Washing Unit Dynamic Rinsing Control for Thermal Management
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Solution Overview
Problem
Standard washing units consume excessive fresh water during the rinsing phase due to a fixed flow rate, which is inefficient and can result in containers being too hot for subsequent processes, potentially causing thermal shock or altering the quality of beverages.
Innovation Solution
A washing unit with a control system that adjusts the rinsing liquid flow based on the thermal effect measured after the rinsing phase, using a sensing unit to monitor the temperature of the containers and adjust the sprinkling means to maintain optimal container temperature, thereby reducing water consumption while ensuring containers are at the desired temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the flow of rinsing liquid is reduced to save water, then water consumption is reduced, but the container temperature becomes too high causing thermal shock or beverage quality deterioration
Solution Approach 1:
The rinsing system transitions from a static fixed flow rate to a dynamic variable flow rate system. The control unit adjusts the rinsing liquid flow rate in real-time based on feedback from temperature sensors, allowing the system to optimize water consumption while maintaining container temperature within acceptable ranges for subsequent processes
Solution Approach 2:
A feedback control loop is implemented where temperature sensors monitor the container temperature after rinsing, and the control unit uses this information to adjust the rinsing liquid flow rate. This closed-loop system ensures that water consumption is minimized while preventing thermal shock to containers and maintaining beverage quality
2Temperature
If the flow of rinsing liquid is increased to cool containers, then container temperature is controlled, but water consumption increases
Solution Approach 1:
The system uses variable flow rate control instead of a constant high flow rate. The control unit dynamically adjusts the rinsing liquid flow based on actual container temperature measurements, applying maximum cooling only when necessary and reducing flow when less cooling is needed, thereby controlling temperature while minimizing water consumption
Solution Approach 2:
The system changes the flow rate parameter of rinsing liquid based on measured container temperature and thermal conditions. By adjusting this parameter dynamically rather than maintaining a constant high value, the system achieves effective cooling when needed while reducing overall water 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
This solution reduces fresh water consumption while maintaining the desired container temperature, preventing thermal shock and ensuring beverage quality by dynamically adjusting the rinsing liquid flow based on real-time thermal measurements.
Implementation Method 1
at least one sensing unit for measuring the thermal effect of the sprinkling means on the containers and sending a corresponding information to the control unit
Implementation Method 2
a sprinkling means for sprinkling said rinsing liquid on containers in said final rinsing zone
Implementation Method 3
The temperature of the container at this subsequent process step can be of a critical importance
Data Source
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AI summary
Washing unit (1) and method for washing empty containers (2), the unit comprising a washing tunnel (3) in which the containers (2) are conveyed, said washing tunnel (3) having a washing zone (6), and having also a final rinsing zone (7), disposed after the washing zone (6) and where a rinsing liquid like water is used to rinse the containers (2), a sprinkling means (8) for sprinkling said rinsing liquid on containers (2) in said final rinsing zone (7), and a control unit (9) for controlling the operation of at least the sprinkling means (8). Said washing unit is characterized in that it comprises at least one sensing unit (10) measuring the thermal effect of the sprinkling means (8) on the containers (2) and sending a corresponding information to the control unit (9).