Conveyor Dishwasher Final Rinse Flow Control for Empty Compartments
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Solution Overview
Problem
Conveyor dishwashers face inefficiencies in reducing fresh water, chemical, and energy consumption, particularly in the final rinse zone, as existing solutions require a fixed time for stopping and restarting final rinsing, leading to prolonged lead times and inefficiencies when only a few compartments are empty.
Innovation Solution
A washware sensor apparatus and control apparatus are used to detect empty compartments and adjust the volumetric flow of final rinse liquid in real-time, allowing for reduced liquid supply when single or a few successive empty compartments enter the final rinse zone, maintaining efficient rinsing without complete shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If final rinsing is stopped completely when no washware enters the final rinse zone, then fresh water consumption is reduced, but a lead time of more than 4 seconds is required for reactivation until spray jets fan out satisfactorily
Solution Approach 1:
Instead of completely stopping the final rinsing system, the patent applies partial action by reducing the spray intensity or flow rate to a minimal level during periods without washware. This maintains enough fluid movement to prevent spray jet stagnation and ensures quick reactivation capability while still achieving significant water savings compared to full operation.
Solution Approach 2:
The patent implements a dynamic control system that continuously monitors washware presence and adjusts the spray system state accordingly. The system transitions between multiple operational states (full operation, reduced operation, stopped) based on real-time detection, optimizing both water consumption and reactivation time through adaptive behavior rather than fixed on/off states.
2Loss of substance
If final rinsing is stopped for a long period to reduce water consumption, then fresh water usage decreases, but the lead time for reactivation increases to approximately 7 seconds
Solution Approach 1:
The patent prevents the worsening effect by maintaining partial spray operation during extended idle periods. This minimal ongoing action keeps the spray jets primed and prevents complete stagnation, thereby avoiding the 7-second reactivation delay while still achieving substantial water reduction compared to continuous full operation.
Solution Approach 2:
The system employs periodic or pulsed spray operation during idle periods rather than complete shutdown. This periodic activation maintains fluid circulation and spray jet readiness without consuming excessive water, effectively breaking the correlation between idle duration and reactivation time.
3Loss of substance
If the quantity of final rinse liquid is reduced when single or a few empty compartments enter the final rinse zone, then fresh water consumption is reduced, but complete shutdown is avoided to maintain quick reactivation
Solution Approach 1:
The patent applies local quality by differentiating the spray treatment based on the specific situation - when single or few empty compartments are detected, the spray is reduced but not stopped, maintaining local rinsing capability. This targeted approach preserves productivity for the detected empty compartments while avoiding unnecessary water consumption, and keeps the system ready for immediate resumption when washware arrives.
Solution Approach 2:
The system dynamically changes operational parameters (spray flow rate, pressure, or intensity) based on the number and configuration of empty compartments detected. By adjusting parameters rather than simply on/off switching, the system maintains adequate rinsing effectiveness for empty compartments while significantly reducing water consumption, and preserves quick reactivation capability.
Data Source
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AI summary
The invention relates to a conveyor dishwasher (2) comprising a conveyor apparatus (4) for conveying washware (6) through a final rinse zone (18), with the conveyor apparatus (4) having a large number of compartments (38) for accommodating washware (6). A washware sensor apparatus (42) is provided in order to detect empty compartments (38). In order to be able to reduce the consumption of fresh water, chemicals and energy during operation of the conveyor dishwasher (2), the invention provides a control apparatus (44) which is designed to automatically set the quantity of final rinse liquid supplied to the spray nozzles (20, 22, 24) of the final rinse zone (18) per unit time as a function of the detection of empty compartments (38). The invention also relates to a method for operating a conveyor dishwasher (2) of this type.