US20240023786A1

US20240023786A1 - Immersion Systems & Methods for Pre-Washing or Washing Silverware

Info

Publication number: US20240023786A1
Application number: US18/229,555
Authority: US
Inventors: John Cantrell; Richard Powers; Roger SHEALY; Mark Churchill
Original assignee: Immersion Systems Inc
Current assignee: Immersion Systems Inc
Priority date: 2019-05-07
Filing date: 2023-08-02
Publication date: 2024-01-25

Abstract

A silverware pre-washing and washing system made up of a unitary basin with one to five, and preferably three, vertically movable porous baskets arranged radially around a central vertical lifting and lowering mechanism. The base with unitary basin contains a quantity of washing fluid(s) into which each of the vertically movable porous baskets may be repeatedly immersed. The base cover defines cylindrical ports through which the baskets are raised and lowered. The porous baskets include perforation arrays to allow washing fluid to flow in non-linear paths through the silverware contained in the basket, thereby washing all sides of the silverware and beneficially re-arranging the silverware in the basket as the washing process proceeds.

Description

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims the benefit under Title 35 United States Code § 120 as a Continuation-in-Part of co-pending U.S. patent application Ser. No. 16/869,539, filed May 7, 2020, which claims the benefit under Title 35 United States Code § 119(e) of U.S. Provisional Patent Application Ser. No. 62/844,385; Filed: May 7, 2019, the full disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to systems and methods for washing objects. The present invention relates more specifically to immersion and agitation systems and methods for washing multiple loose items such as silverware and table ware (predominantly sets of forks, knives, and spoons) and performing other tasks where the process of immersing and agitating the items in a body of fluid would have benefit.

2. Description of the Related Art

Silverware pre-washing and washing systems currently available generally use complex, expensive, and high maintenance pumping systems and structures. These systems are heavy, expensive, and generally require complex installations or in some cases do not integrate easily into existing end user operations. Other challenges for existing systems include their general operation in only one direction which tends to heavily wash one side of the silverware and not thoroughly wash the other side of the silverware. Such systems also typically lock the silverware down into one position within layers which can preclude some areas of the silverware from getting washed. A system that would offer a full bidirectional washing action and at the same time continually rearrange the silverware for proper, complete, and thorough pre-washing and washing would be a major advancement over the prior art.

SUMMARY OF THE INVENTION

There exists a need for a system that can wash or pre-wash silverware where complex and expensive pumping and manifold systems and structures are not required and system weight, cost and installation complexity are greatly reduced. It would be desirable for such a system to easily integrate into an end users existing operation and require minimal training for proper usage to be achieved. A system that can be added to an existing operation by simply placing it onto existing dish room tabling as opposed to any type of more complex or less integrated installation, is optimal. It would also be beneficial to have a system that offers large amounts of processing capacity and the ability to sort the various types of silverware for those end users that desire to do so.
In fulfillment of these and other objectives the present invention provides a unitary basin with one to five, and preferably three, vertically movable porous baskets arranged radially around a central vertical lifting and lowering mechanism. The base with unitary basin contains a quantity of washing fluid(s) into which each of the vertically movable porous baskets may be repeatedly immersed. The base cover defines cylindrical ports through which the baskets are raised and lowered. The porous baskets include perforation arrays to allow washing fluid to flow in non-linear paths through the silverware contained in the basket, thereby washing all sides of the silverware, and beneficially re-arranging the silverware in the basket as the washing process proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a three-basket embodiment of the silverware washing system of the present invention with baskets raised and empty.

FIG. 2 is a perspective view of the three-basket embodiment of the silverware washing system of the present invention with the baskets, guard, and lift mechanism cover removed for clarity.

FIG. 3 is a perspective rear view of the three-basket embodiment of the silverware washing system of the present invention with the lift mechanism cover removed for clarity.

FIG. 4 is a perspective bottom view of the three-basket embodiment of the silverware washing system of the present invention.

FIG. 5 is a perspective front view of the three-basket embodiment of the silverware washing system of the present invention with the water tub, guard, and center basket removed for clarity.

FIG. 6A is a centerline cross-sectional view of the three-basket embodiment of the silverware washing system of the present invention with the lifting mechanism in a raised condition.

FIG. 6B is a centerline cross-sectional view of the three-basket embodiment of the silverware washing system of the present invention with the lifting mechanism in a lowered condition.

FIG. 7A is a perspective view of a typical installation of two of the silverware washing systems of the present invention in a food service facility with an adjacent fill faucet.

FIG. 7B is a perspective view of a typical installation of two of the silverware washing systems of the present invention in a food service facility with plumbed water supply lines and chemical additive reservoirs.

FIG. 8 is a detailed perspective rear view of the drive and lift mechanisms of the system of the present invention with the covers removed for clarity.

FIG. 9 is a detailed perspective view of the control elements of a typical installation of two of the silverware washing systems of the present invention in a food service facility with an adjacent fill faucet.

FIG. 10A is a perspective front view of an alternate embodiment of the three-permeable enclosure version of the silverware washing system of the present invention.

FIG. 10B is a detailed perspective front view of the alternate embodiment of the three-permeable enclosure version of the silverware washing system of the present invention shown in FIG. 10A.

FIG. 10C is a detailed perspective rear view of the alternate embodiment of the three-permeable enclosure version of the silverware washing system of the present invention shown in FIG. 10A with the rear cover removed to show internal sensors and LEDs connections to an onboard controller.

