Conveyor Warewasher Unloading System for Automatic Tray Stacking
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Solution Overview
Problem
Conveyor warewashers face inefficiencies in cleaning trays due to the need for manual handling and sorting, which increases labor time and resource consumption, as trays must be placed transversely on the conveyor belt, obstructing other washware and requiring double handling.
Innovation Solution
An unloading system for conveyor warewashers that automatically unloads upended trays in a tray stacking station, using a sliding surface and guide for tilting and linear movement, allowing trays to be oriented horizontally and reducing manual intervention, with separate conveyor belts for trays and other washware to optimize space and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trays are placed transversely on the conveyor belt for cleaning, then trays can be cleaned effectively, but the cleaning process becomes slower and obstructs other washware
Solution Approach 1:
The patent changes the orientation dimension of tray placement on the conveyor belt. Instead of placing trays transversely (perpendicular to transport direction), the trays are placed longitudinally (parallel to transport direction) on a separate conveyor belt. This dimensional change allows trays to be cleaned without obstructing other washware and enables faster throughput while maintaining cleaning effectiveness through dedicated spray zones.
Solution Approach 2:
The patent segments the conveyor system into separate conveyor belts: one dedicated to trays and another for other washware. This segmentation allows independent optimization of each belt's function, enabling trays to be cleaned at higher speeds without interfering with the cleaning of other items, thus resolving the contradiction between cleaning effectiveness and productivity.
2Adaptability or versatility
If trays are manually sorted and placed on the conveyor belt, then presorting can be achieved, but labor time increases
Solution Approach 1:
The system enables self-service by allowing trays to be automatically fed onto the conveyor belt in an upended position without requiring manual removal of items or manual placement. The automatic unloading system at the outlet further reduces labor by automatically removing cleaned trays from the belt. This eliminates the need for double handling and significantly reduces labor time while maintaining presorting capabilities.
Solution Approach 2:
The patent implements preliminary action by providing a tray stack at the inlet region where trays are pre-positioned in an upended state, ready for immediate loading onto the conveyor belt. This preliminary preparation eliminates the need for manual sorting and handling during operation, reducing labor time while maintaining the presorting function.
3Area of stationary object
If trays are cleaned on the same conveyor belt as other washware, then space utilization is maximized, but spray shadows are created and cleaning quality deteriorates
Solution Approach 1:
The patent segments the conveyor system into separate conveyor belts: one dedicated to trays and another for other washware. This segmentation physically separates the spray zones, eliminating spray shadow interference between different types of washware. Each belt can be optimized for its specific item type, ensuring high cleaning quality while still achieving effective space utilization through parallel processing.
4Adaptability or versatility
If trays are placed manually in the inlet region, then presorting is achieved, but double handling is required
Solution Approach 1:
The system implements self-service by enabling automatic loading of trays from the tray stack onto the conveyor belt in an upended position. The automatic unloading system at the outlet further eliminates manual handling. This reduces the process from double manual handling to automated operation, significantly improving ease of operation while maintaining the presorting function through the dedicated tray stack.
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 solution significantly reduces labor time and resource consumption by automating the unloading process, enabling faster throughput and efficient cleaning of trays without obstructing other washware, thus enhancing the overall washing and rinsing efficiency in commercial settings.
Implementation Method 1
a sliding surface inclined in the direction of the tray stacking station... with which upended trays can be transferred in succession to the sliding surface
Data Source
AI summary
The present invention relates to an unloading system (70) for conveyor warewashers (1) for the automatic unloading of upended trays (100) in a tray stacking station (80) in which the stacked trays (100) are oriented horizontally, wherein the unloading system (70) has a sliding surface (71) inclined in the direction of the tray stacking station (80) and a guide (72), with which upended trays (100) can be transferred in succession to the sliding surface (71), preferably in the outlet region of the conveyor warewasher (1), by a combined tilting and linear movement.