Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CONDITION WARNING SYSTEM, CONTROL SYSTEM AND METHOD FOR POT
AND PAN WASHING MACHINE
Field of the Invention
[0002] The present invention relates to a condition warning system, control
system and
control methods for a pot and pan washing machine.
Background of the Invention
[0003] Pot and pan washing machines, of the type used in restaurants,
institutions and
other eating facilities often involve a large wash tank or basin in which
water is circulated to
provide a continuous motion rolling wash action for the pots and pans and
other "wares" (i.e.
pots, pans, utensils, flatware/silverware, etc.). One such continuous motion
style pot and pan
washing machine is described in U.S. Pat. No. 4,773,436 issued to Cantrell et
al. The machine of
Cantrell includes a wash tank with multiple jets evenly spaced apart at an
elevated position along
the rear wall of the wash tank. The tank is filled with water to a level above
the position of the
jets. Pots and pans are placed in the wash tank, and a wash pump is activated
to draw water from
within the wash tank and direct it through the jets to create a jet stream.
Each jet directs its jet
stream toward the bottom wall of the wash tank, the bottom wall then deflects
the jet stream
upward and towards the front wall of the tank. The front wall then deflects
the upward moving
jet stream towards the rear wall of the tank, and the rear wall deflects the
jet stream downward
and back towards the
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front wall along the bottom wall. The combination of deflections of the jet
stream from the
bottom, front and rear walls provides a rolling washing action within the wash
tank. Typically,
the rolling wash action is continuous through the washing cycle of the
machine, and wares are
loaded and unloaded during the washing cycle as they are deemed clean by an
operator of the
machine. In this manner, multiple loads of wares are cleaned during a single
washing cycle.
[0004] Although the prior art pot and pan washing machine disclosed in U.S.
Patent No.
4,773,436 provides an exceptional wash action, many of the components
discussed above hinder
the overall efficiency and performance of the machine. The inventions
disclosed in U.S.
Application Serial Nos. 09/947,484; 09/947,485; and 10/744,666 provide
components that
greatly increase the overall efficiency and performance of the machine,
including improvements
to the intake and discharge manifolds, jets, pump and system assembly methods.
Nevertheless,
none of these improvements, nor the machine of U.S. Patent No. 4,773,436
address a number of
disadvantages in typical condition warning systems, control systems and
control methods for
such machines.
[0005] Conventional control systems and control methods for continuous motion
style
pot and pan washing machines typically include control logic that limits a
washing cycle to a
predetermined run-time. Once the predetermined run-time has elapsed, operation
of the wash
pump is disabled and the wash tank of the machine must be drained and refilled
before another
wash cycle can begin. This ensures that the cleansing fluid solution in the
wash tank is usually
drained and refilled before the soil level in the fluid significantly and
detrimentally impacts the
cleaning efficiency of the fluid within the washing machine. In many
applications, a run-time of
four (4) hours has been found to be an adequate cycle run-time before
refilling of a wash tank is
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desired. Nevertheless, it will be appreciated that a number of different
factors impact the desired
predetermined run-time for a particular application. Also, in certain
situations, a wash cycle will
be prematurely terminated before the predetermined runtime has elapsed. For
example, in some
machines a safety kill switch is included in the control system to shut down
the entire system
when the fluid temperature in the wash tank exceeds a predetermined safe
operating temperature.
In such case, regardless of the elapsed run time, the wash tank must be
drained and refilled, and a
new wash cycle must be initiated before the washing machine will operate
again.
[0006] Although conventional control systems and methods discussed above do
provide
benefits in ensuring safe and/or efficient conditions for the cleansing fluid
solution in the wash
tank, the requirement that a new wash cycle be initiated limits the ability to
utilize the same or
similar control systems or methods for enforcing compliance with many desired
machine
operational conditions, that are less critical than safe operating temperature
and/or cleansing
fluid soil level (such as: preferred wash, rinse or sanitizer fluid operating
temperatures; preferred
wash, rinse or sanitizer tank/supply operating fluid levels; preferred wash,
rinse or sanitizer fluid
operating chemical concentration levels; chemical supply levels, pressures or
concentrations;
etc.). Therefore, it would be beneficial to provide control systems and
methods that help to
ensure or enforce compliance with such operational conditions, and which do
not require
resetting of the washing cycle and/or draining and refilling of the wash tank.
[0007] Furthermore, the predetermined run-time often causes difficulties
toward the end
of a wash cycle. Because wares are loaded and unloaded throughout the wash
cycle, wares
loaded towards the end of the wash cycle may not become adequately cleaned
before the wash
cycle is completed. Thus, the wash tank must be drained and refilled and a new
wash cycle
initiated to finishing cleaning those wares. If a facility is close to
shutting down for the day,
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refilling the wash tank ends up being extremely time consuming as well as a
waste of resources.
This problem is further augmented by the fact that conventional washing
machines do not
provide operator's any indication of elapsed run-time or any notice in advance
of completion of a
wash cycle. Thus, unless an operator makes note of when a wash cycle is
initiated, it is
impossible for the operator to determine when a wash cycle will be completed.
Therefore, it
would be beneficial to provide control systems and methods that allow an
operator to adequately
wash wares at or toward the end of a wash cycle without requiring initiation
of a new wash
cycle.
[0008] Conventional control systems and control methods for continuous motion
style
pot and pan washing machines typically include a single standard/normal
washing cycle, which
limits a wash cycle to a predetermined run-time in the manner discussed above.