FIGS. 11A-11C are flowcharts detailing the functionality and the method steps associated with operation of the system of the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The system that is contemplated by the inventors is one that does not require heavy, complex pumping systems or manifold structures, is easy and inexpensive to both install and use and easily integrates into any end user operations. The elimination of the above-mentioned complex pumping and manifold systems allows for a system that can be light weight, compact and installed by simply being set onto an end user's existing dish table structure.
The invention utilizes a vertical structure that is associated with a mechanical lift system and is further associated with one or more permeable structures for holding a mass of objects. This set of systems enables the mechanical system to raise and lower the mass of objects into and out of a body of fluids. This can be done at varying speeds and varied cycles based on the pre-washing or washing task being performed. The action of immersing the mass of objects into and out of the body of fluids creates a powerful and comprehensive wash action as fluid rushes up into and though the mass of objects and then via gravity rushes out of the mass of objects as the objects pass through the fluid. During this process objects are moved and rearranged by the flow of the fluids and by being momentarily at least partially levitated by that flow of fluids on the downward stroke of the system.
It is important and critical to note that the system is designed to operate safely while being fully open to allow for the loading of silverware (or other objects) into the system while the system is fully in operation. It is further contemplated that the system would employ a sensing system to determine when a full load has been achieved and washing was complete at which time the baskets would be delivered into an elevated position for unloading. It is also anticipated that temperature sensing, fluid level sensing, and total dissolved solids (TDS) sensing would be incorporated as standard or optional features of the design.
In a preferred embodiment, the entire process of raising and lowering the items into and out of the body of fluids is performed and enabled by a variable speed, DC motor which is geared and associated with a cam system and drive linkage. This preferred embodiment is further associated with a programmable controller and the above noted vertical structure and permeable structure for holding objects. It is contemplated that further embodiments could employ custom sizes and a multiplicity of permeable structures for holding objects. While the current structure locates the DC motor and gear box below the system's operating fluid level, they could alternatively be located above the system's operating fluid level and still achieve the same results.
Reference is made to FIG. 1 for a perspective view of a three-basket (or more generally, three-permeable structure) version of the silverware washing system of the present invention. In this view, the silverware washing system is shown to be made up of a base and washing fluid tank with a washing fluid tank cover and a centrally located reciprocating vertical motion device. In this view, three porous baskets are shown in fully elevated positions, generally above the surface of the washing fluid (not shown). The base cover defines three cylindrical portals through which the porous baskets are raised and lowered.
FIG. 1 is the view of the three-basket embodiment of the silverware washing system of the present invention that the user would encounter before beginning operation of the system with baskets raised and empty. Immersion wash system 10 generally comprises a system base 14 that supports an open top wash tank 16 that is partially covered with tank cover 18. To the rear of the wash tank 16 is lift mechanism 22 that extends up from base frame 14. In the view of FIG. 1 , the functional components of lift mechanism 22 are enclosed within drive mechanism cover (and support) 12 and lift mechanism cover 24. A movable basket holder frame (hidden in FIG. 1 ) is operationally connected to lift mechanism 22 and supports each of a number (three in the embodiment shown) of porous baskets. In the three-basket embodiment shown, baskets 20 a-20 c are shown positioned in the holder frame in the elevated state. The diameter of the baskets is such as to just fit within the respective circular ring support (described in more detail below) forming part of the basket holder frame. In turn, the openings in the tank cover 18 are just large enough to allow for the removal and/or insertion of the removable baskets from the basket holder frame. See FIG. 5 for more detail on the basket holder frame.
Operational elements of the system additionally seen in FIG. 1 include: LED indicators 19 a & 19 b that may be used to indicate the progress of steps in the wash cycling process; LED indicators 21 a-21 c that may be used to alert the user to a proper basket loading or unloading sequence; overflow tube 25 with drain line/valve 26; and chemical feed line 23 (if applicable in the particular embodiment). Once again, the functionality of each of these components is described in more detail below.
Although the number of baskets in the system of the present invention may be as few as one and as many as four or five or more, the three-basket embodiment shown is advantageous for handling the three typical types of tableware: forks, knives, and spoons. As seen below, multiple units of the system of the present invention may be preferred over a unit that exceeds three baskets as positioning of the systems for ergonomic loading must be considered. The baskets used may be any shape but are preferably circular to facilitate a random alignment or misalignment of the individual utensils in a manner that serves to prevent “nesting” and therefore to better clean and rinse the silverware. Additionally, the random loading of different types of silverware into all three baskets may be desirable to further discourage any type of “nesting” of the silverware. The baskets are preferably wire mesh or molded plastic and have a porosity open enough to allow for the easy flow of fluid through the basket while closed enough to prevent the items of silverware from slipping through the openings. The baskets preferably have handles (as shown in the preferred embodiment) to permit the user to easily lift the basket (empty or full) from the basket holder, potentially even while the system is in operation. It is anticipated that the user will fill a basket or add items of silverware (or other objects that require washing) while the system is in operation. The LED indicators 21 a-21 c assist the user in identifying which baskets have been washing the longest and which are best available for the addition of silverware for washing as the system continues to operate. The LED indicators 21 a-21 c may also be used to indicate which basket to load at any given time.
The system structural components are preferably stainless steel as is typical in commercial food preparation and food service facilities. Tank cover 18 is preferably removable from wash tank 16 for periodic cleaning access to the submersible components of the system and the interior of the wash tank 16 itself. Drive mechanism cover (and support) 12 and lift mechanism cover 24 are also preferably made of stainless steel components. As will be described in more detail below, the system of the present invention is sized and structured to be positioned on a table or other support platform at approximately waist height for the users of the system. At a minimum, the basic embodiment of the system requires an external power connection while alternate embodiments further include water line connections and/or chemical wash additive flow line connections.
FIG. 2 is a perspective view of the three-basket embodiment of the silverware washing system of the present invention with the baskets, tank cover, and lift mechanism cover removed for clarity. The functional components of the immersion wash system of the present invention are again seen to generally comprise a system base 14 that supports an open top wash tank 16 that, during operation of the system, is partially covered with the tank cover (removed in this view). To the rear of the wash tank 16 are the components that make up the lift mechanism. The fixed components are generally positioned exterior to the wash tank 16 while some of the movable components extend inside of the wash tank 16. In FIG. 2 , the rear frame portion of system base 14 in part helps secure the lift components to the wash tank 16 structure, while the drive mechanism cover (and support) and the lift mechanism cover (both not shown in FIG. 2 ) additionally serve to position and support the fixed components of the lift mechanism.
Of the lift mechanism components shown in FIG. 2 , only the bearing block 38 is fixed (with respect to the wash tank 16) while lift rod 36, lift rod connector 34, actuator rods 32, and basket holder frame 28, are all movable components of the lift mechanism. As seen in FIG. 2 , the three basket holders 30 a-30 c are fixed on basket holder frame 28 and oriented to position the baskets (when inserted into the holders) appropriately for the reciprocating vertical motion they undergo in the washing process. Basket holder frame 28 is fixed to the lower ends of actuator rods 32 which are generally held in lateral position by the fixed position of bearing block 38. Bearing block 38 allows for the free vertical motion of the actuator rods 32 while keeping them (and all the components attached to them) laterally positioned within wash tank 16.
Actuator rods 32 are fixed to basket holder frame 28 at their lower end and to lift rod connector 34 at their upper end. Lift rod connector 34 is pivotally secured to lift rod 36, which, under direction of the drive components not seen in this view, lifts and lowers the actuator rods 32 and therefore, by the linkages described above, lifts and lowers the baskets supported in the basket holders 30 a-30 c.
Additional components shown in FIG. 2 include overflow tube 25 positioned through the side wall of wash tank 16 at a height just above the maximum desired fluid level in the tank and drain line/valve 26 positioned through the bottom wall of wash tank 16 and configured to drain the tank when desired. Once again, optional chemical feed line 23 is shown extending down from an external chemical additive reservoir (not shown) where the system utilizes such chemical additives. Alternatively, the chemical additive reservoir may also be located under the system. Not seen in FIG. 2 are the external power connection (described above as standard) and an optional external water supply line.
