WO2020079023A1

WO2020079023A1 - Ware separation apparatus

Info

Publication number: WO2020079023A1
Application number: PCT/EP2019/078008
Authority: WO
Inventors: Mehmet Oktay Kaya
Original assignee: Elior Group
Priority date: 2018-10-15
Filing date: 2019-10-15
Publication date: 2020-04-23
Also published as: GB2578107A; GB201816775D0

Abstract

An apparatus for selectively transferring wares in a warewasher system is disclosed. The apparatus comprises a conveyor comprising a first conveyor part and a second conveyor part; a plurality of ware receiving stages for receiving wares from the first conveyor part, each ware receiving stage being arranged at a different respective vertical position relative to each other ware receiving stage; and means for controlling the first conveyor part. The first conveyor part is configurable in a first configuration for transferring wares from a surface of the first conveyor part to a surface of the second conveyor part in the first of the plurality of ware receiving stages; and in at least one further configuration for transferring wares to a corresponding one of the plurality of ware receiving stages. The first conveyor part is configured for rotation about an axis to move between the configurations.

Description

Ware separation apparatus

The present invention relates to a ware separation apparatus in a warewasher and has particular, although not exclusive, relevance for use as an apparatus for selectively removing wares from a conveyor.

In large kitchens such as those found in hotels or hospitals there is a need to rapidly clean very large quantities of dining ware. In these high-volume environments, it is prohibitively time consuming to wash the objects (wares) by hand, and so the process is typically automated using a warewasher system.

Warewasher systems process large numbers of objects, such as crockery or dining trays, to clean the objects of debris such as food waste, liquid waste, napkins, yoghurt pots, receipts, and the like. Objects that enter the machine are often separated into different transport lanes or storage areas. For example, this may be done so that a ware can be routed to a corresponding washing area optimised for washing that particular type of ware, or so that a particular ware may be stored in a tank for soaking. In low-capacity warewasher systems, objects may be manually separated by a user. High capacity warewasher systems on the other hand are highly complex machines able to process hundreds to thousands of objects per hour, and may separate objects automatically.

There is often a need to selectively remove wares from a transport lane, such as a conveyor, and to transport the removed wares to another area of a warewasher. This may be needed, for example, when an object is incompatible with a particular stage of a warewasher. A specialised wash stage of a warewasher may be ineffective at cleaning a particular type of ware, or there may be a risk of damage to the ware or the machinery. One possible solution to this problem is to provide a system such as a robotic arm to remove wares from the conveyor. However, such separation systems often require large amounts of space in which to operate, which is a particularly undesirable characteristic when the warewasher is installed in a kitchen environment where the available space is limited. Moreover, such systems are relatively complex, and may significantly increase the cost of the warewasher system.

The present invention seeks to provide apparatus for selectively transferring wares in a warewasher system, for addressing or at least partially ameliorating one or more of the above issues. In a first aspect the invention provides apparatus for selectively transferring wares in a warewasher system, the apparatus comprising: a conveyor comprising a first conveyor part and a second conveyor part; a plurality of ware receiving stages for receiving wares from the first conveyor part, each ware receiving stage being arranged at a different respective vertical position relative to each other ware receiving stage; and means for controlling the first conveyor part; wherein the first conveyor part has an upstream end and a downstream end, the first conveyor part being configured to receive wares at the upstream end and to transfer the received wares towards the downstream end; wherein second conveyor part forms at least part of a first of the plurality of ware receiving stages; wherein the first conveyor part is configurable: in a first configuration for transferring wares from a surface of the first conveyor part to a surface of the second conveyor part in the first of the plurality of ware receiving stages; and in at least one further configuration for transferring wares from the surface of the first conveyor part to a corresponding one of the plurality of ware receiving stages; and wherein the first conveyor part is configured for rotation about an axis, to change the angle of the surface of the first conveyor, to move between the first configuration and each at least one further configuration.

The axis may be a transverse axis located towards an upstream end of the first conveyor part.

For the at least one further configuration, the first conveyor part may be configured to rotate about the axis to form an angled surface for conveying wares downwardly to a corresponding one of the plurality of ware receiving stages.

At least one of the plurality of ware receiving stages may be located at least partially below the surface of the second conveyor part.

At least one of the plurality of ware receiving stages may be located at least partially above the surface of the second conveyor part.

The at least one further ware receiving stage may comprise a plurality of the further ware receiving stages, at least one of the plurality of the further ware receiving stages may be located at least partially below the surface of the second conveyor part, and at least one of the plurality of ware receiving stages may be located at least partially above the surface of the second conveyor part.