In some
machines, the control systems maintain a minimum or predetermined fluid
temperature within
the wash tank after a washing cycle is completed to improve soaking
effectiveness. This enables
an overnight washing mode in which heavily soiled wares can be placed in the
wash tank and
cleaned during the entire washing cycle and additionally soaked for the
remainder of the night
after the washing cycle is completed and before the items are removed in the
morning. While
this does improve the ability to clean heavily soiled items, the fluid is
often no longer emulsified
by the time items are removed, soil coagulates on the surface the fluid and
even reattaches to the
wares. Thus, additional or redundant cleaning is often necessary. Thus, it
would be beneficial to
provide control system and methods that improve a washing machine's cleaning
of heavily
soiled items.
[0009] Conventional control systems and control methods for continuous motion
style
pot and pan washing machines, as well as those for other apparatuses
(including, but not limited
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to kitchen appliances, automated manufacturing machinery, milling machines,
conveyor systems,
condition monitoring equipment, and the like) in which operational, safety or
compliance
parameters are monitored, typically utilize condition warning systems that
either require an
operator (defined broadly herein as any person that controls or monitors an
apparatus) to closely
monitor a display or control panel directly in front of the operator, or
otherwise provide loud
audible alarms or visual warnings that are directly in the line of sight of
the operator. In addition
to alerting the operator of an apparatus, audible alarms and line of sight
visual warning signals
also tend to alert other persons in the general vicinity to whom such alarms
or signals are not
intended and often undesirable to be communicated. In particular, in
restaurants, loud audible
buzzers and/or line of sign visual signals tend to detract from a customer's
dining experience,
and also can cause confusion and/or frustration among employees that are
delegated to various
different tasks that each utilize similar alert methods. Therefore, it would
be beneficial to
provide a condition warning system that does not require an operator to
closely monitor a display
or control panel and which at the same time minimizes the communication of
alert signals to
undesired and/or inappropriate recipients.
Summary of the Invention
[0010] The instant inventions provide improvements to condition warning
systems for
apparatuses such as continuous motion style pot and pan washing machines (and
also including,
but not limited to apparatuses such as kitchen appliances, automated
manufacturing machinery,
milling machines, conveyor systems, condition monitoring equipment, and the
like), and control
systems and control methods for continuous motion style pot and pan washing
machines, such as
those described in any of U.S. Pat. No. 4,773,436, or U.S. application Ser.
Nos. 09/947,984,
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09/947,484 and 10/744,666. It will be appreciated that other apparatuses,
washing machines, or
various combinations of washing machine or other components may be utilized
without
departing from the spirit and scope of the instant invention.
[0011] An embodiment of the instant invention includes a control system
incorporated
into a continuous motion style pot and pan washing machine. In a preferred
embodiment, the
control system includes a microprocessor, or other suitable computer
processor, for performing
various operations as defined in the firmware/software programming of the
logic of the control
system. The microprocessor includes, or is otherwise connected to one or more
storage media,
including but not limited to ROM, RAM, magnetic disk drives, etc., in which
firmware for,
software for and/or data collected or generated by the control system is
utilized, accessed and/or
stored. The microprocessor is connected to and/or controls all operational
functions/components
of the machine, including but not limited to: a wash pump, heater, chemical
supply system
pumps, valves (drain or fill), timers, temperature sensors, fluid level
sensors, chemical/fluid
supply level sensors, pressure sensors, chemical concentration sensors, etc.
[0012] In one embodiment of the instant invention, the control system includes
a punitive
wash action lockout in which operation of the wash pump (and thus circulation
within the wash
tank) of a continuous motion pot and pan washing machine is punitively and
temporarily locked
out by the control system to help ensure or enforce compliance with certain
operational
conditions, without requiring resetting of the washing cycle and/or draining
and refilling of the
wash tank to restore operation of the wash pump. In one embodiment, the
operational conditions
are independent of conditions of the wash tank (e.g. within a sanitizer tank,
or rinse tank/system);
but the punitive lockout locks out operation of the wash pump of the wash
tank. This encourages
an operator to correct the compliance issue so that washing may continue. In
one embodiment,
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the punitive wash action lockout comprises a method of washing wares in a
continuous motion
style pot and pan washing machine, said method comprising the steps of:
[0013] monitoring by a control system one or more compliance parameters
relating to
operation of the pot and pan washing machine during normal operation;
[0014] locking out punitively and temporarily by said control system operation
of a wash
pump based upon said one or more compliance parameters meeting one or more
specified
punitive lockout conditions, wherein said locking out step includes the step
of locking out the
operation of the wash pump during a washing cycle when said one or more
compliance
parameters meet said one or more punitive lockout conditions;
[0015] restoring operation of the wash pump when said one or more compliance
parameters no longer meet said one or more punitive lockout conditions.
[0016] In a preferred embodiment of the punitive wash action lockout said
restoring step
is performed without requiring the complete draining or refilling of one or
more tanks of the pot
and pan washing machine. In one such embodiment, said restoring step is
performed without
requiring the complete draining or refilling of the wash tank of the pot and
pan washing machine.
[0017] In another preferred embodiment of the punitive wash action lockout
said
restoring step requires substantially completely draining and refilling of one
or more tanks of the
pot and pan washing machine without resetting said washing cycle. In one such
embodiment,
said restoring step requires substantially completely draining and refilling
of one or more tanks
of the pot and pan washing machine other than the wash tank.