Reference is next made to FIG. 3 which is a perspective rear view of the three-basket embodiment of the silverware washing system of the present invention with the lift mechanism cover and the drive mechanism cover removed for clarity. In FIG. 3 , system base 14 is again seen to support the open top wash tank 16 which is partially covered with tank cover 18. To the rear of the wash tank 16 is the rear frame portion of system base 14. In the three-basket embodiment shown, baskets 20 a-20 c are positioned in the holder frame (not visible in this view) in an elevated state. In the view of FIG. 3 , the functional components of the drive and lift mechanisms are exposed where they are positioned and secured to the rear frame portion of system base 14 and drive mechanism cover (and support) (not shown in FIG. 3 ). Once again, the structures of enclosure cover 40 and lift mechanism cover 24 further serve to support and enclose the lift and drive mechanism components. As described above in FIG. 2 , actuator rods 32 are positioned through bearing block 38 and extend downward to their point of attachment to the basket holder frame (not visible in FIG. 3 ). The top ends of actuator rods 32 are pivotally connected to lift rod 36 by way of lift rod connector 34. Lift rod 36 serves as the linkage between the drive mechanism of the system and the lift of the system.
The drive mechanism of the system is generally made up of DC motor 42, gear box 46 and crank arm 44. DC motor 42 is powered from an external source, typically from a remote (wall mounted) controller as described in more detail below. DC motor 42 drives the gears within gear box 46 which turn crank arm 44. Crank arm 44 is pivotally linked to lift rod 36 and moves lift rod 36 vertically a distance approximately twice the length of crank arm 44. The combination of DC motor 42 and gear box 46 are fixed within drive mechanism cover (and support) 12 with enough clearance between gear box 46 and enclosure cover 40 to allow for the free rotation of crank arm 44 and its pivotal attachment to lift rod 36.
In addition to overflow tube 25 and drain line/valve 26 shown in FIG. 3 , optional water and chemical additive flow lines are shown. As shown, the drain valve 26 is manual, however, it may also be an electric valve which would be controlled by the controller. External water line 47 may be connected to a water source (such as a typical commercial or residential pressurized potable water supply) to provide a controlled filling of the wash tank of the system. Auto fill valve 48 is preferably an electric solenoid actuated valve that may be controlled by the same controller that powers the DC motor 42. Water may flow directly from auto fill valve 48 into wash tank 16 or, as shown in FIG. 3 , may pass through chemical inductor 45 before flowing into wash tank 16. Where used, chemical inductor 45 receives a flow of chemical additive from a remote reservoir by way of chemical feed line 23. The inductor incorporates various metering tips that have varying orifice sizes to control the amount of chemical that is introduced into the system. The auto-fill valve may also be set up to deliver water to a third-party system (not shown in the figures) that mixes the water with a chemical (typically a solid form of chemical that dissolves) where it then flows to the wash tank. Various chemicals may be added to the water within the system as may be desired for assisting with the dissolving of food particles and other soils on the silverware or sanitizing the wash bath after repeated use. Used in conjunction with a solenoid-controlled drain line/valve 26, and monitoring water conditions with sensors 50 a & 50 b, a flow of chemicals through chemical fed line 23 can serve to help maintain the tank fluid in optimal condition. It should be noted that the wash system of the present invention is not intended to replace the high temperature disinfecting wash and rinse that typically occurs in a commercial foodservice dishwasher in a foodservice facility. Rather the system of the present invention primarily serves a pre-wash function that would typically be followed by a separate disinfecting wash and rinse in a commercial foodservice dishwasher.
FIG. 4 is a perspective bottom view of the three-basket embodiment of the silverware washing system of the present invention, structured as described above for placement on a typical dish table or other platform of an appropriate height. As seen in FIG. 4 , system base 14 extends under and supports wash tank 16 with associated tank cover 18 and further supports the drive and lift mechanisms of the system (covered in the view of FIG. 4 with drive mechanism cover (and support) 12 and lift mechanism cover 24). External water line 47 is shown as it feeds through drive mechanism cover 12 to the auto fill valve (not visible) of the water line connected version of the system. Overflow tube 25 is shown exiting through the side wall of wash tank 16 and drain line/valve 26 is shown exiting from the bottom of wash tank 16. System base 14 provides enough clearance under wash tank 16 to facilitate this placement of drain line/valve 26. Adjustable (leveling) base rubber feet 35 are positioned on the cross member and legs of system base 14 to help retain the system in place when positioned on a dish table or the like.
FIG. 4 additionally shows the placement of an optional heating element 37 under and in thermal contact with the bottom wall of wash tank 16. While the primary function of the system of the present invention may be pre-washing, it would still be advantageous to maintain the wash fluid at an elevated temperature in some circumstances. Heating element 37 should, as with the balance of the electrical components of the system adjacent the wash tank, be lower voltage DC powered to avoid any issues with proximity to a wet environment. Regardless, heating element 37 is preferably sealed against the bottom of wash tank 16 with no exposed electrical connections near the base of the unit. Alternatively, other heating element systems that might be extended into wash tank 16 may also be incorporated into the design.
Reference is next made to FIG. 5 for a detailed perspective front view of the three-basket embodiment of the silverware washing system of the present invention with the wash tank, tank cover, and center basket removed for clarity. System base 14 supports the structured enclosures made up of enclosure cover 40, drive mechanism cover (and support) 12, and lift mechanism cover 24. Passing through enclosure cover 40 and through the rear wall of the wash tank are a pair of sensors designed to collect data on the level and condition of the wash fluid within the wash tank. Sensors 50 a & 50 b may serve to measure liquid level, temperature, and/or total dissolved solids (TDS) within the wash fluid. Such information assists in alerting the user as to the need to change the wash fluid and/or add chemicals and/or modify the temperature of the fluid. Heating element 37 is shown positioned as it would be beneath the wash tank (not shown) even though it would, as described above, typically be adhered to (and sealed against) the bottom wall of the wash tank. Alternatively, a heating element of the type that extends into the wash tank could also be used.
FIG. 5 shows in clearer detail the structure and function of basket holder frame 28 and the three associated basket holders 30 a-30 c. Left basket 20 c is shown positioned fully within left basket holder 30 c while the center basket is removed for clarity from center basket holder 30 b. Right basket 20 a is shown removed from right basket holder 30 a being lifted vertically up from the holder. Each basket is preferably structured with a perimeter lip that rests on the appropriately sized ring of the aligned basket holder. Once again, each basket preferably includes one or more handles to facilitate the placement into or removal from the associated basket holder.
Although the embodiment shown herein uses three baskets that are structured to be raised and lowered in unison, the same basic principles for pre-washing and/or washing silverware positioned in baskets that move in opposite directions can be applied. With the appropriate linkages in the drive and lift mechanisms, along with separated basket holder frames, it is possible to implement the reciprocating up and down motion of each basket at different points in the cycle. In the embodiment shown, for example, one basket holder frame might be associated with the left and right baskets while a separate basket holder frame would be associated with the center basket. Such a structure would require two separate lift rods linked to separate actuator rods although each could still operate through a single bearing block and could be driven by a single (two arm) crank. The rates of reciprocating motion, regardless of whether the baskets were moving in unison or not, can be controlled and varied by a programmable controller (described below) positioned remote from the unit shown that sits on the tabletop. As mentioned above, LED indicators 19 a & 19 b positioned on the front facing wall of lift mechanism cover 24, provide cycle process status information to the user to further optimize ongoing use of the system without having to simply stop and start the operation to load or unload silverware.
Reference is next made to FIGS. 6A & 6B for clearer depiction of the manner of raising and lowering the baskets into the wash fluid. FIG. 6A is a centerline cross-sectional view of the three-basket embodiment of the silverware washing system of the present invention with the lifting mechanism in a raised condition. FIG. 6B is the same centerline cross-sectional view with the lifting mechanism in a lowered condition. Drive mechanism cover (and support) 12 and lift mechanism cover 24 are shown in place as they each enclose the drive and lift components of the system. Bearing block 38 (for example) is seen to be supported by the top of drive mechanism cover 12 where the cover extends forward over the tank cover 18. The drive components (DC motor 42, gear box 46, and crank arm 44) are positioned with the appropriate clearances within drive mechanism cover (and support) 12. The lift components (lift rod 36, lift rod connector 34, and actuator rods 32) are positioned with the appropriate clearances within the lift mechanism cover 24.
Wash tank 16 is seen in cross-section as it is supported on system base 14 (the base fitted with a plurality of base rubber feet 35) with heating element 37 adhered to the bottom exterior surface of the wash tank. Sensor 50 b and tank fluid line 49 are shown in this view as they extend through the back wall of wash tank 16 from outside the tank. Tank fluid line 49 directs wash fluid 17 to flow into wash tank 16 from auto fill valve 48 (and optionally through the chemical inductor or other chemical mixing system). LED indicators 19 a & 19 b are again visibly positioned on lift mechanism cover to provide process cycle information to the user. LED indicator 21 b is associated with center basket 20 b positioned in center basket holder 30 b to assist the user with identifying a proper basket loading sequence. Each of these LEDs are driven by the remote (wall mounted) controller described in more detail below.
