Conveyor warewasher and method for operating a conveyor warewasher
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Solution Overview
Problem
Conveyor warewashers lack the ability to automatically differentiate and optimize treatment parameters for various types of washware, leading to suboptimal cleaning and drying results, especially for reusable plasticware, due to mixed loading and the need for manual program adjustments.
Innovation Solution
A conveyor warewasher equipped with a camera system for image processing to detect washware categories, including reusable plasticware, and a control device that automatically adjusts treatment parameters such as washing and rinsing liquid flow rates, nozzle pressures, and drying air settings based on detected categories, utilizing machine learning to optimize processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conveyor warewashers are designed as a compromise to handle multiple types of washware, then the machine can be used for several different types of washware, but the cleaning and drying results are suboptimal for specific categories such as reusable plasticware
Solution Approach 1:
The system dynamically adjusts treatment parameters (washing liquid flow rate, rinsing liquid flow rate, drying air flow rate, nozzle pressures, conveyor speed) based on real-time detection of washware categories. The control device modifies operational parameters on-the-fly according to the detected washware type, enabling optimal treatment for each category while maintaining versatility across multiple types.
Solution Approach 2:
The invention changes physical parameters of the treatment process based on washware category. Different flow rates, pressures, temperatures, and conveyor speeds are applied depending on whether the detected washware is reusable plasticware, glassware, cutlery, or other categories. This parameter adaptation resolves the contradiction by allowing high-quality treatment for each specific type while maintaining multi-type capability.
2Manufacturing precision
If the cleaning staff manually changes or fits the treatment program for reusable plasticware, then optimal cleaning results can be achieved, but this requires continuous staff intervention and training
Solution Approach 1:
The system performs self-service by automatically detecting washware categories and adjusting treatment parameters without human intervention. The camera system continuously monitors the conveyor, identifies washware types, and the control device autonomously selects and applies the appropriate treatment program. This eliminates the need for staff to manually change programs or receive extensive training, while maintaining optimal cleaning quality.
Solution Approach 2:
The system implements continuous feedback through the camera system that monitors washware on the conveyor and provides real-time information to the control device. Based on this feedback about washware category, the control device automatically adjusts treatment parameters. This closed-loop feedback mechanism replaces manual staff intervention with automated decision-making, simplifying operation while preserving cleaning quality.
3Extent of automation
If a camera system with image processing is added to detect washware categories, then automatic differentiation and optimization is enabled, but the device complexity increases
Solution Approach 1:
The camera system serves multiple functions: it detects washware categories, determines their positions on the conveyor, and provides data for treatment optimization. This single multi-functional component enables automatic differentiation without requiring separate detection systems for each washware type, thereby limiting the increase in complexity while achieving high automation.
Solution Approach 2:
The invention replaces manual mechanical operations (staff visually identifying washware and manually adjusting programs) with an optical detection system and automated control. The camera-based optical system substitutes for human visual inspection and decision-making, automating the process while reducing the need for complex manual intervention mechanisms.
4Productivity
If the conveyor warewasher operates continuously with mixed loading, then productivity is maintained, but reusable plasticware is not optimally cleaned or dried
Solution Approach 1:
The system dynamically adapts treatment parameters during continuous operation based on real-time detection of mixed washware categories. As different types of washware pass through the detection zone, the control device continuously adjusts flow rates, pressures, and conveyor speed to optimize treatment for the currently detected category, maintaining both continuous productivity and high cleaning quality for each type.
Solution Approach 2:
During continuous mixed loading operation, the system changes treatment parameters according to the detected washware category. When reusable plasticware is detected, specific parameters (lower flow rates, adjusted pressures, modified conveyor speed) are applied; when other categories are detected, different parameters are used. This dynamic parameter adjustment enables optimal cleaning of each type while maintaining continuous operation and high productivity.
Data Source
AI summary
A conveyor warewasher has at least one washing zone, at least one rinsing zone and a conveyor apparatus. A camera system is arranged above or below or to the side of the conveyor apparatus and is configured in order capture at least one image of a portion of the conveyor apparatus, preferably continuously or at predetermined or determinable times and/or events. An evaluation device is configured in order to evaluate and determine on the basis of the at least one image whether, at the time of the image capture, washware of the following washware category was present in the portion of the conveyor apparatus: reusable plasticware, in particular in the form of plastic trays, plastic mugs, plastic bowls, plastic covers for plastic bowls, and/or plastic plates.