[0018] In another preferred embodiment of the punitive wash action lockout
said step of
locking out the operation of the wash pump interrupts a timed length of said
washing cycle. In
such embodiment, the total elapsed time from when the washing cycle is
initiated to when the
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washing cycle is completed will include the predetermined timed length (run-
time) of the wash
cycle plus whatever length of time the wash pump is locked out.
[0019] In another preferred embodiment of the punitive wash action lockout
said step of
locking out the operation of the wash pump does not interrupt a timed length
of said washing
cycle. In such embodiment, the total elapsed time from when the washing cycle
is initiated to
when the washing cycle is completed will equal the predetermined timed length
(run-time) of the
washing cycle.
[0020] In another preferred embodiment of the punitive wash action lockout
said
continuous style pot and pan washing machine includes more than one wash pump.
[0021] In another preferred embodiment of the punitive wash action lockout
said one or
more compliance parameters includes one or more of fluid temperature, fluid
level, or fluid
chemical concentration level within a wash tank of the pot and pan washing
machine, and said
one or more punitive lockout conditions includes one or more of a fluid
temperature above a
predetermined high limit or below a predetermined low limit, a fluid level
above a predetermined
limit or below a predetermined limit, or a fluid chemical level above a
predetermined limit or
below a predetermined limit. In one such embodiment said one or more
compliance parameters
includes fluid temperature and said one or more punitive lockout conditions
includes a fluid
temperature above a predetermined high limit, said method further comprising
the step of
requiring substantially completely draining and refilling the wash tank to
resume normal
operation if said fluid temperature exceeds a second predetermined safety
limit that is in excess
of said high limit.
[0022] In another preferred embodiment of the punitive wash action lockout
said one or
more compliance parameters includes one or more of fluid temperature, fluid
level or fluid
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chemical concentration level within a sanitizer tank of the pot and pan
washing machine, and
said one or more punitive lockout conditions includes one or more of a fluid
temperature above a
predetermined limit or below a predetermined limit, a fluid level above a
predetermined limit or
below a predetermined limit, or a fluid chemical concentration level above a
predetermined limit
or below a predetermined limit. In one such embodiment the pot and pan washing
machine
includes a wash tank in addition to the sanitizer tank and said locking out
step includes the step
of locking out punitively temporarily the operation of a wash pump for the
wash tank. It will
further be appreciated that in some embodiments of the instant invention, non-
chemical
sanitizers, such as UV light, or other sanitizers now known or hereafter
developed, may be
utilized instead of a chemical sanitizer without departing from the spirit and
scope of the instant
invention. In such embodiments, specific compliance parameters will be
apparent to those of
ordinary skill in the art.
[0023] In another preferred embodiment of the punitive wash action lockout
said one or
more compliance parameters includes one or more of fluid temperature, fluid
level or fluid
chemical concentration level within a rinsing tank of the pot and pan washing
machine, and
wherein said one or more punitive lockout conditions includes one or more of a
fluid temperature
above a predetermined limit or below a predetermined limit, a fluid level
above a predetermined
limit or below a predetermined limit, or a fluid chemical concentration level
above a
predetermined limit or below a predetermined limit. In one such embodiment of
the punitive
wash action lockout the pot and pan washing machine includes a wash tank in
addition to the
rinsing tank and said locking out step includes the step of punitively
temporarily locking out the
operation of a wash pump for the wash tank.
[0024] In another preferred embodiment of the punitive wash action lockout
said one or
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more compliance parameters includes one or more of fluid temperature, fluid
level or fluid
chemical concentration level within a spray rinsing system of the pot and pan
washing machine,
and said one or more punitive lockout conditions includes one or more of a
fluid temperature
above a predetermined limit or below a predetermined limit, a fluid level
above a predetermined
limit or below a predetermined limit, a fluid chemical concentration level
above a predetermined
limit or below a predetermined limit, or a fluid pressure above a
predetermined limit or below a
predetermined limit. In one such embodiment the pot and pan washing machine
includes a wash
tank in addition to the spray rinsing system and wherein said locking out step
includes the step of
punitively temporarily locking out the operation of a wash pump for the wash
tank. An
exemplary embodiment of a spray rinsing system suitable for use in connection
with this
particular embodiment of the instant invention is described in U.S.
Application Serial No.
61/178,617. Nevertheless, it will be appreciated that alternative spray
rinsing systems, including
but not limited to a traditional spray rinsing hose and rinse sink assembly,
may be utilized
without departing from the spirit and scope of the instant invention.
[0025] In another preferred embodiment of the punitive wash action lockout
said one or
more compliance parameters includes one or more chemical supply levels,
pressures or
concentrations within a chemical supply system that supplies chemical to one
or more tanks or
spray rinsing systems of the pot and pan washing machine, and said one or more
punitive lockout
conditions includes at least one chemical supply level below a predetermined
level, pressure or
concentration.
[0026] In another preferred embodiment of the punitive wash action lockout the
method
further comprises the step of activating a condition warning system during
said locking out step.
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In one such embodiment said condition warning system includes a light that is
focused to
illuminate a location that is below an operator's direct line of sight and
wherein a source of
illumination is outside of the operator's direct line of sight. In another
such embodiment said
condition warning system includes an audible alarm.
