperature and increased detergent concentration to compensate for reduced time. The wash phase duration is reduced but temperature and chemical concentration are increased to maintain the sanitizing effect. This allows throughput improvement without sacrificing cleaning effectiveness.
Solution Approach 2:
The short cycle applies excessive detergent concentration and elevated temperature to achieve adequate cleaning in reduced time. Rather than attempting to maintain all parameters at optimal levels, the system uses enhanced chemical and thermal action to compensate for the shortened duration, ensuring effectiveness is maintained despite time reduction.
3Productivity
If wash phase duration is reduced, then cycle time is shortened, but heat transfer to articles may be insufficient
Solution Approach 1:
When wash phase duration is reduced, the system increases wash water temperature to compensate. This parameter change ensures that the reduced time is offset by intensified thermal energy transfer. The higher temperature maintains the heat transfer effectiveness needed for sanitizing even though the duration is shorter.
4Productivity
If detergent concentration is increased, then cleaning effectiveness is maintained in shorter cycles, but chemical usage increases
Solution Approach 1:
The system increases detergent concentration specifically during short cycles to maintain cleaning effectiveness despite reduced contact time. This parameter adjustment allows the machine to achieve adequate sanitation in shorter cycles, accepting increased chemical usage as the trade-off for improved productivity and cycle efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables increased throughput by reducing cycle times while ensuring effective cleaning and sanitizing, particularly during high-volume periods, and can lead to labor and energy savings.
Implementation Method 1
The short cycle wash phase duration and the short cycle wash water temperature may be sufficient to transfer at least 3600 Heat Unit Equivalents (HUEs) to the articles in the wash chamber
Implementation Method 2
one or more cleaning products and/or rinse agents are applied to the articles during a cleaning process
Data Source
AI summary
An automated cleaning machine may include one or more short cleaning cycles in which the duration of a cleaning cycle is shortened relative to the duration of a default cleaning cycle. During a short cleaning cycle, other cleaning cycle parameters may also be adjusted to ensure that the articles subjected to the short cleaning cycle are adequately cleaned and sanitized. For example, the wash temperature, rinse temperature, and/or cleaning product amounts or concentrations, may be adjusted to account for the shortened duration of the cleaning cycle. The automated cleaning machine may further include one or more short cycle mode(s) during which short cleaning cycle parameters are used and one or more default cycle mode(s) during which default cleaning cycle parameters are used.