Warewash Machine Vapor Extraction Using Condenser and Air Movers
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Solution Overview
Problem
Hood-type warewash machines release large amounts of hot water vapor during the wash and rinse cycle, creating an uncomfortable work environment and increasing facility costs due to water dripping on ceilings and the need for conditioning.
Innovation Solution
A warewash machine with a multi-sided hood assembly and a vapor extraction unit that includes a condenser and air movers to pull hot water vapor from the chamber after the rinse cycle, using controlled water flow and air movement to condense and recycle the vapor, while maintaining make-up air to retain heat within the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the hood assembly is opened to allow ware inlet and outlet, then access to the wash zone is enabled, but hot water vapor escapes creating an uncomfortable work environment
Solution Approach 1:
The vapor extraction unit operates during and after the wash cycle to remove hot water vapor before the hood is opened for ware loading/unloading. This preliminary vapor removal action prevents the harmful vapor escape that would otherwise occur when the hood is opened, thus resolving the contradiction between maintaining hood closure for vapor containment and opening the hood for operational access.
2Stability of the object's composition
If hot water vapor is allowed to exit the machine, then the chamber is depressurized, but facility walls contact the vapor causing ceiling water dripping and increased conditioning costs
Solution Approach 1:
The vapor extraction unit captures the hot water vapor that would otherwise be harmful and waste it as a resource by directing it through a heat exchanger. Here, the vapor's thermal energy is recovered to pre-heat incoming cold water for the next wash cycle, thus converting the harmful vapor escape into a beneficial energy recovery mechanism that reduces facility conditioning costs.
Solution Approach 2:
Instead of allowing hot water vapor to escape unused to the facility environment, the system recovers the vapor through the heat exchanger and utilizes its thermal energy to pre-heat makeup water. This recovery process prevents both the harmful effect of vapor contact with facility walls and the energy waste of unutilized thermal content.
3Object-affected harmful factors
If a vapor extraction unit is added to reduce hot water vapor escape, then operator comfort and energy retention improve, but device complexity increases
Solution Approach 1:
The vapor extraction unit is integrated with the existing hood assembly structure, utilizing the hood's enclosure and airflow pathways. The heat exchanger is connected to the existing cold water supply line, allowing the vapor extraction system to serve multiple functions: vapor removal, energy recovery, and water pre-heating, thereby reducing the incremental complexity of adding vapor extraction capability.
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 solution effectively reduces the exit of hot water vapor, improving operator comfort and reducing facility conditioning costs by retaining heat energy within the machine for subsequent cycles.
Implementation Method 1
an enclosure with a condenser therein, wherein incoming water to the machine from a cold water input passes through the condenser
Implementation Method 2
wherein the enclosure includes an air outlet to surrounding ambient environment and at least one air mover selectively controllable for moving hot water vapor from the chamber, into the vapor extraction unit, over the condenser
Data Source
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AI summary
A warewash machine (10) includes a chamber (14) with a wash zone (16) and front, left and right access openings. At least one spray arm (23a, 23b) is disposed to spray liquid toward the wash zone. A multi-sided hood assembly (30) includes movable front, left, right and top wall sections, and is movable between a lowered and closed position for washing and a raised open position for inlet and outlet of wares. A stationary chamber rear wall (50) includes an outlet opening (52) fluidly connected with a vapor extraction unit (54) at a back side of the rear wall (50). The vapor extraction unit (54) includes an enclosure with a condenser (58) therein, wherein incoming water to the machine from a cold water input (90) passes through the condenser (58), wherein the enclosure includes an air outlet (60) to surrounding ambient environment and at least one air mover (62).