[0027] In another embodiment of the instant invention, the control system
includes a
extended wash cycle, that allows an operator to adequately wash wares at or
toward the end of a
wash cycle without requiring initiation of a new wash cycle. The extended wash
cycle allows
the operator to run the pump(s) of the wash tank for an additional finite
period of time, after the
predetermined run-time of the wash cycle has elapsed. In one such embodiment
the extended
wash cycle includes a method of washing wares in a continuous motion style pot
and pan
washing machine, said method comprising the steps of:
[0028] monitoring by a control system one or more parameters of fluid within a
wash
tank of the washing machine, wherein said one or more parameters includes a
wash cycle run-
time parameter (e.g. the length of time in which a fluid has been circulating
in or present in the
wash tank);
[0029] locking out by said control system operation of the washing machine
based upon
said one or more parameters meeting one or more specified conditions, wherein
said locking out
step includes the step of locking out the operation of a wash pump when said
wash cycle run-
time parameter reaches a wash cycle run-time condition (e.g. predetermined
washing cycle run-
time);
[0030] activating the wash pump by said control system to circulate a fluid
(such as
water, water/soap mixture, or other cleansing solution) within said wash tank
during a wash
cycle; and
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[0031] providing by said control system an option to delay said step of
locking out
operation of said wash pump for at least one additional finite time period;
[0032] locking out operation of said wash pump by said control system after
the at least
one additional finite time period has concluded; and
[0033] requiring substantially complete draining of said wash tank after the
at least one
additional finite time period has concluded and prior to initiation of a new
wash cycle.
[0034] In a preferred embodiment of the extended wash cycle said one or more
parameters includes one or more fluid level parameters, and said locking out
step includes the
step of locking out the operation of the wash pump when said fluid level
parameter is below a
fluid level condition; said method further comprising:
[0035] determining by said control system whether said fluid level parameter
is below a
low fluid level condition;
[0036] filling said wash tank with fluid upon determining said fluid level
parameter is
below said low fluid level condition;
[0037] providing by said control system selection options of at least a
standard wash
mode upon determining said fluid level parameter is above a high fluid level
condition; and
[0038] initiating a wash cycle upon selection of said standard wash mode. In
one such
embodiment, the method further comprises the step of:
[0039] adding a cleansing chemical to said fluid to result in a cleansing
fluid solution in
said wash tank.
[0040] In another embodiment of the extended wash cycle of the instant
invention the
method further comprises the step of:
[0041] alerting a machine operator as said wash cycle run-time parameter
closely
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approaches said wash cycle run-time condition.
[0042] In another embodiment of the extended wash cycle of the instant
invention said at
least one additional finite time period is less than said wash cycle run-time
condition. In one
such embodiment said at least one additional finite time period is less than
25% of said wash
cycle run-time condition.
[0043] In another embodiment of the extended wash cycle of the instant
invention a
combination of said at least one additional finite time period and said wash
cycle run-time
condition is no greater than a predetermined maximum safe cycle time for a
wash cycle of said
machine.
[0044] In another embodiment of the instant invention, the control system
includes a
deep clean cycle to improve a washing machine's cleaning of heavily soiled
items. The deep
cleaning cycle is a separate washing cycle or mode from the normal or standard
washing cycle of
a preferred embodiment. In one such embodiment the deep clean cycle includes a
method of
washing wares in a continuous motion style washing machine, said method
comprising the steps
of:
[0045] providing by a control system selection options of at least two
different wash
modes, said at least two different wash modes including at least a standard
wash mode and a
deep cleaning wash mode;
[0046] initiating a standard washing cycle upon selection of said standard
wash mode,
said first washing cycle including the steps of:
[0047] activating a wash pump by said control system to circulate a fluid
within a wash
tank;
[0048] maintaining a standard temperature range for said fluid during said
standard
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washing cycle; and
[0049] locking out said pumping system upon completion of said standard
washing
cycle;
[0050] initiating a deep cleaning washing cycle upon selection of said deep
cleaning
wash mode, said deep cleaning washing cycle including the steps of:
[0051] operating continuously a wash pump by said control system to circulate
a fluid
within said wash tank during a first segment of said deep cleaning washing
cycle;
[0052] maintaining a deep cleaning temperature range for said fluid during
said first
segment of said deep cleaning washing cycle, said deep cleaning temperature
range being
generally higher than said standard temperature range;
[0053] deactivating and subsequently reactivating said wash pump for periodic
intervals
during an energy saving idle mode segment of said deep cleaning washing cycle
after completion
of said first segment;
[0054] maintaining a lower deep cleaning temperature range for said fluid
during said
energy saving idle mode segment of said deep cleaning washing cycle, said
lower deep cleaning
temperature range being generally lower than said deep cleaning temperature
range.
[0055] In one embodiment of said deep clean wash cycle said deactivating and
subsequently reactivating step of said deep cleaning washing cycle intervals
of deactivation of
said wash pump are generally longer than intervals of reactivation of said
wash pump.
[0056] In another embodiment of said deep clean wash cycle said steps of
maintaining
temperatures include the step of energizing a heating element solely during
operation of said
wash pump. In such embodiment, the heating element may be located within a
pumping system
to heat the fluid as it is drawn through the pumping system.
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[0057] In one embodiment of said deep clean wash cycle said steps of
maintaining
temperatures include the step of energizing a heating element both during
operation and during
deactivation of said wash pump. In such embodiment, the heating element is
capable of heating
fluid within the wash tank within requiring fluid to be drawn through the
pumping system.
