Tray Conveyor Unloading Layout for Spray-Shadow-Free Warewashing
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Solution Overview
Problem
Conveyor warewashers face inefficiencies in processing trays and other washware, leading to increased work time and resource consumption due to the need for manual handling and sorting, as well as the challenge of cleaning trays without causing spray shadows on other items.
Innovation Solution
A conveying apparatus with a separate conveyor belt for trays oriented parallel to the transport direction, allowing for automatic unloading and loading of trays, and additional conveyor belts for other washware, reducing manual intervention and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If trays are placed into the conveyor belt transversely to the transport direction, then the entire available surface of the conveyor belt is filled, but a relatively large amount of time has to be expended to clean trays and manual handling increases
Solution Approach 1:
The patent changes the loading dimension from transverse (perpendicular) to longitudinal (parallel) by providing a separate conveying apparatus that runs parallel to the main conveyor belt. Trays are conveyed in the same direction as the main belt and then unloaded automatically onto it, transforming the loading operation from a time-consuming manual transverse placement to an automated longitudinal process that utilizes the conveyor system's existing transport direction.
Solution Approach 2:
The conveying apparatus is designed to automatically unload trays onto the main conveyor belt without manual intervention. The automatic unloading station transfers trays from the separate conveying apparatus to the main conveyor belt automatically, eliminating the need for operators to manually place each tray and significantly reducing the time required for tray cleaning operations.
2Area of stationary object
If trays are cleaned in the same conveyor belt as other washware, then space is utilized efficiently, but spray shadows are cast on smaller washware articles stacked behind the trays
Solution Approach 1:
The patent segments the cleaning process by providing a separate conveying apparatus dedicated to tray transport, distinct from the main conveyor belt that carries other washware. This segmentation allows trays to be conveyed and unloaded separately, preventing them from casting spray shadows on smaller articles while still maintaining efficient space utilization through the parallel arrangement of the conveying apparatus alongside the main conveyor belt.
Solution Approach 2:
The separate conveying apparatus acts as an intermediary system between the tray loading area and the main conveyor belt. It serves as a mediator that transfers trays to the main belt at a controlled point (the unloading station), allowing trays to be introduced into the cleaning process without directly interfering with the spray patterns and cleaning zones of other washware on the main conveyor belt.
3Reliability
If operating personnel manually sort and place trays into the conveyor belt, then trays can be fully sorted before cleaning, but the stacking and de-stacking workflow becomes less efficient and work time increases
Solution Approach 1:
The separate conveying apparatus performs preliminary action by conveying trays in advance of the main cleaning process. Trays are prepared and conveyed along the parallel apparatus, allowing for pre-sorting and positioning before they are automatically unloaded onto the main conveyor belt. This preliminary conveying action separates the sorting function from the time-critical loading operation, maintaining sorting quality while improving overall workflow efficiency.
Solution Approach 2:
The patent replaces the manual mechanical system of operators physically placing trays with an automated mechanical conveying system. The separate conveying apparatus with its automatic unloading station substitutes human labor with an automated mechanism that can continuously transfer trays to the main conveyor belt without the delays and limitations of manual handling, thereby increasing productivity while maintaining sorting integrity.
Data Source
AI summary
The invention relates to a conveying apparatus (200, 200′, 200″, 200′″) for feeding washware (100, 101) to at least one conveyor belt (50, 51, 52) of a commercial conveyor warewasher (1), with a conveying system (201) for conveying the washware (100, 101), in particular for feeding trays or tray-like washware (100), of cutlery and/or of other washware (101). The invention is characterized by an unloading station (202, 202′, 202″, 202′″) for automatically unloading the washware (100, 101) from the conveying apparatus (200, 200′, 200″, 200′″) transversely to the conveying direction of the conveying system (201), in which the trays (100), with or without cutlery (103) lying on them, can be oriented on edge and parallel to the transport direction of the conveying system (201), so as to be capable of being placed onto a conveyor belt (50) of the conveyor warewasher. The invention relates, furthermore, to a flight-type warewasher (1) and to a combination of this warewasher (1) and of the conveying apparatus (200, 200′, 200″, 200′″). The invention relates, moreover, to a method for loading a flight-type warewasher (1), by means of a conveying apparatus (200, 200′, 200″, 200′″) and to a preferred use of same for loading a warewasher with trays or tray-like washware (100).