In the cross-sectional view of FIGS. 6A & 6B, the manner in which tank cover 18 extends downward into wash tank 16 is apparent. In addition to partially covering the open top of wash tank 16, tank cover 18 forms three cylindrical columns within which the baskets and basket holders vertically move. The wash fluid level in the wash tank preferably comes up to the bottom edge of the cylindrical columns formed by the tank cover that surrounds each basket and basket holder. This configuration forces the fluid to predominantly flow vertically through the silverware in the basket as opposed to off the silverware and over through the sides of the basket. The cylindrical columns also reduce splashing as the baskets are immersed into the wash fluid and/or lifted from the wash fluid. The system as described is designed to operate optimally with the wash tank about half full of wash fluid. The exact depth of the wash tank and location of the water line is variable for achieving multiple washing objectives. This allows the baskets to be alternately fully submersed into and fully removed from the wash fluid. The relatively turbulent flow of fluid through the randomly oriented silverware positioned in the baskets provides an effective, powerful pre-wash more than adequate for most commercial food service facility applications.
FIG. 6B provides the same cross-sectional view as that shown in FIG. 6A but with the basket and lift mechanism in the lowered and immersed condition. In this view, actuator rods 32 have travelled downward to their limit where lift rod connector 34 is adjacent to the top of bearing block 38 and basket holder frame 28 approaches the bottom of wash tank 16. In this condition, any silverware in center basket 20 b is nearly fully immersed in wash fluid 17 as center basket holder 30 b ends up at approximately the wash fluid surface. It should be noted that the crank arm configuration allows for the continuous rotation of the gears in gear box 46 in one direction to drive the reciprocating up and down motion to the baskets. In order to reduce wear on the drive system, the DC motor can be easily reversed by the controller to reverse the direction of the gear box and crank arm rotation while not altering the essential reciprocating vertical motion of the baskets.
FIGS. 7A & 7B provide alternative installations of the system of the present invention dependent on the availability of plumbed water lines and the use of chemical additives to the wash fluid. While each figure shows the installation of two systems of the present invention, similar installations can be implemented with only a single system or with more than two systems. In each installation, the food service facility is presumed to have a dish table/stand 56 which may or may not be positioned adjacent to an open facility wall 58. Many other practical arrangements may be made depending on the dish room table layouts in various foodservice outlets where the systems would be installed.
FIG. 7A is a perspective view of a typical installation of two of the silverware washing systems of the present invention in a food service facility where an adjacent fill faucet is available for use. A first wash system 60 a is positioned next to a second wash system 60 b on the top surface of dish table/stand 56 in front of facility wall 58. Fill faucet 57 is preferably centered between the two systems such that a pivoting faucet neck can alternately swing over the two systems to supply wash water into the respective wash tanks. Positioned above the two systems 60 a & 60 b on wall 58 is control box 64. External power connection 65 provides AC power to control box 64 where controller/DC power source 66 connects to each of the systems by way of power and control cables 62 a & 62 b. Control box 64 provides the necessary user interface to not only switch the respective systems on and off but also to direct the cyclical process of operation for each of the systems.
FIG. 7B is a perspective view of an alternate installation of two of the silverware washing systems of the present invention in a food service facility with plumbed water supply lines and the use of chemical additive reservoirs. In this alternate installation, a first wash system 60 a is again positioned next to a second wash system 60 b on the top surface of a dish table/stand 56 in front of facility wall 58. Positioned above the two systems 60 a & 60 b on facility wall 58 is control box 64. As above, external power connection 65 provides AC power to control box 64 where controller/DC power source 66 connects to each of the systems by way of power and control cables 62 a & 62 b. In place of a fill faucet, however, this installation incorporates the auto fill features of the system shown and described above in FIG. 3 . Water supply lines 69 a & 69 b connect each system 60 a & 60 b respectively to external water supply 70. Water supply lines 69 a & 69 b preferably incorporate separate manual cutoff valves (not shown) as a manner of controlling the flow of water to each system in addition to the auto fill valve configured within each system.
The installation shown in FIG. 7B also incorporates the optional chemical additive feed process shown and described above in FIG. 3 and further described in FIG. 8 below. Chemical supply/reservoirs 68 a & 68 b connect to each system 60 a & 60 b respectively to provide a venturi vacuum induced flow of chemical additive to the wash fluid through the above described chemical feed line 23 and chemical inductor 45 (not visible in FIG. 7B).
As mentioned, the basic system of the present invention only requires connection to an external power source, preferably a standard AC power source, to operate through the described wall mounted controller/DC power source. More specifically, and preferably, a 100 to 240 volt AC power connection (50 or 60 Hz) is supplied and an internal power converter inside the control panel converts that power to low voltage DC power (12, 24, 48 volts DC etc.). The additional (optional) connection to a plumbed external water supply allows for the use of the auto fill functionality of the system and the additional (optional) connection to a chemical reservoir allows for the use of various chemical additives in the wash fluid. Further external connections could include a common drain line with or without automating the activation of the described drain valves on each system.
FIG. 8 is a detailed perspective rear view of the drive and lift mechanisms of the system of the present invention with the covers removed for clarity. Once again, the functional components of the drive and lift mechanisms are exposed where they are positioned and secured within the drive mechanism cover (and support) 12. Actuator rods 32 are positioned through bearing block 38 and extend downward to their point of attachment to the basket holder frame inside of the wash tank. The top ends of actuator rods 32 are pivotally connected to lift rod 36 which serves as the linkage between the drive mechanism of the system and the lift of the system. DC motor 42 is powered from an external source, preferably from a centralized remote (wall mounted) controller as shown and described below in FIG. 9 . This power and control connection has been omitted for clarity from FIG. 8 but comprises one of the system cables 62 a & 62 b shown in FIGS. 7A & 7B. DC motor 42 drives the gears within gear box 46 which turn crank arm 44 which is pivotally linked to lift rod 36. The rotational motion of crank arm 44 translates into the vertical motion of lift rod 36 and through such linkage to the vertical motion of the actuator arms 32. As described above, the reciprocating vertical motion of the actuator arms 32 provides the same oscillating vertical motion to the baskets in and out of the wash fluid. DC motor 25 is preferably a variable speed reversable motor whose speed and direction can be controlled by the controller/DC power source shown in FIGS. 7A & 7B.
Further shown in FIG. 8 is external water line 47 which may be connected to an available external water source to provide a controlled filling of the wash tank of the system. In the preferred embodiment, external water line 47 is preferably attached to the system through auto fill valve 48. Auto fill valve 48 is preferably an electric solenoid actuated valve that may be controlled (on and off) by the same controller that powers the DC motor 42. In one embodiment of the system of the present invention, auto fill valve 48 may connect directly to wash tank 16, delivering “tap water” into the system. Alternately, as shown in FIG. 8 , the flow of water may pass first through chemical inductor 45 before flowing into wash tank 16. Chemical inductor 45 receives a controlled flow of chemical additive from a remote reservoir by way of chemical feed line 23. Control of the venturi vacuum induced flow of chemical additive may occur through the use of a valve (automated or manual) associated with the system as previously noted.
In addition to controlled power to the DC motor and the solenoid actuated water valve, the cable connections between the individual wash units and the centralized controller would include signal lines directing the operation of the various LED indicators as well as signal lines receiving data from the various wash fluid condition sensors. Once again, the basic functionality of the system requires only power to the DC motor in the system while the optional functionalities of automated water flow, chemical additive, fluid condition measurements, and operational indicators may all be added individually or collectively to further improve operation of the system.
Reference is next made to FIG. 9 which is a detailed perspective view of the control elements of a typical installation of two of the silverware washing systems of the present invention in a food service facility, in this case with an adjacent fill faucet 57. Control box 64 is mounted on facility wall 58 and is connected to the individual units (represented by wash system 60 b in FIG. 9 ) by way of system cables 62 a & 62 b respectively. Power to controller/DC power source 66 within control box 64 is provided by external power connection 65. In this view, control box 64 is shown to include audible alarm 63 and communications port 67 that provide additional functionality to the system in the manner of user interface and wide area network connectivity. Audible alarm 63, as driven by controller/DC power source 66, serves to alert the user to a condition in one or more of the attached systems that requires attention. This could be anything from a cycle completion event to a low wash fluid level within the system. Controller/DC power source 66 preferably includes an informational display that facilitates both user control of the systems (such as with a touchscreen display) and the display of the conditional status of the systems. Communications port 67 is preferably a standard USB port that allows for both the transmittal of operational data from the controller and the receipt of programming for system operation to the controller. Such transmission and receipt of digital information and programming may be wired or wireless as is known in the art as the USB port can also be used as a connection point for a Wi-Fi, Bluetooth, or cellular communication module.