[0058] In one embodiment of said deep clean wash cycle said deactivating and
subsequently reactivating step of said deep cleaning washing cycle includes
first intervals of
deactivation and reactivation of said wash pump while the temperature of said
fluid is above said
lower deep cleaning temperature range, and second intervals of deactivation
and reactivation of
said wash pump after the temperature of said fluid is lowered to a temperature
within said lower
deep cleaning temperature range.
[0059] Another embodiment of the instant invention includes a condition
warning system
connected to the control system. On embodiment of the condition warning system
includes:
[0060] a control system that monitors operational, safety or compliance
parameters of an
apparatus; and
[0061] a light operably connected to said control system, said light being
mounted at a
position and focused in a direction that illuminates a location below an
apparatus operator's
direct line of site and wherein a source of illumination is outside of the
operator's direct line of
sight.
[0062] In one embodiment of the condition warning system said apparatus
comprises a
kitchen appliance. In one specific embodiment, said kitchen appliance
comprises a continuous
motion style pot and pan washing machine.
[0063] In another embodiment of the condition warning system said apparatus
includes a
work surface at a height that is generally convenient for access by the
apparatus operator. In one
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such embodiment said light is mounted below the height of said work surface.
In a more specific
embodiment said light is mounted underneath said work surface. In another such
embodiment of
the condition warning system said light is focused in a direction that
illuminates a location
generally directly below said light. In a more specific embodiment said
location generally
directly below said light is a floor surface directly below said light. In
another embodiment said
location generally directly below said light is at least partially shaded from
light sources within
the area in which said light is located.
[0064] In another embodiment of the condition warning system said light is
mounted at a
height generally below 52 inches. In one such embodiment, said light is
mounted at a height
generally below 48 inches. In another embodiment, such as an embodiment in
which said light is
mounted below a work surface such as a counter or sink, said light is mounted
at a height
generally below 34 inches. In another embodiment, such as an embodiment in
which the light is
mounted below a control panel of said control system, said light is mounted at
a height generally
below 30 inches.
[0065] In another embodiment of the condition warning system said light is
mounted in a
location that is remote from said apparatus. For example, the light may be
mounted at a location
in which the apparatus (such as the pot and pan washing machine) is not
visible by the operator.
For example, the operator may be located at a drive through counter of a quick
serve restaurant
(away from the pot and pan washing machine), and the light may thus be mounted
below the
drive through counter.
[0065a] We describe herein a method of washing wares in a continuous motion
style pot
and pan washing machine, comprising the steps of:
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causing, via a wash pump, a recirculating fluid flow path of a volume of fluid
within a
tank of said washing machine;
monitoring by a control system one or more compliance parameters relating to
operation
of the pot and pan washing machine during normal operation;
locking out punitively and temporarily by said control system operation of the
a wash
pump based upon said one or more compliance parameters meeting one or more
specified
punitive lockout conditions, wherein said locking out step includes the step
of locking out the
operation of the wash pump during a washing cycle when said one or more
compliance
parameters meet said one or more punitive lockout conditions;
maintaining said volume of fluid within said tank after said control system
performs said
locking out step; and
restoring operation of the wash pump when said one or more compliance
parameters no
longer meet said one or more punitive lockout conditions. The restoring step
includes allowing
said wash pump to recirculate said volume of fluid within said tank.
{0065b] We describe herein a method of washing wares in a continuous motion
style pot
and pan washing machine, comprising the steps of:
monitoring by a control system one or more parameters of fluid within a wash
tank of the
washing machine, wherein said one or more parameters includes a wash cycle
run-time parameter;
locking out by said control system operation of the washing machine based upon
said one
or more parameters meeting one or more specified conditions, wherein said
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locking out step includes the step of locking out the operation of a wash pump
when said
wash cycle run-time parameter reaches a wash cycle run-time condition,
indicating that a standard wash cycle is completed;
providing by said control system an option to delay said step of locking out
operation of
said wash pump for at least one extended wash period;
activating the wash pump by said control system to circulate a fluid within
said wash tank
after said standard wash cycle has completed, thereby creating said extended
wash
period;
locking out operation of said wash pump by said control system after the at
least one
extended wash period has concluded; and
requiring substantially complete draining of said wash tank after the at least
one extended
wash period has concluded and prior to initiation of a new standard wash
cycle.
The option to delay said step of locking out operation of said wash pump is
provided to a user of the washing machine.
1100650 We describe herein a method of washing wares in a continuous motion
style
washing machine, comprising the steps of:
providing by a control system selection options of at least two different wash
modes, said
at least two different wash modes including at least a standard wash mode and
a
deep cleaning wash mode;
initiating a standard washing cycle upon selection of said standard wash mode,
the first
washing cycle including the steps of:
activating a wash pump by said control system to cause a recirculating fluid
flow
path of a volume of fluid within a wash tank of the washing machine;
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maintaining a standard temperature range for said fluid during said standard
washing cycle; and
locking out said pumping system upon completion of said standard washing
cycle;
initiating a deep cleaning washing cycle upon selection of said deep cleaning
wash mode.
The deep cleaning washing cycle includes the steps of:
operating continuously a wash pump by said control system to cause a
recirculating fluid flow path of a volume of fluid within a wash tank of the
washing machine during a first segment of said deep cleaning washing
cycle;
maintaining a deep cleaning temperature range for said fluid during said first
segment of said deep cleaning washing cycle, said deep cleaning
temperature range being generally higher than said standard temperature
range;
deactivating and subsequently reactivating said wash pump for periodic
intervals
during an energy saving idle mode segment of said deep cleaning washing
cycle after completion of said first segment; and
maintaining a lower deep cleaning temperature range for said fluid during said
energy saving idle mode segment of said deep cleaning washing cycle,
said lower deep cleaning temperature range being generally lower than
said deep cleaning temperature range.
