Automated Dishwasher Loading System with Parallel Conveyor Sorting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conveyor dishwashers in commercial settings require significant manual effort for loading and sorting, leading to increased operational time and physical strain on personnel, as trays must be placed transversely on the conveyor belt, occupying all available space and necessitating double handling for trays and other items.
Innovation Solution
A system with a feed conveyor belt and sorting arrangement that automatically or partially automatically sorts and loads washware into predefined groups, using a tray lane and cutlery lane parallel to the main conveyor belt, allowing for the automatic placement of trays and cutlery, reducing manual handling through the use of a washware detector device and manipulator with gripper systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If trays are placed transversely on the conveyor belt to be cleaned, then trays can be sorted by type and prevented from casting spray shadows, but all available surface area of the conveyor belt is occupied and cleaning time for trays increases significantly
Solution Approach 1:
The conveyor system introduces a second dimension by running parallel conveyor belts in opposite directions. Trays are placed longitudinally on one belt while other washware is placed on the adjacent belt, allowing simultaneous cleaning of different item types without spatial conflict. This dimensional expansion resolves the contradiction between proper tray orientation for cleaning quality and overall system productivity.
Solution Approach 2:
The conveyor system segments the cleaning process by dividing washware into different lanes based on type. Trays are separated from plates, bowls, and cutlery onto different conveyor belts, allowing each item type to be optimized for its specific cleaning requirements while maintaining continuous high-volume processing across the entire system.
2Adaptability or versatility
If manual sorting and loading of washware is performed, then flexibility in handling different washware types is maintained, but operational time increases and physical strain on personnel increases
Solution Approach 1:
The system implements self-service through automatic detection devices that identify washware types and trigger appropriate sorting actions. The conveyor system automatically directs different washware items to their designated lanes without human intervention, maintaining adaptability to various item types while eliminating the time loss and physical strain associated with manual sorting and loading operations.
3Reliability
If trays are removed from place settings and stacked separately, then trays can be cleaned independently without blocking smaller items, but double handling is required and operational efficiency decreases
Solution Approach 1:
The parallel conveyor system enables continuous useful action by processing trays and other washware simultaneously in separate lanes. Trays are never removed or repositioned manually; instead, they remain on their designated conveyor belt throughout the entire cleaning process, eliminating double handling while maintaining cleaning effectiveness through proper longitudinal orientation that prevents spray shadowing.
Data Source
AI summary
A system (10) for loading a dishwasher which is designed as, in particular, a commercial conveyor dishwasher (1). The system (10) has a feed conveyor belt (11) for feeding washware (9a, 9b, 9c) to a loading region of the conveyor dishwasher (1). The system (10) also has a sorting arrangement for sorting the washware (9a, 9b, 9c), which is fed to the loading region of the conveyor dishwasher (1) by means of the feed conveyor belt (11), in accordance with predefined or predefinable washware groups. At least one loading arrangement (13a, 13b, 13c) is associated with the sorting arrangement for the purpose of automatically loading the conveyor dishwasher (1) with washware (9a, 9b, 9c) of one of the predefined or predefinable washware groups.