Conveyor Dishwasher with Robot Arm for Automated Tableware Sorting
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Solution Overview
Problem
The food service industry faces labor challenges and inefficiencies in dishwashing processes, requiring significant worker intervention and attention to timing, which is troublesome and labor-intensive.
Innovation Solution
A dishwashing system incorporating a conveyor-type dishwasher and a robot device with a robot arm mechanism that picks up tableware from a washing chamber, transfers it to a stock area, and uses image processing and sensors to manage the picking and stacking operations, enabling automated sorting and reducing manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a worker manually performs dishwashing operations including removing leftover food, immersing tableware in dipping sink, preliminary washing with brush, placing on washing rack, and sorting after washing, then the dishwashing process can be completed, but the labor intensity and troublesomeness increase significantly
Solution Approach 1:
The system enables self-service automation where the robot device independently performs all dishwashing operations including removing leftover food, immersing tableware in dipping sink, preliminary washing with brush, placing on washing rack, and sorting after washing without human intervention. The control device coordinates these operations automatically based on sensor inputs and pre-programmed sequences
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robot device equipped with various mechanisms including a brush mechanism for preliminary washing, a dipping sink mechanism, and a sorting mechanism. The robot arm manipulates tableware through programmed mechanical movements, substituting human manual labor with automated mechanical systems
2Productivity
If a worker performs dishwashing operations during gaps between other work tasks, then dishwashing can be completed, but the worker must pay constant attention to timing which increases operational complexity
Solution Approach 1:
The system incorporates sensors that detect the presence and status of tableware at various stages of the washing process. The control device receives feedback from these sensors and automatically adjusts operations, eliminating the need for manual timing coordination. The feedback loop ensures operations proceed in the correct sequence without human intervention
Solution Approach 2:
The automated system maintains continuous operation of the dishwashing process without interruptions or idle periods. The robot device continuously performs operations including conveying tableware, washing, drying, and sorting without the timing gaps required in manual operations, maximizing productivity continuously
3Productivity
If manual sorting of washed tableware into respective kinds is performed, then proper stacking can be achieved, but additional labor time and complexity are required
Solution Approach 1:
The patent employs an automated sorting mechanism with sensors that identify different kinds of tableware and direct them to appropriate stacking locations. The robot arm automatically sorts washed tableware into respective categories (large bowls, plates, small bowls) and stacks them on the stock rack without manual intervention, replacing complex manual sorting operations with automated mechanical sorting
Data Source
AI summary
A dishwashing system includes: a conveyor-type dishwasher that washes tableware in a washing machine main body while conveying the tableware by means of a conveyor; a robot device having a robot arm mechanism that is installed in the vicinity of a picking area outside of the washing machine main body in order to pick up tableware that is conveyed to the picking area by conveyors, and to transfer the tableware to a stock area; and a control device that generates an enabling signal relating to operations of the conveyors with respect to the dishwasher.