The at least one further ware receiving stage may comprise a storage area for storing the transferred wares. The at least one further ware receiving stage may comprise a moveable ware receiving trolley.

The at least one further ware receiving stage may comprise at least one further conveyor for receiving the transferred wares.

The first conveyor part may comprise an actuator for causing the first conveyor part to move between the first configuration and the at least one further configuration.

The control means may be configured to control a ware conveying speed or angular velocity of the first conveyor part based on a tilt of the first conveyor part.

The apparatus according may further comprise: a vision system for capturing an image of an area of the conveyor; wherein the control means may be configured to identify, based on the captured image, a ware on the surface of the conveyor to be transferred from the conveyor, and may be further configured to control the first conveyor part to transfer the identified ware.

The control means may be configured to determine a class of the identified ware, and may be further configured to control the first conveyor part to transfer the identified ware to a corresponding ware receiving area based on the determined class.

The control means may be configured to determine a class of the identified ware, and the control unit may be configured to control a ware conveying speed or angular velocity of the first conveyor part based on the determined class.

The apparatus may further comprise ware weighing means for determining a weight of a ware on the conveyor; and the control means may be configured to identify a ware to be transferred from the conveyor based on the weight of the ware.

The wares may comprise at least one of crockery, glassware, dining trays, service trays, cookware or cutlery.

Each feature disclosed in this specification (which term includes the claims) and/or shown in the drawings may be incorporated in the invention independently (or in combination with) any other disclosed and/or illustrated features. In particular but without limitation the features of any of the claims dependent from a particular independent claim may be introduced into that independent claim in any combination or individually. Embodiments of the invention will now be described, by way of example only, with reference to the attached figures in which:

Figure 1a shows a simplified schematic diagram of a ware separation system in a first configuration;

Figure 1 b shows a simplified schematic diagram of the ware separation system in a second configuration;

Figure 2 shows a simplified schematic diagram of the ware separation system in an alternative configuration;

Figure 3 shows a simplified schematic diagram of the ware separation system in a further alternative configuration; and

Figure 4 shows a simplified block diagram of a control unit.

Overview

Figure 1a shows, for illustrative purposes, a simplified schematic diagram of a ware separation system, generally at 100, in a ware conveying configuration. The ware separation system 100 comprises a conveyor 30, a ware separation stage 10 and a ware receiving area 20.

The conveyor 30 comprises a first conveyor part 1 and a second conveyor part 2. The ware separation stage 10, in this example, comprises a distributing conveyor part 1 1 that is configured for movement between a ware conveying configuration for distributing wares to the second conveyor part 2, and a ware separating configuration for distributing wares to the ware receiving area 20. The distributing conveyor part 1 1 has an upstream end, at which the distributing conveyor part 1 1 receives wares 6 from the first conveyor part 1 , and a downstream end at which the distributing conveyor part 1 1 distributes wares 6 to the second conveyor part 2 or to the ware receiving area 20, depending on its current configuration. In normal operation, the distributing conveyor part 11 , when in the ware conveying configuration, is arranged to transport wares 6 from the first conveyor part 1 to the second conveyor part 2, in the direction indicated by arrow A. Accordingly, in operation, when the ware separation system 100 is in the ware conveying configuration, a ware 6 on the surface of the first conveyor part 1 is transported onto the surface of the distributing conveyor part 1 1 , and the distributing conveyor part 1 1 transports the ware 6 to the second conveyor part 2, for subsequent transport to another area of the warewasher system.

Figure 1 b shows the ware separation system 100 in a ware separating configuration. The distributing conveyor part 1 1 is configured to pivot about an axis, at the upstream end, that is generally perpendicular to the direction of transport of the distributing conveyor part 11 , to alter the incline of the ware transporting surface of the distributing conveyor part 11. When in the ware separating configuration, the distributing conveyor part 1 1 is arranged to transport wares 6 from the first conveyor part 1 to the ware receiving area 20, in the direction indicated by arrow B. In this example, the ware receiving area 20 comprises a storage area for storing wares 6, located in the area below the distributing conveyor part 1 1 and the second conveyor part 2. Alternatively, the distributing conveyor part 1 1 , when in the ware separating configuration, may instead transport the wares 6 to another conveyor, as described in more detail later. In operation, when a ware 6 that is to be transported to the ware receiving area 20 is approaching, or on the surface of, the distributing conveyor part 1 1 , the distributing conveyor part 11 pivots downwards towards the ware receiving area 20, and the ware 6 is transported into the ware receiving area 20 by the distributing conveyor part 11.

