Dual-Zone Batch Dishwasher for Mixed-Soil Rack Processing
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Solution Overview
Problem
Commercial batch dishwashers face bottlenecks during busy periods due to long cycle times required for heavily soiled items, leading to reduced capacity and increased manual workload, while conventional solutions fail to optimize resource usage and efficiency.
Innovation Solution
A dishwasher with a treatment chamber divided into two zones, allowing independent treatment of items with different soiling levels, where one zone can operate continuously and the other intermittently, using a single wash pump and control device to manage wash and rinse cycles efficiently, and a mechanism for moving racks between zones to optimize loading and unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single treatment zone is used in commercial batch dishwashers, then the device complexity is low, but the productivity is reduced during busy periods due to long cycle times for heavily soiled items
Solution Approach 1:
The treatment chamber is divided into two independent treatment zones (first and second zones), each capable of operating with its own wash and rinse cycles. This segmentation allows simultaneous processing of differently soiled items, increasing overall dishwasher capacity without requiring a completely separate machine.
2Productivity
If the treatment chamber is divided into two zones for simultaneous treatment, then the productivity increases, but the device complexity increases
Solution Approach 1:
Both treatment zones share common systems including a single wash pump, water supply lines, and control device. This merging of resources reduces the overall complexity compared to having completely separate systems, while still maintaining independent operation of each zone for simultaneous processing.
Solution Approach 2:
The wash pump and water distribution system serve both treatment zones universally, allowing a single system to perform multiple functions. The control device manages both zones independently, enabling flexible operation modes including simultaneous wash-rinse cycles or sequential operations.
3Ease of operation
If a mechanism for moving racks between zones is added, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
A rack movement mechanism serves as an intermediary system that facilitates easy transfer of racks between the two treatment zones. This mechanism includes guides and positioning systems that enable smooth movement without requiring complex automated handling systems, balancing ease of operation with acceptable complexity.
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 design enhances the dishwasher's capacity and efficiency by allowing simultaneous treatment of items with varying soiling levels without reducing the standard zone's capacity, while optimizing resource usage and minimizing recontamination risks.
Implementation Method 1
The wash liquid situated in the wash tank can, by way of the wash pump, be delivered via the line system to the wash nozzles
Implementation Method 2
wash liquid can flow back from the treatment chamber under the action of gravitational force
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A batch dishwasher (1) has a treatment chamber (2) with at least one wash system which is designed as a recirculation system, wherein the treatment chamber (2) has at least two treatment zones (6, 7) in which washware can be treated at the same time but independently of one another, in particular independently of one another in respect of action time, wash and/or rinse mechanics, and/or independently in respect of the selected treatment program. The at least two treatment zones (6, 7) are each realized in such a way that at least one dish rack (5) can be inserted and removed, and wherein the dishwasher (1) has a mechanism for retracting or extending a dish rack (5) into at least one and, respectively, out of at least one of the at least two treatment zones (6, 7) as required.