FIGS. 10A-10C are perspective views of an alternate exemplary embodiment of the three-permeable enclosure version of the silverware washing system of the present invention shown with additional sensors and visual indicators associated with expanded system functionality. Reference is made to FIG. 10A for a front perspective view of this three-permeable enclosure version of the present invention. In this view, the silverware washing system is again shown to be made up of a base and washing fluid tank with a washing fluid tank cover and a centrally located reciprocating vertical motion device. In this view, three porous basins or baskets are shown in fully elevated positions, generally above the surface of the washing fluid (not shown). The base cover defines three cylindrical portals through which the porous basins are raised and lowered.
FIG. 10A is the view of the three-permeable enclosure embodiment of the silverware washing system of the present invention that the user would encounter before beginning operation of the system with the permeable enclosures raised and empty. The immersion wash system shown generally comprises a system base 84 that supports an open top wash tank 86 that is partially covered with tank cover 88. To the rear of the wash tank 86 is the lift mechanism (internally structured in a manner similar to lift mechanism 22 shown in FIG. 1 ) that extends up from base frame 84. In the view of FIG. 10A, the functional components of the lift mechanism are generally enclosed within lift mechanism cover 94. A movable support frame (hidden in FIG. 10A) is operationally connected to the lift mechanism and supports each of a number (three in the embodiment shown) of permeable enclosures (porous cylindrical basins in the embodiment shown). In the three-permeable enclosure embodiment shown, porous basins 90 a-90 c are shown positioned in the holder frame in the elevated state. The diameter of the porous basins is such as to just fit within the respective circular ring support (as described above with FIG. 2 ) forming part of the holder frame. In turn, the openings in the tank cover 88 are just large enough to allow for the removal and/or insertion of the removable porous basins from the holder frame.
Operational elements of the alternate embodiment of the system of the present invention additionally seen in FIG. 10A include: LED indicators 91 a-91 c that are used to alert the user to an appropriate permeable enclosure loading or unloading sequence; object detection sensors 93 a-93 c that are used to detect and quantify the load in each permeable enclosure; proximity sensor 95 that is used to detect the presence of a worker (kitchen staff) within the vicinity of the system; and drain line/valve 85 used in conjunction with a water inlet valve (not shown) to control the volume (level) of wash fluid within the open top tank. The functionality of each of these components is described in more detail below with reference to FIGS. 10B & 10C.
The system structural components are again preferably stainless steel as is typical in commercial food preparation and food service facilities. Tank cover 88 is preferably removable from wash tank 86 for periodic cleaning access to the submersible components of the system and the interior of the wash tank 86 itself. The drive mechanism cover (seen removed from the rear of the system in FIG. 10C) and lift mechanism cover 94 are also preferably made of stainless steel components. At a minimum, the basic embodiment of the system shown requires an external power connection while alternate improved embodiments may further include water line connections and/or chemical wash additive flow line connections.
FIG. 10B is a detailed perspective front view of the alternate embodiment of the three-permeable enclosure version of the silverware washing system of the present invention shown in FIG. 10A. Seen in detail are the various sensors and display indicators that facilitate the efficient operation of the system and the interaction of the system with the workers (kitchen staff). Shown on the three oriented panels of lift mechanism cover 94 are: color variable visual indicators 91 a-91 c to alert the user to the most appropriate permeable enclosure loading or unloading sequence; targeted object detection sensors 93 a-93 c used to detect and quantify the load in each permeable enclosure; and proximity sensor 95 that is used to detect the presence of a worker (kitchen staff) within the vicinity of the system.
Color variable visual indicators 91 a-91 c are preferably multicolor LEDs driven by the controller of the system that are responsive to the load conditions of each of the permeable enclosures. The orientation of the indicators, as defined by their placement on the panels of lift mechanism cover 94, provides the association with the relevant permeable enclosure. Information about the load within each enclosure can be conveyed using combinations of indicator color and intermittent illumination. For example, a light could be illuminated green to indicate that silverware could be loaded into the specific permeable enclosure; the light could then be illuminated yellow to indicate that the specific permeable enclosure is full (instructing the user not to load anymore silverware); and then after a prescribed time period of operation while full, the light would turn to red to indicate that the specific permeable structure is ready to be removed, emptied, and replaced. Alternate functional uses (information communication to the user) of illumination color and intermittent illumination are anticipated. The LEDs shown and described herein are but one manner of alerting the user to the conditions of the baskets and the proper sequence of loading and unloading. The indicators may be other types of visual indicator devices (lights, LCD displays, alphanumerical displays, etc.) that may optionally be combined with audible alerts. The indicators may preferably be located on the system close to the relevant baskets or may be remotely located and connected by wired or wireless signal communication. Remote indicators that fulfill the above functionality may be integrated into remote smart personal devices through operational software applications that the user might retain with them while they move about the food service and preparation space.
Targeted object detection sensors 93 a-93 c are used to detect and quantify the load in each permeable enclosure. The orientation of the sensors, also as defined by their placement on the panels of lift mechanism cover 94, provides the association with the relevant permeable enclosure. The detection sensors 93 a-93 c are preferably non-contact sensors that operate at a distance using reflected waves or disrupted electromagnetic fields. Sensors that use reflected infrared (IR) light or that use reflected acoustic waves are available that can not only detect objects but also quantify the mass of objects within a field of view. Sensors that measure disruptions in electromagnetic fields induced by masses of metal objects can also detect and quantify such objects. Other contact type devices capable of measuring loads within the various permeable structures are anticipated. Such conventional contact load sensors could be placed beneath each permeable enclosure in contact with the wash tank floor and effectively measure the weight of the loaded permeable enclosure at the lowest point in the vertical motion (at the instance where the direction of motion changes from downward to upward). Alternately, angular torque sensors could be incorporated into the holder frame (see FIG. 2 ) and calibrated to indicate load based on the angular torque measured at the junctions between the ring shaped holders and the support frame.
Proximity sensor 95 is centrally positioned on the top of lift mechanism cover 94 to provide a 360 degree view of the space around the system and may be used to detect the presence of a worker (kitchen staff) within a specific distance from the system. Proximity sensor 95 is preferably of a type that distinguishes changes in distance as opposed to simply detecting a mass within the field of view. Various sensors that use reflected electromagnetic waves (IR or other higher frequency EM waves) or reflected acoustic waves are capable of determining distance to an object within the field of view. How long the object stays within the measured proximity may also be relevant to using the information to automatically trigger actions that pause or otherwise interrupt the operation of the system. Basically, proximity sensor 95 tells the system when a user has positioned themselves within a prescribed distance from the system and how long they remain within that proximity range. The system controller may then use that information to distinguish between a user approach that involves dropping additional silverware into a basket and a user approach intended to pause the system for the purpose of removing and replacing a basket.
FIG. 10C is a detailed perspective rear view of the alternate embodiment of the three-permeable enclosure version of the silverware washing system of the present invention shown in FIG. 10A with the rear cover removed to show internal sensor and LED connections to the onboard controller. As indicated above with reference to FIGS. 7A & 7B, each unit of the system of the present invention may be controlled by a “remote” (wall mounted, in FIGS. 7A & 7B) programmable controller, potentially configured to operate multiple units positioned adjacent each other. Alternately, each unit may have an onboard controller as shown and described in FIG. 10C. A third option is to have a single “smart” unit incorporating an onboard controller that may be linked to other “basic” units (no onboard controller but the same sensors, heaters, valves, etc.) in a networked fashion to carry out automated control of multiple units at the same time.
