INTELLIGENT WASH PERIOD WITH LOAD/UNLOAD ALERT AND IDLE MODE, SYSTEM AND METHODS FOR WASHING MACHINE

Abstract

The present general inventive concept relates to a condition alert and/or operator instructing system, control system and control methods for a pot and pan, or other similar washing machine. A method of washing wares in a continuous motion style washing machine is provided. A wash period is provided. A cumulative wash cycle time, of a plurality of individual wash cycles within the wash period, is monitored. The wash period is expanded or increased beyond a base period if the cumulative wash cycle time is less than a maximum cumulative wash cycle condition value. The wash period is contracted or reduced if the cumulative wash cycle time reaches a maximum cumulative wash cycle condition value during the wash period.

Description

BACKGROUND

Pot and pan washing machines, of the type used in restaurants, institutions and other eating facilities often involve a large wash tank or basin in which water or other cleaning fluid is circulated to provide a continuous motion rolling wash action for the pots and pans and other “wares” (i.e. pots, pans, utensils, flatware/silverware, etc.). One such continuous motion style pot and pan washing machine is described in U.S. Pat. No. 4,773,436 issued to Cantrell et al., the entire disclosure of which is incorporated herein by reference. The machine of Cantrell includes a wash tank with multiple jets evenly spaced apart at an elevated position along the rear wall of the wash tank. The tank is filled with fluid (i.e. water, detergent, etc.) to a level above the position of the jets. Pots and pans are placed in the wash tank, and a wash pump is activated to draw fluid from within the wash tank and direct it through the jets to create a jet stream. Each jet directs its jet stream toward the bottom wall of the wash tank, the bottom wall then deflects the jet stream upward and towards the front wall of the tank. The front wall then deflects the upward moving jet stream towards the rear wall of the tank, and the rear wall deflects the jet stream downward and back towards the front wall along the bottom wall. The combination of deflections of the jet stream from the bottom, front and rear walls provides a rolling washing action within the wash tank. Typically, the rolling wash action is continuous through the washing cycle of the machine, and wares are loaded and unloaded during the washing cycle as they are deemed clean by an operator of the machine. In this manner, multiple loads of wares are cleaned during a single washing cycle.

Although the prior art pot and pan washing machine disclosed in U.S. Pat. No. 4,773,436 provides an exceptional wash action, many of the components discussed above hinder the overall efficiency and performance of the machine. The inventions disclosed in U.S. application Ser. Nos. 09/947,484; 09/947,485; and 10/744,666, the entire disclosures of which are incorporated herein by reference, provide components that greatly increase the overall efficiency and performance of the machine, including improvements to the intake and discharge manifolds, jets, pump and system assembly methods. In addition, International Patent Application PCT/US09/59600, the entire disclosure of which is incorporated herein by reference, provides a condition warning system, control system and control methods for a pot and pan washing machine that addresses a number of disadvantages in typical condition warning systems, control systems and control methods for such machines. Notwithstanding, none of the prior art machines, systems or methods provide a simple and/or effective mechanism for quickly and easily instructing or providing guidance to the typically unskilled and/or untrained personnel (operators, crew members, etc.) that tend to operate these types of machines in commercial eating facilities. Therefore, it would be beneficial to provide a system and method that alerts operators of conditions requiring operator action and/or that easily instructs, or communicates to, the operator as to the specific action that must be taken.

In addition, prior art machines typically include a preset wash period, in which the machine will operate. After the wash period time is expired, the operator is forced to drain and refill the wash tank with clean washing fluid. This is intended to ensure that the machine is not operated once the cleaning fluid has too high of a soil load in which too much soil from items being cleaned emulsifies in the wash fluid and the fluid is no longer able to clean. In many prior art machines the wash period is either factory set, or adjustable by a machine technician within a predetermined range. The adjustable range does globally accommodate establishments of various average soil loads. For example, if one establishment typically has a higher than average soil load, the wash period can be set by the technician to be shorter, within the range. Likewise, if an establishment typically has a lower than average soil load, the wash period can be set by the technician to be longer, within the range. Nevertheless, this global setting does not allow an establishment to actively adjust the wash period to account for varying soil loads that may be encountered at different times within the establishment. For example, between noon to 6 PM an establishment may have a relatively high soil load, and a much lower soil load after 6 PM, when business is much slower. Thus, the global wash period setting may be too long and result in wash fluid that has too high of a soil load to effectively clean, during the high volume period, and may be too short and result in wash fluid that is still able to clean being prematurely drained during lower volume periods. Therefore, it would be beneficial to provide a system and method that allow for varying degrees of soil loads encountered at various times within an establishment.