As those skilled in the art will appreciate, movement of the distributing conveyor part 1 1 between the ware conveying configuration and ware separating configuration may be achieved using any suitable mechanics. For example, an actuator system (e.g. a pneumatic or electro-mechanical actuator or the like) may be provided, as part of the separation stage 10, that is configured for causing the distributing conveyor part 1 1 to move between the ware conveying configuration and ware separating configuration. The actuator system may, for example comprise one or more linear actuators that have a rod that moves reciprocally between an extended position and a retracted position. Such a system could be arranged beneath the distributing conveyor part 11 such that, when the rod is in the extended position it holds the conveyer in the ware conveying configuration and then, as the rod moves to the retracted position, the distributing conveyor part 1 1 moves into ware separating configuration.

In summary, therefore, a ware separation system 100 is provided comprising a conveyor 30 and a ware separation stage 10. The system 100 provides a relatively compact and inexpensive apparatus for selectively removing wares from the conveyor 30, and for distributing the wares to other conveyors or storage areas. Beneficially, the system 100 does not require the use of relatively complex and expensive machinery, such as robotic arms, to selectively remove the wares 6 from the conveyor 30. Moreover, the system 100 can be configured to make efficient use of the space above and below the conveyor 30, compared to other systems for separating wares.

Illustrative Examples

The ware separation system 100 will now be described in more detail, by way of example only, with reference to Figures 1 a to 4.

In the present example the ware separation stage 10 is controlled by a control unit 5. Figure 4 shows a simplified block diagram of the control unit 5. In this example, the control unit 5 comprises a separation stage interface 51 , a transceiver circuit 52, a controller 53 and a memory 54.

Software stored in the memory 54 includes, among other things, an operating system 55, a communication control module 56 and a ware identification module 57. It will be appreciated that whilst, for ease of understanding, the controller 53 is described as operating under the control of a number of discrete software modules, the functionality attributed to these modules may be built into the overall operating system 55 or as separate code in such a way that the modules may not be discernible as discrete entities.

The transceiver circuit 52 is operable to transmit signals to, and to receive signals from, the separation stage 10 via the separation stage interface 51. The operation of the transceiver circuit 52 is controlled by a controller 53 in accordance with the software stored in the memory 54.

The communication control module 56 controls communication with the separation stage 20. For example, the communication control module 56 may send instructions for the distributing conveyor part 1 1 to be moved into the ware separating configuration, and/or for the speed of the conveyor belt of the distributing conveyor part 11 to be decreased. The communication control module 56 may, for example, generate signals for operating one or more actuators for causing the distributing conveyor part 11 to move between the ware conveying configuration and ware separating configuration. Such signals would be sent via the separation stage interface 51. The ware identification module 56 identifies a ware 6, such as an item of crockery, that is present on the ware transporting surface of the first conveyor part 1 , and determines if that ware 6 should be transported to the ware receiving area 20. For example, the ware identification module 56 may receive, from a vision system not shown in the figures, an image of the ware transporting surface of the first conveyor part 1. The ware identification module 56 may also receive other information from sources not shown in the figures, such as information relating to a weight, size, or class of a ware that is approaching (or is already on the surface of) the distributing conveyor part 1 1. The ware identification module may determine that a ware 6 in the image is to be transported to the ware receiving area 20. It will be appreciated that the ware identification module 56 may determine whether a ware 6 should be transported to the ware receiving area 20 using any other suitable determination method, such as by using information about the weight of the ware 6.

Modifications and alternatives

An exemplary system and apparatus for selectively removing wares from a conveyor 10 has been described above in detail. As those skilled in the art will appreciate, a number of modifications and alternatives can be applied in the above examples and variations whilst still benefiting from the inventions embodied therein.