Where an onboard controller is configured into the unit, direct data signal connections are made with each of the sensors as data inputs into the controller, and direct control signal/power connections are made with the drive motor, the heater (if any), the various flow valves, and the visual indicators. In FIG. 10C, some of the interior structures of the lift mechanism within lift mechanism cover 94 are shown. Actuator rods 74 are positioned through bearing block 78 and extend downward to their point of attachment to the holder frame inside the wash tank. The top ends of actuator rods 74 are pivotally connected to lift rod 76 which serves as the linkage between the drive mechanism of the system and the lift mechanism of the system. DC motor 42 (schematically represented in FIG. 10C) is connected to and is operated by controller 96. DC motor 42 is preferably a variable speed reversable motor whose speed and direction can be set by programmed operation of controller 96. Data signal connections are shown between controller 96 and load detection sensors 93 a-93 c that are used to detect and quantify the load in each permeable enclosure. Control signal connections are shown between controller 96 and LED indicators 91 a-91 c that are used to facilitate the loading, removal, and replacement of the permeable enclosures. Data signal connections are also shown between controller 96 and proximity sensor 95 used to detect the presence of a worker (kitchen staff) within the vicinity of the system. Control signal connections are also shown between controller 96 and solenoid operated water inlet valve 48 as well as solenoid operated chemical additive valve 45 (each schematically represented in FIG. 10C). Data signal connections are shown between controller 96 and fluid level sensors 51 a & 51 b as well as temperature sensor 53. Not shown in FIG. 10C are similar control signal (power) connections between controller 96 and a heating device (not shown) as well as a solenoid operated drain valve (not shown). Where the unit is configured as a “basic” unit (without an onboard controller) the controller shown would be replaced with a wiring harness terminating in wiring block connector/plug that would make a network connection to an adjacent “smart” unit or a separately configured stand alone controller as described above. In a preferred embodiment, controller 96 includes a programmable microprocessor with a programming port (not shown) similar to that described above in FIG. 9 . In more complex versions of the system, the above described programming functionality may be brought onboard by providing a keypad entry and/or touchscreen display (not shown) to the user. In a more “basic” version of the system, controller 96 may be a simpler microcontroller (with onboard timer) that responds to basic sensor conditions with stop and start functionality.
Motor 42 in each embodiment of the present invention described above is preferably a DC reversing motor that allows for operation in both directions. As described above (referencing FIGS. 6A & 6B), DC motor 42 drives the gears within gear box 46 which turn crank arm 44. Crank arm 44 is pivotally linked to lift rod 36 and moves lift rod 36 vertically a distance approximately twice the length of crank arm 44. Because of this offset crank arm, the continuous rotation in one direction will direct the oscillating vertical motion that the system utilizes. This motor and gear box arrangement does not, however, prevent the system from directing a smaller stroke oscillation of the support frame and baskets by way of reversing the motor itself within less than a full rotation of the drive from the gear box. The method of the present invention anticipates implementation of the oscillation for a vertical stroke less than that of a top to bottom and back vertical motion. In most circumstances, it is preferable that the oscillation of the system causes the silverware to break the surface of the wash fluid with each cycle but other patterns of oscillation are anticipated.
FIGS. 11A-11C are flowcharts detailing the functionality and the method steps associated with operation of the system of the present invention. Referencing FIG. 11A, the initial steps associated with preparing the open top tank with a body of wash fluid are detailed in Process 100. Step 102 introduces a metered flow of water into the open top tank and may involve manually pouring water into the tank from above, directing a flow of water from a sink tap positioned adjacent the system, from a hose on a third party chemical solution dispenser (typically a water flow metered with a chemical additive), or automatically directing a flow of water through an inlet water valve as described in the embodiment shown in FIG. 1 and/or that shown in FIG. 10A. Optional Step 104 introduces a metered flow of chemical additive(s) into the open top tank and may involve manually introducing the additive(s) into the tank from above, or automatically introducing the additive(s) by actuating an inlet chemical valve as described in the embodiment shown in FIG. 1 and/or that shown in FIG. 10A.
Steps 106, 108, and 110 involve monitoring and controlling the physical quantity and quality of the wash fluid. Step 106 provides for optionally monitoring and controlling the temperature of the wash fluid. A variety of temperature sensor types may be placed in one or more locations within the wash tank to provide a signal to the controller indicative of the wash fluid temperature. Controlling the temperature of the wash fluid can be carried out by a number of heating and/or cooling structures. In addition to the contact plate heater described above with the embodiments of FIG. 1 and FIG. 10A, other ways of heating (primary mode of temperature change) or cooling (secondary mode of temperature change) are anticipated. Immersion heaters may be placed in the wash tank as long as they do not obstruct the movement of the permeable enclosures. Heaters may likewise surround a section of water inlet flow lines to introduce warmer water into the tank (while draining a commensurate quantity of cooler water if necessary). The motion of the permeable structures (with their silverware loads) may also generate heat through friction as the multiple surfaces push through the wash fluid in both directions of vertical travel. This frictional heating may be controlled by varying the rate of the vertical oscillating motion with faster motion generating more heat.
Step 108 provides for monitoring and controlling the volume of wash fluid in the tank by tracking the level of fluid in the tank. While tracking the level of the surface of the wash fluid is important to adequately cover the loads in the permeable enclosures during operation (and still allow for their removal from the wash fluid at the end of the upward motion), translating this level measurement into a volume of fluid is important for providing the appropriate heating of the fluid and for providing an appropriate quantity of chemical additives as required. Various fluid level sensors of the type described above with the embodiment of FIG. 1 may be used. Alternately, a variety of acoustic or infrared reflective depth sensors may be employed when positioned at the top of the wash tank directed down into the tanks. Any type of fluid level sensor employed will need to consider rapid changes in the wash fluid level caused by the agitation, displacement, and vertical flow that occurs with oscillation of the system, and will generally need to establish an average measurement over time to produce an accurate wash fluid volume quantity to the controller. This monitoring could also be achieved with the use of a high or a low water level sensor or with the use of both high and low water level sensors. Controlling the volume of fluid in the wash tank will generally involve opening and closing drain valves and inlet valves. As indicated above, this process may be as simple as manually operating the valves or as complex as programming the controller to automatically open and close the valves in response to programmed process requirements or sensed conditions in the wash fluid. One or more overflow drains may also be used as a final safeguard against overfilling the open top tank.
Still referencing FIG. 11A, the next steps associated with positioning the open top permeable enclosures on the vertically movable support structure above the open top tank, and starting the operation of the system are detailed in Process 112. Step 114 involves initially lowering the open top permeable enclosure(s) that are positioned on the vertically movable support structure into the prepared wash fluid in the open top tank. This step may be manually initiated (by user activated switch) or may proceed automatically when the wash tank reaches the required level of wash fluid. Step 116 involves the process of repeatedly raising and lowering or oscillating the open top permeable enclosures into, within, and out from the wash fluid. Step 118, which may occur prior to Step 114 and/or during Step 116, involves introducing a quantity of silverware and/or kitchen utensils into one of more of the oscillating permeable enclosures. Washing or pre-washing using such oscillation and the ability of the system to carry out Step 118 while the system is oscillating are important improvements over existing pre-wash and wash systems. Step 118 can be carried out continuously while the system is in continuous operation mode during Process 120. Generally, the system only pauses for unloading as loading is almost always done while the system is oscillating.
Referencing FIG. 11B, the steps associated with continuous operation mode (automated functionality) are detailed within Process 120 made up of Steps 122-136. Step 122 involves continuing the oscillating or raising and lowering of the open top permeable enclosures, with their incorporated loads, into, within, and out from the wash fluid. Step 124 involves continuing the ad hoc introduction of quantities of silverware and/or utensils into the one or more permeable enclosures while the permeable enclosures are in motion. Step 126 involves controlling the rate and duration of the vertical motion oscillation of the permeable enclosures and their respective loads. This control of the speed of the drive motor by the controller of the system may be responsive to a variety of directives. Preprogrammed motor speeds and cycle durations may generally direct the operation of the system. Input from any of the above-described sensors (user proximity, individual basket loads, fluid levels, fluid temperature, and dissolved solids) can trigger a change in motion speed and/or the pausing or stopping of the motion. The pausing or stopping of the motion can occur immediately (as in a safety condition) or at the end (top or bottom) of a motion cycle. The system therefore has the ability to park the permeable enclosure(s) with their respective loads in a position fully immersed in the wash fluid (as to soak the contents, for example), partially immersed (as to allow the user to visually inspect the condition of the loads), or fully removed from the wash fluid (as to allow the removal and replacement of one or more permeable enclosures).
Step 128 involves the continuous process of monitoring the load of silverware and/or other kitchen utensils within each permeable structure. Any of the various load sensing devices described above (with reference to FIGS. 10A-10C) may be utilized to provide the controller with information necessary to drive the indicator LEDs associated with each permeable enclosure and, if necessary, to pause or stop the motion of the system in response to an overload or anomalous load condition, all as described in more detail below. Step 130 involves monitoring and controlling the volume (level) of wash fluid in the open top tank. In addition to the importance of this step during the initial filling of the wash tank, maintaining the volume of fluid during operation is important because the varying loads in the permeable enclosures will displace significant quantities of wash fluid when immersed. It may be necessary, for example, to drain some wash fluid from the tank when the permeable enclosures are full or nearly full. Likewise, if the system is paused for the removal of a full load that has been fully cycled in the system, and the subsequent replacement of an empty permeable enclosure, it will be necessary to add wash fluid to bring the level back up to a preferred operation level. Other actions during the operation of the system (such as replacing a quantity of contaminated wash fluid with clean fluid) will likewise involve measurement and control of the wash fluid level (volume) in the open top tank.
