Verification of cleaning process efficacy
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Solution Overview
Problem
Automated cleaning machines lack a reliable method to verify the efficacy of cleaning processes, leading to potential unsatisfactory cleaning results due to variations in wash cycle duration, detergent concentration, water temperature, and other parameters.
Innovation Solution
A system that uses color data from verification coupons exposed to the cleaning process to determine efficacy, including ratios and percent color values, and adjusts cleaning machine settings in real-time to ensure optimal results by sensing and adjusting parameters such as wash cycle duration, detergent concentration, and water temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated cleaning machines operate without verification methods, then device complexity is reduced, but cleaning reliability deteriorates due to parameter variations
Solution Approach 1:
The patent uses colorimetric indicators on verification coupons that change color based on exposure to cleaning agents. The coupon contains substrates with specific colors that undergo measurable color changes when exposed to detergents, sanitizers, or other cleaning chemicals, providing a visual and digital verification of cleaning efficacy without complex mechanical verification systems.
Solution Approach 2:
The patent replaces complex mechanical verification systems with optical detection. Instead of using mechanical sensors or complex measurement devices to verify cleaning parameters, the system uses colorimetric changes detected by simple optical sensors or cameras to determine cleaning efficacy, substituting mechanical complexity with optical measurement.
2Manufacturing precision
If cleaning parameters are not monitored and adjusted, then device complexity is reduced, but manufacturing precision of cleaning results deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the colorimetric verification results are used to determine whether the cleaning cycle was successful. The system compares the measured color changes against expected ranges and can trigger alerts, re-cleaning cycles, or parameter adjustments, creating a closed-loop feedback system that ensures consistent cleaning results without requiring continuous complex monitoring during the cleaning process.
Solution Approach 2:
The patent uses verification coupons that are prepared in advance with known color substrates and placed in the cleaning chamber before the cleaning cycle. These pre-prepared coupons serve as reference standards that allow post-cycle verification of cleaning efficacy, enabling precision measurement of cleaning results without requiring real-time parameter monitoring during the actual cleaning process.
3Reliability
If real-time parameter sensing and adjustment is implemented, then cleaning reliability is improved, but device complexity increases
Solution Approach 1:
The verification coupon system is self-service in that it automatically verifies cleaning efficacy without requiring external intervention. The coupon undergoes colorimetric changes during the cleaning cycle that directly indicate whether cleaning parameters were adequate, and the system automatically compares results against thresholds and triggers appropriate responses, eliminating the need for complex manual monitoring and adjustment systems.
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 verifies the cleaning process efficacy and automatically adjusts parameters to ensure satisfactory cleaning outcomes, even when initial settings are not optimal, thereby improving the reliability and consistency of cleaning operations.
Implementation Method 1
obtain a color sensor reading associated with the verification area
Data Source
AI summary
Experimental color data obtained from a plurality of cleaning process verification coupons is used to determine optimized cleaning process parameters in an automated cleaning machine. Color data may also be obtained from cleaning process verification coupon(s) to verify the efficacy of a real-world cleaning processes in an automated cleaning machine and/or to obtain one or more suggested corrective action(s) in the event the cleaning process yields an unsatisfactory cleaning result. Based on the optimized cleaning process parameters, an automated cleaning machine may automatically adjust one or more cleaning process parameters to correct for non-optimized parameters sensed during execution of a cleaning process to help prevent an unsatisfactory cleaning result.