SUMMARY

The present general inventive concept provides a method of washing wares in a continuous motion style washing machine. In one embodiment, the method includes the following steps. A wash pump is activated by a control system to circulate fluid within a wash tank of the washing machine during a wash period. The wash period begins with the first activation of the pump to follow the wash tank being filled with fluid. When the pump is activated, whether for the first or any subsequent time following the wash tank being filled with fluid, the control system simultaneously starts a wash cycle timer. A unload/load period is initiated when the wash cycle timer reaches a predetermined wash cycle timer condition value. A unload/load alert is initiated simultaneously with the beginning of the unload/load period. A wash cycle timer condition value is added to a cumulative wash cycle timer. The wash cycle timer is reset and restarted upon completion of the unload/load period. The steps of initiating the unload/load period (and accompanying unload/load alert) and resetting and restarting the wash cycle timer are repeated until the cumulative wash cycle timer reaches a predetermined cumulative wash cycle timer condition value. When the cumulative wash cycle timer reaches the cumulative wash cycle timer condition value, the wash pump is deactivated and locked. The wash tank is required to be drained and refilled in order to unlock and reactivate the wash pump and begin a new wash period. In some embodiments, the method further includes a step of resetting the wash cycle timer and the cumulative wash cycle timer upon initiation of the new wash period.

In some embodiments, the unload/load alert is a visual alert and/or an audible alert. In some embodiments, the visual alert includes a light connected to the control system and the light is mounted at a position and focused in a direction that illuminates a location below a washing machine operator's direct line of site and the source of illumination is outside of the operator's direct line of sight.

In some embodiments, the step of initiating a unload/load period further includes activating (for receipt of operator input) an unload/load control button connected to the control system and completing the unload/load period upon receipt of the operator input (via the unload/load control button). In some embodiments, the method further comprises starting an unload/load timer upon a first input of the active unload/load control button by an operator and completing the unload/load period upon the first to occur of: (a) a second input of the active unload/load control button by the operator, or (b) the unload/load timer meeting a predetermined unload/load timer condition value.

In some embodiments, the wash pump remains activated during the unload/load period. In other embodiments, the wash pump is deactivated or placed into an idle mode during the unload/load period. In some embodiments, the method further includes the step of deactivating the wash pump and locking out the wash pump if the cumulative wash cycle timer fails to meet a minimum cumulative wash cycle timer condition value within a predetermined period of time. In other embodiments, the method further includes the step of deactivating the wash pump and locking out the wash pump if the cumulative wash cycle timer fails to meet the cumulative wash cycle timer condition value within a predetermined maximum wash period. In some embodiments, the method further includes providing an option to delay the step of locking out operation of the wash pump for at least one additional finite time period and locking out operation of the wash pump after the at least one additional finite time period has concluded.

In another aspect, the present general inventive concept provides a method of washing wares in a continuous motion style washing machine. The method includes the following steps. A wash period is provided. A cumulative wash cycle time, which is a plurality of individual wash cycles within the wash period, is monitored. The wash period is expanded or extended if the cumulative wash cycle time is less than a maximum cumulative wash cycle condition value. The wash period is contracted or reduced if the cumulative wash cycle time reaches the maximum cumulative wash cycle condition value during the wash period.

The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

FIG. 1 is a pot and pan washing machine of an embodiment of the present general inventive concept.

FIG. 2 (FIGS. 2a and 2b) is one embodiment of operation and control logic of a control system relating to alerts and instructions for unloading and loading of the pot and pan washing machine of FIG. 1.