For example, Figure 2 shows an alternative configuration of the ware separation system 100 in which the distributing conveyor part 1 1 is configured to transport wares 6 to the second conveyor part 2 when in the ware conveying configuration, and is configured to transport wares 6 to either a third conveyor part 3, for transport in the direction indicated by arrow C, or to a fourth conveyor part 4, for transport in the direction indicated by arrow D, when in the ware separating configuration. Beneficially, the ware separation system 100 shown in Figure 2 provides a particularly compact apparatus for distributing wares 6 from a single transport lane (i.e. the first conveyor part 1 ) to three vertically-stacked transport lanes (i.e. the second, third and fourth conveyor parts). The provision of the vertically-stacked transport lanes downstream of the ware separation stage 10 beneficially allows the total length of the warewasher to be shortened. For example, when the vertically- stacked transport lanes transport wares 6 through a subsequent washing stage, the efficient use of the vertical space allows the length of the washing stage to be shortened, without a corresponding reduction in the capacity of the washing stage. It will be appreciated that in such a scenario, whilst a number of vertically stacked transport lanes have been described, each having a respective conveyor, one or more of the transport lanes could as an alternative to, or in addition to the conveyor, comprise a fixed storage area, or a moveable ware receiving storage trolley such as a‘dish dolly’ or the like.

It will be appreciated that in any of the examples disclosed, the storage area may comprise a moveable ware receiving storage trolley such as a‘dish dolly’ or the like.

Beneficially, the control unit 5 may control the ware distributing part 1 1 to route a ware 6 to a particular conveyor part or storage area based on a class or physical property of the ware 6, to reduce the risk of the ware becoming damaged during transportation. For example, in the arrangement shown in Figure 2, when the ware is identified as a relatively fragile item such as glassware the ware may be routed to the third conveyor part instead of the fourth conveyor part 4, since the angle (relative to the generally horizontal ware conveying configuration) of the distributing conveyor part 11 required to transport the ware 6 to the third conveyor part 3 is less than the angle required to transport the ware to the fourth conveyor part 4. Therefore, when the relatively fragile ware is transported to the third conveyor part 3 instead of the fourth conveyor part 4, the risk of the ware 6 becoming damaged by sliding or rolling down the slope of the distributing conveyor part 11 is reduced.

Beneficially, the conveyor belt speed of the distributing conveyor part 11 may be altered during operation, based on the angle (relative to the generally horizontal ware conveying configuration) or the angular velocity of the distributing conveyor part 11. For example, the conveyor belt speed of the distributing conveyor part 1 1 may be slower (compared to normal operation when the distributing conveyor part 1 1 is in the ware conveying configuration) when the distributing conveyor part 1 1 is tilted downwards towards the ware receiving area 20, to reduce the risk of a ware 6 becoming damaged when it is transported into the ware receiving area 20. This is particularly beneficial when the ware 6 is a fragile item such as crockery or glassware, as the distributing conveyor part 11 is able to provide a relatively slow controlled descent to minimise the forces exerted on the ware 6. In another example the conveyor belt speed, or alternatively the angular velocity, of the distributing conveyor part 1 1 may be altered based on a class or physical property of an identified ware 6. For example, the conveyor belt speed of the distributing conveyor part 11 may be slower when the ware 6 is identified as glassware, or the conveyor belt speed may be altered based on the weight of the identified ware 6. Whilst in the above examples the distributing conveyor part 11 has been described as pivoting downwards to transport wares 6 to the ware receiving area 20 or to the third or fourth conveyors, the distributing conveyor part 11 may also pivot upwards from the ware conveying configuration. For example, Figure 3 shows a further alternative configuration of the ware separation apparatus 10 in which the distributing conveyor part 11 is configured to pivot upwards to transport wares 6 to the third conveyor part 3, for transport in the direction indicated by arrow E, or to pivot downwards to transport wares 6 to the fourth conveyor part 4, for transport in the direction indicated by arrow F.

Although in the examples shown in Figures 2 and 3 the distributing conveyor part 11 has been described as transporting wares 6 to one of three different conveyor parts, the number of conveyor parts downstream of the distribution conveyor part 11 may alternatively be greater than or less than three.

In the above examples the ware separation system 100 has been illustrated as transporting, and selectively removing from the conveyor 30, items of crockery. However, it will be appreciated that any other suitable wares 6, such as dining trays, glassware, cookware or items of cutlery may be transported or selectively removed by the ware separation system 100.

Although in the above examples the ware separation stage 10 has been described as comprising a distributing conveyor part 1 1 having a separate ware transporting surface from the first conveyor part 1 , it will be appreciated that a single ware transporting surface (i.e. a single, continuous transport belt) may extend across the first conveyor part 1 and the distributing conveyor part 1 1.

In the above examples a particularly beneficial configuration of the ware separation stage 10, comprising the ware distributing part 1 1 , has been described that allows for a continuous, uninterrupted flow of wares 6 through the warewasher system. In contrast, when an apparatus such as a vertical, elevator-style, conveyor part is used to separate and distribute the wares, there is often a need to interrupt the movement of the first conveyor part 1 to allow the vertical conveyor part to return to a ware conveying position. Nevertheless, it will be appreciated that the ware separation stage 10 may comprise any other suitable means for separating and distributing the wares 6.

