Robotic Immersion Tank Cleaning System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automated cleaning systems for immersion tanks in the poultry processing industry face inefficiencies due to difficulty in reaching all surfaces, high water consumption, and safety hazards associated with manual cleaning processes.
Innovation Solution
The system involves enclosing the tank to create hot, humid conditions that soften contaminants, followed by the application of cleaning solutions and rinsing with low-velocity water sprays, reducing the need for high water volumes and manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If fixed spray stations are used for automated cleaning, then automation is achieved, but cleaning efficacy is low due to difficulty of reaching all surfaces
Solution Approach 1:
The patent employs a robotic arm with articulated joints that can dynamically position spray nozzles to reach all surfaces within the chiller, including hard-to-access areas. This dynamic positioning capability allows the system to maintain high cleaning efficacy while being fully automated, resolving the contradiction between automation and cleaning effectiveness.
Solution Approach 2:
The robotic arm operates in three-dimensional space, moving the spray nozzles along multiple axes to access surfaces that fixed spray stations cannot reach. By transitioning from a fixed two-dimensional spray pattern to a mobile three-dimensional cleaning approach, the system achieves both automation and comprehensive surface coverage.
2Device complexity
If fixed nozzles outside the chiller are used, then equipment complexity is reduced, but water temperature drops due to evaporation before reaching far walls
Solution Approach 1:
The robotic arm dynamically positions the spray nozzles close to the target surfaces, minimizing the distance water travels through air. This reduces evaporative cooling and maintains water temperature effectiveness, while the robotic system itself adds complexity only where needed for positioning rather than for temperature control.
3Reliability
If higher quantities of water are applied over longer periods, then cleaning efficacy is improved, but water consumption and operating expense become unacceptable
Solution Approach 1:
The robotic arm delivers water in concentrated streams to specific soiled areas rather than applying water uniformly over the entire chiller surface. This dynamic, targeted approach maintains high cleaning efficacy while significantly reducing total water consumption by focusing resources only where needed.
Solution Approach 2:
The system applies cleaning resources locally to specific contaminated areas rather than uniformly across all surfaces. The robotic arm can adjust spray intensity, duration, and positioning to match the actual soiling level of each area, optimizing water usage efficiency while maintaining effective cleaning.
4Ease of operation
If workers reach inside the chiller with spray wands, then cleaning access is improved, but safety hazards increase due to rotating motive mechanisms
Solution Approach 1:
The patent replaces the manual mechanical cleaning process with an automated robotic system that performs all cleaning operations outside the hazard zone. The robotic arm extends into the chiller to position nozzles close to surfaces, providing excellent cleaning access while keeping human workers completely isolated from rotating augers and other moving mechanisms.
Solution Approach 2:
The robotic arm serves as an intermediary between the operator and the hazardous environment inside the chiller. It performs the dangerous task of penetrating into the space with moving parts, allowing human operators to control the cleaning process from a safe external location while maintaining full access to all soiled surfaces.
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 method effectively reduces water consumption, labor costs, and cleaning time while ensuring thorough contamination removal from tank surfaces.
Implementation Method 1
The resulting hot and humid conditions soften or melt any fats that may have congealed on the chiller surfaces making it possible to remove contaminants from these surfaces quickly with relatively low velocity water sprays.
Implementation Method 2
increasing the temperature and humidity in the interior volume of the immersion tank
Implementation Method 3
Water that leaves such a nozzle at a relatively high temperature can cool due to evaporation before it impinges the far wall.
Data Source
AI summary
A method for automated cleaning of an immersion tank (14) includes: substantially enclosing an interior volume (30) of the immersion tank (14); increasing the temperature and humidity in the interior volume (30) of the immersion tank (14); then applying cleaning solution to interior surfaces of the immersion tank (14); and rinsing the cleaning solution and soil off the interior surfaces of the immersion tank (14).