DETAILED DESCRIPTION

As required, a detailed description of an embodiment of the present general inventive concept is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the general inventive concept, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present general inventive concept in virtually any appropriately detailed structure.

The present general inventive concept provides a condition alert and/or operator instructing system, control system and control methods for a pot and pan, or other similar washing machine. An embodiment of the present general inventive concept is discussed herein in connection with the pot and pan washing machine, and its condition warning and control systems, disclosed in PCT/US09/59600. Nevertheless, it will be appreciated that the system and methods of the present general inventive concept may be utilized in connection with pot and pan washing machines, such as those described in any of U.S. Pat. No. 4,773,436, or U.S. application Ser. Nos. 09/947,984, 09/947,484, 10/744,666 and PCT/US09/59600, as well as with any other washing machines, or various combinations of washing machine components now known or hereinafter developed without departing from the spirit and scope of the present general inventive concept.

A method of washing wares in a continuous motion style washing machine is provided. The method includes the following steps. A wash tank of the washing machine is filled with a fluid. A fluid level sensor identifies when the fluid level in the wash tank has reached a prescribed threshold fluid level. After the fluid reaches the threshold fluid level, a wash pump is activated via a control system to circulate the fluid within the wash tank of the washing machine. A wash period timer is initiated when the wash pump is activated for the first time after satisfying the fluid level sensor. In some embodiments, the wash period timer is initiated before the wash pump is activated, for example as soon as the fluid level sensors indicate that the fluid has sufficiently drained. In some embodiments, the wash period timer is initiated after the wash pump has been activated, for example upon input from an operator via the control panel. In a preferred embodiment, the wash period timer is initiated simultaneously with the activation of the wash pump. A wash cycle and a wash cycle timer are also simultaneously initiated via the control system. When the wash cycle timer reaches a predetermined wash cycle timer condition value, the wash cycle is ended and an unload/load alert is initiated via the control system. Preferably, the predetermined wash cycle timer condition value is within the range of 10 and 30 minutes. In response to the unload/load alert, an operator initiates an unload/load period via the control system or the unload/load period is automatically initiated based on a preset condition value. Preferably, the preset condition value is in the range of 5 to 30 minutes. The unload/load period ends either manually via operator input to the control system or automatically based on a preset condition value. Preferably, the preset condition value is in the range of 5 to 30 minutes. When the unload/load period ends, a new wash cycle and wash cycle timer are initiated. Throughout the repeating wash cycles, unload/load alerts, and unload/load periods, the overall wash period timer, that is initiated when the wash pump is activated for the first time following satisfying the fluid level sensor, remains uninterrupted.

The method optionally additionally includes the step of monitoring the quality and/or various characteristics of the fluid/wash water throughout the overall wash period. In some embodiments, the quality and/or various characteristics of the wash water is monitored periodically, such as between each wash cycle. In other embodiments, the quality and/or various characteristics of the wash water is monitored continuously. Water monitors and related sensors are well known in the art and are readily available as “off-the-shelf” components. Some of the qualities and/or characteristics that may be monitored include: detergent levels, sanitizer levels, acidity-basicity (pH levels), salinity, conductivity, turbidity, viscosity, foreign particles levels, and flow rate. When the water monitor detects that the fluid quality and/or characteristic has exceeded, fallen below of, or outside an acceptable range for (depending upon the condition being monitored) a predetermined threshold condition value, the wash pump is deactivated and locked out by the control system. The wash pump can not be reactivated until the wash tank is drained, as detected by the fluid level sensor (i.e. low fluid level sensor). When the fluid level sensor detects that the wash tank has been drained, the wash pump is reset and may be reactivated after the wash tank is refilled with fluid, as detected by the fluid level sensor (i.e. high fluid level sensor). As discussed above, a new overall wash period timer is initiated when the wash pump is activated for the first time after satisfying the fluid level sensor.