In the above examples the distributing conveyor part 1 1 has been described as moving from a ware conveying configuration to a ware separating configuration when a ware 6 is to be removed from the conveyor 30, to selectively remove wares 6 from the conveyor 30. Alternatively, the distributing conveyor part 1 1 may move from the ware separating configuration to the ware conveying configuration, to selectively transport wares 6 to the second conveyor part 2. In other words, in normal operation, the default configuration may be either the ware conveying configuration or the ware separating configuration.

Various other modifications will be apparent to those skilled in the art and will not be described in further detail here.

Claims

1. Apparatus for selectively transferring wares in a warewasher system, the apparatus comprising: a conveyor comprising a first conveyor part and a second conveyor part; a plurality of ware receiving stages for receiving wares from the first conveyor part, each ware receiving stage being arranged at a different respective vertical position relative to each other ware receiving stage; and means for controlling the first conveyor part; wherein the first conveyor part has an upstream end and a downstream end, the first conveyor part being configured to receive wares at the upstream end and to transfer the received wares towards the downstream end; wherein second conveyor part forms at least part of a first of the plurality of ware receiving stages; wherein the first conveyor part is configurable: in a first configuration for transferring wares from a surface of the first conveyor part to a surface of the second conveyor part in the first of the plurality of ware receiving stages; and in at least one further configuration for transferring wares from the surface of the first conveyor part to a corresponding one of the plurality of ware receiving stages; and wherein the first conveyor part is configured for rotation about an axis, to change the angle of the surface of the first conveyor, to move between the first configuration and each at least one further configuration.

2. The apparatus according to claim 1 , wherein the axis is a transverse axis located towards an upstream end of the first conveyor part.

3. The apparatus according to claim 1 or 2, wherein, for the at least one further configuration, the first conveyor part is configured to rotate about the axis to form an angled surface for conveying wares downwardly to a corresponding one of the plurality of ware receiving stages.

4. The apparatus according to any preceding claim wherein at least one of the plurality of ware receiving stages is located at least partially below the surface of the second conveyor part.

5. The apparatus according to any preceding claim, wherein at least one of the plurality of ware receiving stages is located at least partially above the surface of the second conveyor part.

6. The apparatus according to any preceding claim, wherein the at least one further ware receiving stage comprises a plurality of the further ware receiving stages, and wherein at least one of the plurality of the further ware receiving stages is located at least partially below the surface of the second conveyor part, and at least one of the plurality of ware receiving stages is located at least partially above the surface of the second conveyor part.

7. The apparatus according to any preceding claim, wherein the at least one further ware receiving stage comprises a storage area for storing the transferred wares.

8. The apparatus according to any preceding claim, wherein the at least one further ware receiving stage comprises a moveable ware receiving trolley.

9. The apparatus according to any preceding claim, wherein the at least one further ware receiving stage comprises at least one further conveyor for receiving the transferred wares.

10. The apparatus according to any preceding claim, wherein the first conveyor part comprises an actuator for causing the first conveyor part to move between the first configuration and the at least one further configuration.

1 1. The apparatus according to any preceding claim, wherein the control means is configured to control a ware conveying speed or angular velocity of the first conveyor part based on a tilt of the first conveyor part.

12. The apparatus according to any preceding claim, further comprising: a vision system for capturing an image of an area of the conveyor; wherein the control means is configured to identify, based on the captured image, a ware on the surface of the conveyor to be transferred from the conveyor, and is further configured to control the first conveyor part to transfer the identified ware.

13. The apparatus according to claim 12, wherein the control means is configured to determine a class of the identified ware, and is further configured to control the first conveyor part to transfer the identified ware to a corresponding ware receiving area based on the determined class.

14. The apparatus according to claim 12 or 13, wherein the control means is configured to determine a class of the identified ware, and wherein when the control unit is configured to control a ware conveying speed or angular velocity of the first conveyor part based on the determined class.

15. The apparatus according to any preceding claim, further comprising ware weighing means for determining a weight of a ware on the conveyor; and wherein the control means is configured to identify a ware to be transferred from the conveyor based on the weight of the ware.

16. The apparatus according to any preceding claim, wherein the wares comprise at least one of crockery, glassware, dining trays, service trays, cookware or cutlery.