Step 132 involves monitoring and controlling the temperature of the wash fluid in the open top tank. In addition to the importance of this step during the initial filling of the wash tank, maintaining the temperature of the fluid during operation is important because heat loss from the system into the environment will naturally occur over time, and further because the introduction of “cooler” loads into the permeable enclosures will tend to lower the temperature when the loads are immersed. Additionally, rapid motion of the system with a significant load in place may serve to increase the temperature due to frictional heat transfer as described above. Each of the various mechanisms for moving heat into or out of the system described above may be used to control the temperature of the wash fluid. It may be necessary, for example, to reheat the wash fluid after a period of time or after a significant change in the loads (the removal of warm washed silverware and its replacement with cooler to-be-washed silverware, for example). Likewise, any change in the volume of wash fluid according to the requirements described with Step 130, will generally involve an adjustment to the temperature of the wash fluid to maintain optimal performance of the system. Other actions during the operation of the system (such as changes in the temperature and humidity of the ambient environment) will likewise involve measurement and control of the temperature of the wash fluid in the open top tank.
Optional Step 134 involves monitoring the purity of the wash fluid (the quantity of total dissolved solids (TDS) in the wash fluid) in the open top tank. In addition to the importance of this step during the initial filling of the wash tank, maintaining the purity of the fluid during operation is important because the ability of the wash fluid to dissolve and remove food and debris from the silverware and/or utensils degrades when the TDS in the fluid gets too high. The ability to constantly monitor TDS combined with the ability to exchange high TDS fluid with “clean” wash fluid, all while the system is in operation, can significantly improve the pre-wash or wash efficiency. Other actions in the operation of the system (such as increasing chemical additives in the wash fluid) may be optionally carried out as appropriately responsive to changes in the level of TDS in the wash fluid in the open top tank.
Finally, within the continuous operation mode (automated functionality) detailed in Process 120, Step 136 involves monitoring the presence of workers in proximity to the operating pre-wash and/or wash system of the present invention. Primarily utilizing the proximity sensor described above, the system detects the proximity of a user (a kitchen worker, for example) and measures the distance and time duration of that users' proximity to the system. In some embodiments of the present invention, manually activated switches could also form a part of the overall system of user inputs that direct the system to alter or stop operation in some manner. Actions taken by the system controller in response to worker proximity are discussed in more detail below.
With all the automated monitoring and control carried out by the system as generally defined in Process 120 active, the system automatically responds to the information continuously gathered by implementing the actions defined in Process 138 wherein user feedback is provided, and actions are taken to pause and/or terminate operation of the oscillating vertical motion of the permeable enclosures and their incorporated loads.
Reference is finally made to FIG. 11C which details specific user feedback functionality and actions that may automatically be taken to pause the oscillating motion of the system and/or terminate the cycle processing, all within Process 138. Fundamental to operation of the system of the present invention is Step 140 wherein the controller, utilizing the sensors for detecting and quantifying the load in each of the individual permeable enclosures, quickly and clearly informs the users (kitchen staff) of the condition of each load in each permeable enclosure. This information is conveyed by variable colored display lights (preferably LEDs) visible to the user and positioned in association with the permeable enclosure to which it pertains. Although various colors and on/off conditions may be utilized, a basic notification system would involve use of a green LED to indicate that a particular permeable enclosure is not near to being full and is therefore available for the addition of silverware and/or utensils; use of a yellow LED to indicate that a particular permeable enclosure is full and cannot receive any additional load; and use of a red LED to indicate a full load that is completely washed or pre-washed and is ready for removal. These LED indicators could additionally provide information on the duration of time that a particular load (or a major portion of that load) has been oscillating. For example, a flashing green LED could signal the user that not only could that permeable enclosure receive an additional load, but also that the load already in the permeable enclosure is early in a timed pre-wash or wash cycle, further encouraging the user to add to the load. In contrary fashion, a flashing yellow or red LED could indicate that the load already in the permeable enclosure is nearing the end of a timed cycle, thereby discouraging the user from adding to the load and/or alerting the user that the specific loaded permeable enclosure would soon or immediately need to be removed and replaced. These indicators could be positioned onboard the system (as shown in FIGS. 10A-10C), remote to the system, or both.
Step 142 involves actions taken when a worker is in close proximity to the system or within close proximity for a preset period of time. As the system is designed to continue the vertical oscillating motion even as additional silverware and/or utensils are introduced into the permeable structures, it is preferable that the system does not pause or stop every time a worker loads the system. The motion of the system would need to be paused, for example, when a permeable enclosure with incorporated load is ready to be removed from the system to be replaced by an empty permeable enclosure. Such non-action or action based on worker proximity would be appropriately programmed into the controller so as to avoid unnecessary stops and starts while maintaining a safe process for the removal and replacement of permeable enclosures. It is anticipated that the system may be calibrated to the ideal proximity distance and duration that will maintain continuous oscillation when an employee approaches for purposes of loading but pause the oscillation when it is clear that the employee approaches for purposes of removing a basket.
Step 146 involves optionally initiating the process, briefly described above, of exchanging contaminated wash fluid with clean wash fluid, even while the vertical oscillating motion continues. By controlling outlet drains (preferably positioned near the bottom of the wash tank) and inlet water valves (preferably positioned near the top of the wash tank) this attention to the total dissolved solids (TDS) in the wash fluid can be carried out without the need to stop the system.
Steps 148, 150, and 152 each represent actions that terminate the cycle processing of the system in response to various events or conditions. Step 148 involves termination of the oscillating motion and cycle processing of the system when a worker remains in proximity to the system for an extended period of time or is within a specific close proximity. This also would typically involve raising the permeable enclosures and their incorporated loads to the highest position for handling by the user. Step 150 involves termination of the oscillating motion and cycle processing of the system where the wash fluid has become contaminated to the point that further operation of the system would be ineffectual or at the very least, inefficient. If the system is not set up to replace contaminated wash fluid “on the fly” then the best option is to stop the cycling process, drain the contaminated wash fluid (manually or by switch control), and refill the wash tank. This type of termination would preferably involve lowering the permeable enclosures and their incorporated loads to the lowest position in the tank so that contaminants within the permeable enclosures might be washed out with the contaminated wash fluid in the process of exchanging the wash fluid. Step 152 involves the fail safe option of terminating oscillating motion and cycle processing by activation (or deactivation) of a manual stop or on/off switch by the user.
For whatever reason the normal operation of system might be stopped, it would typically be beneficial to implement Step 154 with the flushing and cleaning of the open top tank using the various valves, heaters, and sensors described above. A sanitizing process could be programmed to run with higher temperature fluids, specific chemical additives, and the placement of empty permeable enclosures in the system to prepare the system for a new round of pre-wash and/or wash cycles. Finally, Process 155 would involve shutting the system down by draining the open top tank of wash fluid and powering down all electrical components within the system.
Although the present invention has been described in conjunction with a number of preferred embodiments, those skilled in the art will recognize modifications to these embodiments that still fall within the spirit and scope of the invention. Because of the ability of the system of the present invention to function as a standalone unit without extensive space and/or ancillary plumbing, a variety of commercial kitchen table units may be used to support the system. Alternately, the present invention may be implemented with the manufacture of concurrently produced platform sized and structured to accommodate the dimensions of one or more of the proprietary systems. The invention has been described in terms of a basic embodiment with a number of add-on functionalities that may be implemented separately or collectively. Further add-on functionalities will be anticipated by those skilled in the art that do not depart from the spirit and scope of the invention as set forth in the appended claims.