The method optionally additionally includes the step of adding each of the repeating wash cycle timer condition values to a cumulative wash cycle timer. When the cumulative wash cycle timer reaches a predetermined threshold value, the wash pump is deactivated and locked out by the control system. Preferably, the predetermined threshold value is between 90 and 240 minutes. The cumulative wash cycle timer is reset when the wash tank is drained, as determined by the fluid level sensor(s), and a new overall wash period may be initiated when the wash tank is refilled, as determined by the fluid level sensor(s). In some embodiments, the method further includes a step of resetting the wash cycle timer and the cumulative wash cycle timer upon initiation of the new wash period.

In some embodiments, the unload/load alert is a visual alert and/or an audible alert. In some embodiments, the visual alert includes a light connected to the control system and the light is mounted at a position and focused in a direction that illuminates a location below a washing machine operator's direct line of site and the source of illumination is outside of the operator's direct line of sight.

In some embodiments, the step of initiating a unload/load period further includes activating, for receipt of operator input, an unload/load control button connected to the control system. The unload/load period ends upon receipt of the operator input (via the unload/load control button). In some embodiments, the method further comprises starting an unload/load timer upon a first input of the active unload/load control button by an operator and completing the unload/load period upon the first to occur of: (a) a second input of the active unload/load control button by the operator, or (b) the unload/load timer meeting a predetermined unload/load timer condition value. Preferably, predetermined unload/load timer condition value is in the range of 5 to 30 minutes.

In some embodiments, the wash pump remains activated during the unload/load period. In other embodiments, the wash pump is deactivated or placed into an idle mode during the unload/load period. In some embodiments, the method further includes the step of deactivating the wash pump and locking out the wash pump if the cumulative wash cycle timer fails to meet a cumulative wash cycle timer condition value within a predetermined maximum wash period of time. For example, the cumulative wash cycle timer condition value may be set between 90 minutes and 240 minutes and the predetermined maximum wash period of time may be set between 3 hours 40 minutes and 6 hours. If the cumulative wash cycle timer condition value is set to 90 minutes and the predetermined maximum wash period of time is set at 5 hours 45 minutes, but the cumulative wash cycle timer fails to reach 90 minutes before the predetermined maximum wash period of time reaches 5 hours 45 minutes, the control system shuts down the pump anyway, regardless of the cumulative wash cycle timer, forcing a fluid change.

In other embodiments, the method further includes the step of deactivating the wash pump and locking out the wash pump if the cumulative wash cycle timer fails to meet a minimum cumulative wash cycle timer condition value within a predetermined period of time. This prevents a situation in which operators are not utilizing the unload/load feature to maximize time between draining a refilling the wash tank. For example, the minimum cumulative wash cycle timer condition value is 90 minutes and predetermined standard wash period is 4 hours. If the cumulative wash cycle timer fails to reach 90 minutes before the wash period reaches 3 hours 45 minutes, the control system shuts down the pump anyway at 4 hours, regardless of the cumulative wash cycle timer, forcing a fluid change. In some embodiments, the method further includes providing an option to delay the step of locking out operation of the wash pump for at least one additional finite time period and locking out operation of the wash pump after the at least one additional finite time period has concluded. For example, the one additional finite time period may be 15 minutes.

In another aspect, the present general inventive concept provides a method of washing wares in a continuous motion style washing machine. The method includes the following steps. A wash period is provided, initially set at four (4) hours. A cumulative wash cycle time, which is a plurality of individual wash cycles within the wash period, is monitored. The wash period is expanded or extended if the cumulative wash cycle time is less than a maximum cumulative wash cycle condition value. The wash period is contracted or reduced if the cumulative wash cycle time reaches the maximum cumulative wash cycle condition value during the wash period. Preferably, the maximum cumulative wash cycle condition value is set between 90 minutes and 240 minutes.

Referring to FIG. 1, a pot and pan washing machine of an embodiment of the present general inventive concept is shown. In the embodiment of FIG. 1, the pot and pan washing machine utilizes the same or similar control system as is described in PCT/US09/59600. The condition warning light 15 described in PCT/US09/59600 is included in the embodiment shown in FIG. 1, shown below the control panel 10. In one embodiment, a condition warning/alert light 15 is alternatively or additionally located remotely from the washing machine, such as below a drive-through counter, or other similar location away from the washing machine.