[00661 The foregoing and other objects are intended to be illustrative of the
invention and
are not meant in a limiting sense. Many possible embodiments of the invention
may be made
and will be readily evident upon a study of the following specification and
accompanying
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drawings comprising a part thereof. Various features and subcombinations of
invention may be
employed without reference to other features and subcombinations. Other
objects and
advantages of this invention will become apparent from the following
description taken in
connection with the accompanying drawings, wherein is set forth by way of
illustration and
example, an embodiment of this invention and various features thereof
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Brief Description of the Drawings
[0067] A preferred embodiment of the invention, illustrative of the best mode
in which
the applicant has contemplated applying the principles, is set forth in the
following description
and is shown in the drawings and is particularly and distinctly pointed out
and set forth in the
appended claims.
[0068] Fig. 1 is front view of the face of a control panel of a control system
of an
embodiment of the instant invention.
[0069] Fig. 2 is a perspective view of a continuous motion style pot and pan
washing
machine of the instant invention in which the control panel of Fig. 1 is
utilized and including a
condition warning system of an embodiment of the instant invention.
[0070] Fig. 3 is a side view of the pot and pan washing machine of Fig. 2 and
an operator
of the machine.
[0071] Figures 4 through 10 show flow diagrams of the operation and control
logic of a
control system of a preferred embodiment of the instant invention.
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Detailed Description of a Preferred Embodiment
[0072] As required, a detailed embodiment of the present invention is
disclosed herein;
however, it is to be understood that the disclosed embodiment is merely
exemplary of the
principles of the invention, which may be embodied in various forms.
Therefore, specific
structural and functional details disclosed herein are not to be interpreted
as limiting, but merely
as a basis for the claims and as a representative basis for teaching one
skilled in the art to
variously employ the present invention in virtually any appropriately detailed
structure.
[0073] Referring to Fig. 1, the front face of a control panel of a control
system of one
embodiment of the instant invention is shown. Referring to fig. 2, the control
system of Fig. 1 is
shown incorporated into a continuous motion style pot and pan washing machine.
In a preferred
embodiment, the control system includes a microprocessor, or other suitable
computer processor,
for performing various operations as defined in the firmware/software
programming of the logic
of the control system. The microprocessor includes, or is otherwise connected
to one or more
storage media, including but not limited to ROM, RAM, magnetic disk drives,
etc., in which
firmware for, software for and/or data collected or generated by the control
system is utilized,
accessed and/or stored. The microprocessor is connected to and/or controls all
operational
functions/components of the machine, including but not limited to: a wash
pump, heater,
chemical supply system pumps, valves (drain or fill), timers, temperature
sensors, fluid level
sensors, chemical/fluid supply level sensors, pressure sensors, chemical
concentration sensors,
washing cycle run time, etc.
[0074] Referring to Fig. 2, the pot and pan washing machine includes wash tank
30, rinse
tank 40, and sanitizer tank 50 connected together in a single unit via non-
welded field joint 34.
The unit also includes soiled end drain board 32, and clean end drain board 31
to direct fluids
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into wash tank 30 and sanitizer tank 50, respectively. The unit further
includes backsplash 38
and channel rim 36. Wash tank 30 includes a plurality of jets along its rear
wall which direct
fluid from wash pump 20 (controlled by control system 10) into wash tank 30.
An intake draws
fluid back into wash pump 20 for continuous motion within wash tank 30. Wash
tank also
includes utensil basket 60 for washing utensils. In addition, wash tank 30
includes detergent
injector 70 that is connected to a detergent supply system which is controlled
by control system
10. Wash tank also includes fluid high and low sensors 80 connected to
controller 10 to detect
when the fluid level in the tank is drained below a minimum low level and
raised above a
minimum high level. In the embodiment shown in Fig. 2, rinse tank 40 includes
a pre-rinse
faucet for rinsing items in the rinse sink. In a preferred embodiment, rinse
tank 40 also includes
fluid level sensors that operate in the same or similar manner as those in the
wash tank 30.
Sanitizer tank 50 also includes similar fluid level sensors 52, as well as a
sanitizer injector 54
that is connected to a sanitizer supply system controlled by control system
10. Control system
also controls condition warning light 15, which is mounted below control
system 10,
underneath the soiled end drain board, and which directs light onto the floor
directly below the
unit. As is shown in Fig. 3, condition warning light 15, directs light beam 17
into a controlled
zone under the washing machine. Light beam 17 is directed to a location below
operator 100's
direct line of sight 110. Also light 15 is mounted at a location outside of
operator 100's direct
line of sight 110. In a preferred embodiment, light 15 is mounted at a height
below 52 inches,
which is well below the average operator's direct line of sight. In the
embodiment shown in
Figs. 2 and 3, the light is mounted below control system 10, which results in
a mounting height
generally below 30 inches from the floor.
[0075] Referring to Fig. 1, the control panel includes several control buttons
for input by
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an operator and a number of display indicators for monitoring by the operator.
The control panel
includes a power indicator that is illuminated when the control system is
properly connected to
electrical power. The panel includes a error (call service) indicator that
illuminates when certain
error conditions are detected by the control system. In certain conditions,
the error light may
illuminate in combination with other indicators to inform the operator of
certain operational
parameters that are not in compliance with one or more punitive lockout
conditions.
