Immersion Spray Rinse System Water Reduction
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Solution Overview
Problem
Traditional immersion rinsing methods require multiple tanks and are costly, complex, and inefficient in water usage, while existing spray rinsing systems like RinseMaster are expensive and difficult to understand, failing to provide effective cleanliness between immersion and spray rinsing processes.
Innovation Solution
An immersion and spray rinsing system comprising a single tank with a PLC-controlled valve and pump system, a holding tank for contaminated water, and a spray system that uses fresh water for rinsing, allowing for efficient water reuse and reduced water consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional immersion rinsing uses multiple tanks (3+ stations), then rinsing effectiveness is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines multiple rinse tank functions into a single integrated tank system. The first rinse tank performs both immersion rinsing and houses the spray rinse system, eliminating the need for separate tanks while maintaining rinsing effectiveness through sequential immersion-spray operations.
Solution Approach 2:
The single rinse tank is designed to perform multiple functions: it serves as the immersion rinse tank, contains the spray rinse system, and acts as the recirculation system. This multi-functional design replaces traditional multiple specialized tanks, reducing system complexity while maintaining effectiveness.
2Loss of substance
If spray rinsing is used (RinseMaster), then water savings are achieved, but system complexity and cost increase
Solution Approach 1:
The system uses a self-contained recirculation approach where rinse water is continuously pumped from the bottom of the tank and redistributed through spray nozzles. This self-service recirculation system achieves water savings without requiring complex external water treatment or multiple tank systems.
Solution Approach 2:
The patent employs hydraulic recirculation using a pump system that continuously circulates rinse water through spray nozzles. This hydraulic approach enables efficient water reuse and reduces consumption while maintaining system simplicity through straightforward pump-and-spray mechanics.
3Loss of substance
If recirculation is implemented, then water usage efficiency is improved, but contamination control becomes more difficult
Solution Approach 1:
The system implements localized quality control by positioning spray nozzles at specific locations within the tank to create targeted rinse zones. The spray system delivers fresh water directly to contaminated areas while the recirculation pump draws from the cleaner lower tank regions, maintaining contamination separation and effectiveness.
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
The system achieves effective cleanliness with reduced water usage and operational costs, offering equivalent or better results than traditional three-station counterflow rinse tanks while simplifying the process and reducing complexity.
Implementation Method 1
spraying a first water spray over the inside of the barrel; spraying a second water spray over the inside of the barrel
Implementation Method 2
pumping a portion of contaminated water in the holding tank back to the rinse tank
Implementation Method 3
a water sensor to sense the level of water in the holding tank
Data Source
AI summary
Provided herein are systems, methods and apparatuses for an immersion and spray rinsing system comprising a tank with improved cleanliness of the parts between immersion and spray.