Ultrasonic Container Washing With Occupancy-Based Power Modulation
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Solution Overview
Problem
Existing washing machines for containers filled with pourable products face issues with high energy consumption, longer cleaning times, and inefficient management of overspeed operating conditions, leading to improper cleaning due to reduced bathing time.
Innovation Solution
A washing machine with a sensor unit to detect the presence of containers and control ultrasonic wave generation based on occupancy, allowing for modulated ultrasonic wave generation to compensate for overspeed conditions without increasing cleaning bath temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the chain conveyor operates at higher speed to compensate for lower filling rates, then productivity is improved, but cleaning quality deteriorates due to reduced bathing time
Solution Approach 1:
The ultrasonic wave generation is made dynamic and adjustable based on real-time container detection. The control unit modulates ultrasonic wave generation between active and inactive states according to container presence in detection zones, allowing the cleaning intensity to adapt to varying operational conditions and maintain cleaning quality across different conveyor speeds
Solution Approach 2:
The system changes the parameter of ultrasonic wave generation (from continuous to modulated/discontinuous) based on container detection. By activating ultrasonic waves only when containers are present in specific zones, the system maintains effective cleaning while reducing overall energy consumption and adapting to variable throughput requirements
2Reliability
If the temperature of cleaning baths is increased to ensure proper cleaning during overspeed conditions, then cleaning quality is improved, but energy consumption increases
Solution Approach 1:
Instead of continuously maintaining high bath temperature, the system changes the parameter of ultrasonic wave generation from continuous to modulated. Ultrasonic waves are activated only when containers are detected in specific zones, providing intensive cleaning exactly when needed while avoiding unnecessary energy consumption during empty periods or overspeed conditions
Solution Approach 2:
The system replaces thermal energy input (heating) with ultrasonic energy input for cleaning. By using ultrasonic waves to generate cavitation and mechanical agitation in the cleaning bath, the system achieves effective cleaning without relying on increased thermal energy, thus avoiding the energy consumption associated with heating large volumes of water
3Reliability
If ultrasonic waves are generated continuously to maintain cleaning effectiveness, then cleaning quality is improved, but energy consumption increases
Solution Approach 1:
The ultrasonic wave generation is implemented as periodic rather than continuous. The control unit activates ultrasonic waves in specific periods when containers are detected in detection zones, and deactivates them when zones are empty. This periodic action maintains cleaning effectiveness during container passage while significantly reducing energy consumption during idle periods
Solution Approach 2:
The system employs feedback control through sensor units that detect container presence and provide signals to the control unit. Based on this feedback information, the control unit modulates ultrasonic wave generation in real-time, ensuring waves are generated only when containers are present and cleaning is actually needed, thereby optimizing the balance between cleaning quality and energy consumption
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
Improves energy efficiency and ensures proper cleaning by dynamically adjusting ultrasonic wave generation, reducing the need for larger machines and maintaining effective cleaning even during overspeed operations.
Implementation Method 1
The ultrasonic waves propagate in water and, more in general, in a medium with a relative periodic motion with respect to the medium itself, such that local micro-zones within the medium pass periodically from a depressurized to a pressurized state.
Implementation Method 2
During the depressurized state, air dissolved within the medium tends to form many microbubbles, which implode when pressure increases so as to release energy. Such energy may be useful to disaggregate the aforementioned encrusted dirt mounds
Data Source
AI summary
Provided is a washing machine for washing empty containers. The machine includes a conveyor having seats for respective containers to convey a plurality of containers in their respective seats along a washing path. The machine includes at least one treatment station including a tank for holding a cleaning medium for washing the containers, the washing path extending through the tank, and at least one ultrasonic wave generator arranged adjacent to the washing path. Also included is a sensor unit for sequentially inspecting each seat for detecting the presence of containers therein downstream of the inlet station, and for generating signals correlated to the absence of containers in the inspected seats. Also included is a control unit configured to receive said signals and to control the ultrasonic wave generator based on the received signals for modulating a level of ultrasonic wave generation.