[0076] The control panel includes an over temperature indicator that
illuminates a solid
color when the fluid temperature within the wash tank of the machine exceeds a
first temperature
that is outside the preferred operating temperature of the wash tank, but
which is not at an unsafe
level (i.e. 118F). If the fluid temperature exceeds a second predetermined
temperature that is
closer to an unsafe operating temperature (i.e. 123F), the temperature
indicator flashes along
with the error light, and operation of the wash pump is locked out until the
temperature returns to
a safe level, and the operator may select the start button input the restart
operation. In addition,
in a preferred embodiment, a condition warning light (described below) mounted
under the
control panel flashes when an over temperature condition is detected.
[0077] The control panel includes a drain wash tank indicator that lights up a
solid color
when the washing cycle has completed (i.e. the predetermined run-time has
elapsed and met the
run-time condition). The light goes out after the wash tank is drained below
the low water
sensor. In a preferred embodiment, in which an extended wash time is selected,
the light also
will go out for the period of the extended wash time.
[0078] The control panel includes an extend wash time indicator which
functions during
a standard washing cycle. At the end of the standard wash cycle, the indicator
turns solid for a
finite period of time (such as 15 minutes) to allow the operator to initiate
by input of the start
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button the extended wash time for a finite period in which the wash pump will
continue to
operate and items/wares may continue to be washed without requiring draining
and refilling of
the wash tank with wash fluid (i.e. water, soap, etc.). This light remains
illuminated during the
entire extended wash cycle. After the finite extended wash cycle time (single
time period, or
combination of multiple periods) is completed, the wash tank must be drained
and refilled to
initiate a new washing cycle.
[0079] The control panel includes a wash motor lockout indicator which is
illuminate
whenever a wash action lockout occurs due to a compliance parameter meeting a
punitive
lockout condition (e.g. over temperature condition, fill sanitizer condition,
sanitizer out of
temperature range condition, etc.).
[0080] The control system includes a fill sanitizer tank indicator that
illuminates red
when in standard wash mode and the operator needs to fill the sanitizer tank
(because the
sanitizer is below the low level or high level sensors. If the fill is not
performed in 10 minutes
wash pump motor is locked out and lockout light is displayed. To indicate
time, the light flashed
from 3 minutes at an increasing rate to fully illuminated at 10 minutes.
[0081] The control system includes a drain sanitizer tank indicator that
illuminates solid
after a predetermined time period in which the control system measures that
the sanitizer tank
has been used without refilling the fluid.
[0082] The control system includes a start standard wash mode button to input
a selection
to the control system to start a normal washing cycle, and a start deep clean
mode button to input
a start of a deep clean washing cycle. Also the control system includes a stop
button to stop the
wash action and/or the wash pump.
[0083] The control system of Figs. 1 and 2 includes a temperature sensor to
monitor the
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temperature of fluid in the sanitizer tank and also includes an out of
temperature rating indicator
for the sanitizer tank. The system includes minimum and maximum temperature
thresholds that
may be set by a system operator or service professional for the system. For
example, the
minimum threshold is between 50 and 90 degrees F (settable in 5 degree
increments) and the
maximum threshold is between 70 and 120 degrees F (settable in 5 degree
increments). This
allows the system to maintain an optimum temperature range for sanitizer in
the sanitizer tank.
When the temperature goes out of the optimum range, the light is illuminated
and the operator is
required to drain and refill the sanitizer tank.
[0084] The system includes sensors toward the top and bottom of the sanitizer
tank to
sense whether fluid is in the tank and if the tank is being filled/drained or
has been filed/drained.
This allows the system to be fully (or partially) automated. The sanitizer
tank is filled with water
(or other appropriate fluid) to a level above the top sensor (the top sensor
senses the water and
causes a shut off of the filling source). If the temperature is outside of the
set range, the water
will be drained and refilled until the temperature is within the required
range. Once the required
temperature is reached, the sanitizer is added to the water in the sanitizer
tank. The sanitizer may
be added automatically using a pump. A dual head pump for pumping sanitizer
into the sanitizer
tank, and also for pumping detergent into the wash tank is utilized in one
embodiment.
[0085] The system includes an extend standard wash time feature/indicator for
the wash
tank. The prior art system includes a 4 hour wash cycle, after which the wash
tank must be
drained and refilled before the system's circulating pump motor will function
(unlock). The
extend standard wash time feature allows a system operator to extend the wash
time by 15
minutes. This allows the operator to finish minor cleaning jobs without
requiring a timely refill.
[0086] The system further includes an energy efficient deep cleaning mode,
that allows
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the system to operate in a cleaning cycle for a relatively long period of time
(such as over night)
to deep clean heavily soiled items in the wash tank utilizing as little energy
as possible. The
deep clean cycle of the instant invention includes a first cycle period in
which the circulatory
pump operates continuously (as it would in normal cleaning mode, such as the
cleaning mode of
the prior art) and maintains a temperature of 128 degrees F. After 2 hours,
the pump (and heater)
operates in 10 minute cycles, on for 10 minutes and off for 10 minutes, until
the temperature falls
below 115 F. Once this threshold is reached, the system (pump and heater) runs
for 5 minutes
and is then off for 15 minutes. The control system will operate the pump
and/or heater more
often if the temperature falls below 113 F, so as to maintain a temperature
between 113 and 115
F. The system operates in this manner (holding the 113-115 F temperature)
until it is turned off
by the operator. This allows the system to deep clean items for a long period
of time (in excess
of the typical 4 hour cleaning cycle), such as overnight.
