Multi-Track Dishwasher Loading for Automated Washware Sorting
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Solution Overview
Problem
Conveyor dishwashers require significant manual effort for loading and unloading, leading to increased working time and physical strain for personnel, as trays need to be manually sorted and placed, while other washware items like plates and bowls are not efficiently cleaned due to the tray's occupation of the conveyor belt space.
Innovation Solution
A system with a feed conveyor belt and sorting arrangement that automatically sorts washware into dedicated conveying tracks based on type, allowing trays to be conveyed separately and automatically loaded onto a tray track, reducing manual handling and optimizing the orientation of washware for efficient cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If trays are manually sorted and placed into the conveyor belt transverse to the conveying direction, then trays can be cleaned without casting spray shadows on smaller washware items, but the entire available surface of the conveyor belt is occupied and a relatively large amount of time is spent cleaning trays
Solution Approach 1:
The conveyor belt is divided into multiple lanes, with dedicated lanes for different types of washware. Trays are assigned to specific lanes that run parallel to the conveying direction, while smaller items like plates and bowls have separate lanes. This segmentation allows simultaneous cleaning of different washware types without interference, resolving the conflict between cleaning quality and productivity.
Solution Approach 2:
Instead of placing trays transverse to the conveying direction (occupying width), the system uses parallel lanes extending in the conveying direction (using length dimension). This dimensional change allows trays to be cleaned in their own dedicated space without blocking the entire belt surface, enabling other washware to be cleaned simultaneously in adjacent lanes.
2Ease of operation
If service personnel manually remove and sort washware items from trays, then individual items can be cleaned separately, but the manual effort and working time are significantly increased
Solution Approach 1:
The system enables self-service loading where washware items are automatically sorted and placed onto the conveyor belt without manual intervention. The parallel lane configuration allows trays to be loaded directly onto dedicated lanes, and smaller items can be automatically distributed to appropriate lanes, eliminating the need for service personnel to manually remove and sort each item.
Solution Approach 2:
Washware is presorted before being placed into the conveyor belt at the loading region. Trays are stacked in preparation areas and automatically fed onto dedicated lanes, while smaller items are pre-grouped and automatically distributed. This preliminary sorting action occurs before the washing process begins, significantly reducing the manual effort and time required during operation.
3Reliability
If trays are stacked in front of the conveyor apparatus, then they can be placed into the conveyor belt separately, but other washware cannot be cleaned simultaneously because the conveyor belt surface is fully occupied
Solution Approach 1:
The conveyor belt is segmented into multiple parallel lanes, each dedicated to specific types of washware. Trays occupy only their designated lane(s), while adjacent lanes remain available for cleaning plates, bowls, and other smaller items simultaneously. This segmentation resolves the conflict by providing dedicated spaces that prevent trays from blocking the entire belt surface.
Solution Approach 2:
The multi-lane conveyor system provides universal functionality by accommodating different types of washware simultaneously in different lanes. Each lane can be optimized for specific washware types, allowing the system to handle trays, plates, bowls, and other items in parallel, thereby increasing overall throughput capacity while maintaining cleaning effectiveness for each item type.
Data Source
AI summary
A system (10) for loading different conveying tracks (2, 3, 4) of at least one in particular commercial conveyor dishwasher (1, 1′). The system (10) includes a feed conveyor belt (11) for delivering washware (9a, 9b, 9c) to loading regions of the at least one conveyor dishwasher (1, 1′). The system (10) further includes a sorting arrangement for sorting the washware (9a, 9b, 9c) delivered to the loading regions of the at least one conveyor dishwasher (1, 1′) via the feed conveyor belt (11) according to previously defined or definable washware groups. The sorting arrangement is associated with at least one loading arrangement (13a, 13b, 13c) for automatically loading the different conveying tracks of the at least one conveyor dishwasher (1, 1′) with washware (9a, 9b, 9c) of one of the previously defined or definable washware groups.