Automated Cleaning System for Chemically Etched Metal Substrates
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Solution Overview
Problem
Manual cleaning processes for chemically etched products are hazardous, create excess waste, and pose health risks due to residues and deposits on the product surface.
Innovation Solution
A conveyor system with automated rollers, sprayers, brushes, and a fluid collector module that applies and recycles a cleaning solution to scrub and filter residues, followed by a drying module using air knives and brushes to remove chemicals and debris efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cleaning processes are used to remove residues from chemically etched products, then cleaning can be performed, but health risks to workers and creation of hazardous waste increase
Solution Approach 1:
The patent replaces manual mechanical cleaning with an automated cleaning system that uses a conveyor belt to transport products through a cleaning chamber. The system employs spray nozzles to apply cleaning solution and rotating brushes to mechanically remove residues, eliminating direct human contact with hazardous materials while maintaining effective cleaning.
Solution Approach 2:
The patent introduces a cleaning solution as an intermediary substance to facilitate the removal of residues. The cleaning solution is sprayed onto the product surface and works chemically to loosen and dissolve etching residues, making them easier to remove mechanically without requiring direct manual handling of the hazardous residues themselves.
2Productivity
If automated conveyor system with multiple modules is implemented, then productivity and safety improve, but device complexity increases
Solution Approach 1:
The cleaning system is divided into distinct functional modules: a loading module for product entry, a cleaning module with spray nozzles and brushes, a rinsing module with additional spray nozzles, and a drying module with air knives. Each module performs a specific function and can be independently controlled, allowing for optimized throughput while managing complexity through functional decomposition.
Solution Approach 2:
The conveyor belt system serves multiple functions: it transports products through all cleaning stages, positions products for optimal cleaning contact, and controls the timing and sequence of different cleaning operations. This multi-functionality reduces the need for separate handling mechanisms for each cleaning stage, thereby managing overall system complexity.
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
The system effectively removes residues and deposits from product surfaces without manual intervention, reducing hazardous waste and health risks while maintaining product integrity.
Implementation Method 1
applying a cleaning solution to a top surface of the product... to remove residues and deposits that are on the top surface of the product
Implementation Method 2
a filter media that extends between the conveyor system and the collection tray to filter the cleaning solution by removing deposits, debris, etc.
Implementation Method 3
an air knife system that includes one or more air knives that direct air at the product to dry the product
Data Source
AI summary
A system for and method of removing residues, deposits, and debris from a substrate that has been marked by a chemical etching process is disclosed. The system includes one or more upper sprayers that deposit a cleaning solution to a top surface of the product as it passes beneath the one or more upper sprayers. The system further includes at least one upper brush that operates to scrub the top surface of the product after the cleaning solution has been applied thereto. The system optionally includes one or more lower sprayers and lower brushes to clean a bottom surface of the product as it is conveyed through the system. The system further includes an air knife system that assists with drying the product prior to exiting the system. The system further includes a controller that is operable to adjust various system parameters.