[0087] Because items needing deep cleaning (as in the deep clean cycle
described above)
often require a stronger cleaning detergent than is typically used for normal
cleaning of pots and
pans, the system of the instant invention utilizes a 3 head pump instead of
the two head
(parasitic) pump described above to inject both a liquid detergent and a solid
detergent into the
wash tank, and the sanitizer into the sanitizer tank.
[0088] One preferred embodiment of the instant invention includes a condition
warning
system that is designed to notify system users of a condition requiring user
action in a distinct
and easily recognizable manner. In one embodiment a bright warning light is
activated to signal
the condition to the user. In a preferred embodiment, the warning light is a
flashing blue light
such as those used in unmarked police cruisers. The light is positioned below
the control panel
of the washing machine in the manner shown in Figs. 2 and 3. The location of
the light, below
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the control panel of and/or underneath the machine, at a location that is
typically darker than the
environment in which the machine is located due to the shading/shadows caused
by the machine
itself, optimizes the user's ability to recognize the light when it is
activated. The control system
of the instant invention activates the light when a condition requiring user
attention is detected
by the control system, illuminating the typically darkened/shaded underside of
the machine in the
manner shown in Fig. 3. For example, the system of the instant invention may
include a drain
wash tank indicator on the face of the control panel. In the embodiment shown
herein, this
indicator will start flashing 30 minutes before the wash cycle is scheduled to
end and will turn
solid at the end of the 4 hour wash cycle to indicate that the wash tank must
be drained. As this
drain wash tank indicator is typically only visible to a user located in the
proximity of the
system, and may not be noticed for some time by a user located away from the
system (such as
on the other side of a kitchen in which the system is located) the warning
light of the instant
invention will also be activated by the control system of the invention to
bring the condition to
the user's attention regardless of whether the user is in the proximity of the
system or across the
room, etc. It will be appreciated that the warning light of the instant
invention may be utilized to
signal a variety of differing conditions. For example purposes only, the
warning light of the
instant invention may be utilized to signal such other conditions as errors,
over temperature wash
water, fill/drain sanitizer tank, out of temperature rating for sanitizer,
etc. In one preferred
embodiment, the color of the light, the number of flashes, pattern of flashes
and/or frequency of
flashes is varied to signal differing conditions. For example, a solid, non-
flashing red light might
indicate an end of wash cycle condition, while a flashing read light could
indicate an error
condition and a flashing orange light might indicate an over temperature
condition, etc.
[0089] Figures 4 through 10 show flow diagrams of the operation and control
logic of a
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control system of a preferred embodiment of the instant invention. As is shown
in Fig. 5, the
main control module of the control system of a washing machine may be
networked to other
control modules or other components, and includes specific firmware or
information that may be
communicated or installed via data modules such as USB port located on the
control system
panel or wirelessly. Figure 6 shows the beginning wash logic in which a wash
tank is filled to a
monitored level and temperature. Figure 7 shows a normal wash (standard) cycle
that may be
selected by an operator once the wash tank is filled to the proper fluid level
and/or temperature,
etc. as shown in Fig. 6. Figure 7 also shows conditions in which lockout
and/or condition
warning system will be utilized. Figure 8 shows a deep cleaning wash cycle
that may be selected
by the operator once the wash tank is filled, instead of the standard cycle.
Figure 8 also shows
conditions in which lockout and/or condition warning are activated by the
control system.
Figure 9 shows various rinse modes that may be utilized in connection with the
system of the
instant invention, including a dip rinse, spray rinse, and several rinse
window systems (as further
described in US Application Serial Number 61/178617 filed on May 15, 2009.
Figures 10 shows
various sanitize modes that may be utilized in connection with the system of
the instant
invention.
[0090] In the foregoing description, certain terms have been used for brevity,
clearness
and understanding; but no unnecessary limitations are to be implied therefrom
beyond the
requirements of the prior art, because such terms are used for descriptive
purposes and are
intended to be broadly construed. Moreover, the description and illustration
of the inventions is
by way of example, and the scope of the inventions is not limited to the exact
details shown or
described.
[0091] Although the foregoing detailed description of the present invention
has been
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described by reference to an exemplary embodiment, and the best mode
contemplated for
carrying out the present invention has been shown and described, it will be
understood that
certain changes, modification or variations may be made in embodying the above
invention, and
in the construction thereof, other than those specifically set forth herein,
may be achieved by
those skilled in the art without departing from the spirit and scope of the
invention, and that such
changes, modification or variations are to be considered as being within the
overall scope of the
present invention. Therefore, it is contemplated to cover the present
invention and any and all
changes, modifications, variations, or equivalents that fall with in the true
spirit and scope of the
underlying principles disclosed and claimed herein. Consequently, the scope of
the present
invention is intended to be limited only by the attached claims, all matter
contained in the above
description and shown in the accompanying drawings shall be interpreted as
illustrative and not
in a limiting sense.
[0092] Having now described the features, discoveries and principles of the
invention,
the manner in which the invention is constructed and used, the characteristics
of the construction,
and advantageous, new and useful results obtained; the new and useful
structures, devices,
elements, arrangements, parts and combinations, are set forth in the appended
claims.
[0093] It is also to be understood that the following claims are intended to
cover all of the
generic and specific features of the invention herein described, and all
statements of the scope of
the invention which, as a matter of language, might be said to fall
therebetween.
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