Claims

We claim:

1. An open top silverware and kitchen utensil wash system for cycling a variable quantity of objects to be washed into, out of, or within a body of wash fluid, the wash system comprising:

at least one open top permeable structure for holding the variable quantity of objects to be washed;

a vertically movable support frame for receiving and supporting the at least one permeable structure;

at least one vertically movable actuator rod having an upper end and a lower end, the lower end connected to the vertically movable support frame;

at least one fixed guide member slidingly engaging the at least one vertically movable actuator rod;

a drive mechanism comprising a motor and a drive linkage assembly operably connected to the upper end of the at least one vertically movable actuator rod;

at least one open top wash tank containing the body of wash fluid, the wash tank positioned in proximity to the vertically movable support frame; and

a programmable controller in operable communication with the drive mechanism, the programmable controller programmed to operate the drive mechanism to agitate and to cycle the variable quantity of objects to be washed into, out of, or within a body of wash fluid;

wherein the open top wash system allows for additional objects to be washed to be received into the at least one open top permeable structure at all times during operation of the wash system.

2. The wash system of claim 1 wherein the vertically movable support frame comprises at least one circular support collar and the at least one open top permeable structure comprises a cylindrical basket sized to removably fit into the at least one circular support collar.

3. The wash system of claim 1 further comprising a temperature sensor and a heating element positioned in thermal contact with the body of wash fluid, the temperature sensor and the heating element in operable connection to the programmable controller to provide controlled heating of the body of wash fluid.

4. The wash system of claim 1 wherein the at least one open top wash tank further comprises a fluid inflow line, a fluid inflow valve, a fluid drain line, and a fluid drain valve, the inflow valve and the drain valve in operable connection to the programmable controller to direct and control a flow of fluid into and out from the at least one open top wash tank.

5. The wash system of claim 1 wherein the at least one open top wash tank further comprises an overflow drain to allow excess wash fluid to flow out from the at least one open top wash tank.

6. The wash system of claim 1 further comprising a chemical additive reservoir, a chemical additive feed line, and a chemical additive valve, the chemical additive valve in operable connection to the programmable controller to direct and control a flow of chemical additive into the body of fluid.

7. The wash system of claim 1 wherein the at least one open top permeable structure comprises a plurality of open top permeable structures, each positioned to receive a separate variable quantity of objects to be washed.

8. The wash system of claim 7 further comprising at least one indicator display associated with each of the plurality of open top permeable structures, the at least one indicator display in operable connection to the programmable controller to provide information to the user on the status of the programmed cycle in operation.

9. The wash system of claim 8, wherein the at least one indicator display comprises an indicator light adjacent each of the plurality of open top permeable structures controlled by the programmable controller to direct a sequential loading of the plurality of permeable structures.

10. The wash system of claim 8, wherein the at least one indicator display comprises indicator lights to indicate cycle completion, a full load condition, and an overload condition.

11. A method for washing a variable quantity of silverware and/or kitchen utensils in a body of wash fluid, the method comprising the steps of:

(a) providing an open top wash system comprising:

a plurality of open top permeable structures supported on a vertically movable frame;

a vertically movable lift assembly connected to the vertically movable frame;

a drive mechanism connected to the vertically movable lift assembly;

an open top wash tank positioned in proximity to the vertically movable frame; and

a programmable controller in operable communication with the drive mechanism;

(b) at least partially filling the open top wash tank with the body of wash fluid;

(c) inserting a quantity of silverware and/or kitchen utensils into at least one of the plurality of open top permeable structures;

(d) using the programmable controller to direct a programmed cyclic sequence of vertical motions of the plurality of open top permeable structures into, out of, or within the body of wash fluid, the cyclic sequence of vertical motions comprising:

lowering the plurality of open top permeable structures at least partially into the body of wash fluid;

repeatedly raising and lowering the plurality of open top permeable structures within the body of wash fluid;

raising the plurality of open top permeable structures out of the body of wash fluid; and

(e) while the programmed cyclic sequence of vertical motions is occurring, inserting a further quantity of silverware and/or kitchen utensils into at least one of the plurality of open top permeable structures.

12. The method of claim 11 further comprising the steps of sensing a temperature of the body of fluid and heating the body of wash fluid.

13. The method of claim 11 further comprising the step of introducing one or more chemical additives into the body of wash fluid.

14. The method of claim 11 wherein the step of repeatedly raising and lowering the plurality of open top permeable structures within the body of wash fluid comprises varying a speed with which the repeated raising and lowering occurs.

15. The method of claim 11 further comprising the step of sensing a load in each of the plurality of open top permeable structures and providing a visual indication to the user of which of the plurality of open top permeable structures are full and which remain available for inserting a further quantity of silverware and/or kitchen utensils.

16. The method of claim 11 further comprising the steps of sensing a load in each of the plurality of open top permeable structures and providing a visual indication to the user of an overload condition in any of the plurality of open top permeable structures.

17. The method of claim 11 further comprising the steps of:

(f) determining a timed completion of the programmed cyclic sequence of vertical motions of the plurality of open top permeable structures;

(g) raising the plurality of open top permeable structures out of the body of wash fluid;

(h) removing at least a portion of the quantity of silverware and/or kitchen utensils from at least one of the plurality of open top permeable structures; and

(i) repeating the step of using the programmable controller to direct a programmed cyclic sequence of vertical motions of the plurality of open top permeable structures.

18. The method of claim 11 further comprising the steps of sensing a level of wash fluid in the open top wash tank and adding or removing wash fluid to maintain a preferred wash fluid level.

19. The method of claim 11 further comprising the steps of sensing total dissolved solids (TSD) in the wash fluid and on exceeding a preferred limit, draining the open top wash tank and refilling the open top wash tank with fresh wash fluid.

20. The method of claim 11 wherein the cyclic sequence of vertical motions further comprises a timed holding of the plurality of open top permeable structures at least partially within the body of wash fluid.