Conveyor Warewasher Camera System for Washware Orientation Detection
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Solution Overview
Problem
Conventional conveyor warewashers lack automatic differentiation of washware types, leading to inefficient resource utilization and unsatisfactory rinsing and washing results due to improper orientation and alignment of washware items during the cleaning process.
Innovation Solution
Incorporating a camera system with an image processing device to continuously monitor and evaluate the orientation and alignment of washware items, issuing warnings or adjusting the conveyor system to ensure optimal alignment and orientation, and utilizing machine learning to improve the efficiency of the cleaning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional conveyor warewashers are designed with fixed treatment parameters for multiple washware types, then the system can handle various washware items, but the washing and rinsing results become unsatisfactory when items are not optimally oriented
Solution Approach 1:
The camera system captures images of washware items before they enter the treatment zones, and the image processing device determines their orientation and alignment in advance. This preliminary detection allows the system to identify misoriented items before treatment begins, enabling corrective actions such as issuing warnings to loading personnel or adjusting treatment parameters to accommodate the actual item orientation, thereby ensuring satisfactory washing and rinsing results despite variations in item placement
Solution Approach 2:
The system establishes a feedback loop where the camera system continuously monitors washware item orientation on the conveyor apparatus, the image processing device evaluates the captured images to determine orientation status, and the control device receives this information to adjust treatment parameters or issue warnings. This closed-loop feedback mechanism enables real-time adaptation of treatment parameters based on actual item orientation, resolving the contradiction between handling multiple washware types and maintaining consistent washing quality
2Productivity
If the conveyor apparatus conveys washware items quickly through treatment zones, then productivity increases, but the washing personnel cannot ensure optimal orientation and alignment of items
Solution Approach 1:
The invention replaces the manual mechanical orientation process with an automated optical detection system. Instead of relying on washing personnel to manually orient each item correctly during rapid loading, the camera system and image processing device automatically detect item orientation and alignment. The control device then uses this information to adjust treatment parameters or issue warnings, substituting human manual orientation tasks with automated detection and control, thereby maintaining high productivity while ensuring proper item orientation
Solution Approach 2:
The system enables self-service by allowing the conveyor warewasher to automatically detect and respond to item orientation issues without requiring manual intervention for each item. The camera system and image processing device autonomously monitor item placement, and the control device automatically adjusts treatment parameters or triggers warnings, freeing washing personnel from the burden of manually ensuring optimal orientation of every item during rapid loading operations
3Device complexity
If conventional systems use fixed treatment parameters for all washware types, then device complexity is reduced, but resource utilization becomes inefficient
Solution Approach 1:
The system transitions from static fixed treatment parameters to dynamic adjustable parameters. The camera system and image processing device detect washware item characteristics and orientation in real-time, and the control device dynamically adjusts treatment parameters such as spray pressure, water flow rate, and chemical dosage based on the detected item type and orientation. This dynamic adaptation optimizes resource utilization for each specific item while maintaining manageable system complexity through automated control
Solution Approach 2:
The invention implements automatic parameter changes based on detected washware characteristics. Instead of using fixed treatment parameters for all items, the system varies parameters such as water pressure, spray angle, treatment zone duration, and chemical concentration according to the specific item type, size, and orientation detected by the camera and image processing systems. This parameter adaptation improves resource efficiency by matching treatment intensity to actual item requirements while the automated nature of the system keeps operational complexity manageable
Data Source
AI summary
A conveyor warewasher includes at least one washing zone, at least one rinsing zone and a conveyor apparatus. A camera system is configured in order to capture at least one image of an portion of the conveyor apparatus continuously or at predetermined or determinable times and/or events. An image processing device is associated with the camera system and is configured to determine a position, orientation and/or alignment of washware items present in the at least one captured image. An evaluation device is further provided that is adapted to determine based on the determined position, orientation, and/or alignment of the washware items whether, at the time of the image capture, washware items are present in the portion of the conveyor apparatus (2) that: i) are transported incorrectly oriented by the conveyor apparatus (2); and/or ii) are transported misaligned by the conveyor apparatus.