The pot and pan washing machine in FIG. 1 includes wash tank 30, rinse tank 40, and sanitizer tank 50 connected together in a single unit via non-welded field joint 34. The unit also includes soiled end drain board 32, and clean end drain board 31 to direct fluids into wash tank 30 and sanitizer tank 50, respectively. The unit further includes backsplash 38, end splash 33 and channel rim 36. Wash tank 30 includes a plurality of jets along its rear wall which direct fluid from wash pump 20 (controlled by control system) into wash tank 30. An intake draws fluid back into wash pump 20 for continuous motion within wash tank 30. Wash tank also includes utensil basket 60 for washing utensils. In addition, wash tank 30 includes detergent injector 70 that is connected to a detergent supply system which is controlled by control system. Wash tank also includes fluid high and low sensors 80 connected to the control system to detect when the fluid level in the tank is drained below a minimum low level and raised above a minimum high level. In the embodiment shown in FIG. 1, rinse tank 40 includes a pre-rinse faucet 45 for rinsing items in the rinse sink 40. In a preferred embodiment, rinse tank 40 also includes fluid level sensors that operate in the same or similar manner as those in the wash tank 30. Sanitizer tank 50 also includes similar fluid level sensors 52, as well as a sanitizer injector 54 that is connected to a sanitizer supply system controlled by control system. The control system also controls condition warning light 15, which is mounted below control panel 10, underneath the soiled end drain board 32, and which directs light onto the floor directly below the unit. The system also optionally includes one or more instruction light 90. FIG. 1 includes five (5) instruction lights (90a, 90b, 90c, 90d, and 90e) that are located along the channel rim 36 in front of the soiled end drain board 32, wash tank 30, rinse tank 40, sanitizer tank 50, and clean end drain board 31, respectively. Each instruction light 90 includes three upward pointing arrows 93 and a button 95. In alternative embodiments, in addition to or in place of the soiled end drain board 32, the machine may include a scrapper sink or other similar feature. In further alternative embodiments, one or more of the rinse tank 40 and sanitizer tank 50 may be replaced with alternative features that provide similar functionality, such as the rinse and/or sanitizer systems disclosed in U.S. patent application Ser. No. 12/781,750, the entire disclosure of which is incorporated herein by reference.

Referring to FIG. 2 (FIGS. 2a and 2b), one embodiment of operation and control logic of a control system of the instant invention relating to alerts and instructions for unloading and loading of the pot and pan washing machine of FIG. 1 is shown. It will be appreciated that additional operation and control logic may be included in the control system in combination with that shown in FIG. 2. For example, in a preferred embodiment, the control logic includes one or more of the features discussed in PCT/US09/59600. Referring to FIG. 2, Wash Action Start and Stop buttons that are located on the control panel 10 of the pot and pan washing machine of FIG. 1 are illustrated in the flow diagram. When the Start button is pressed an Intelligent Wash Period (explained in detail in FIG. 2a) timer is initiated. In general, the Intelligent Wash Period can only be cancelled or restarted by draining and refilling the wash tank 30. Once the Intelligent Wash Period has expired, the pump 20 shuts down and within a period of 15 minutes following the end of the period can be restarted for up to five separate one-minute “mini-unload cycles” and a change wash water LED illuminates on the control panel 10 (and alert light 15 under panel) to indicate to the operator that the Intelligent Wash Period is over and the water must be changed in the wash tank 30. After the 15 minute window, the pump 20 is locked out and the fluid in the wash tank 30 must be changed. When the wash tank 30 is drained below a low level sensor 80, a new Intelligent Wash Period begins, and/or a Wash Tank Improper Fill Error clears (if applicable). As is shown in FIG. 2, after a Cumulative Wash Cycle Time reaches a preset number of minutes (adjustable between 90 and 240 minutes), or reaches 3 hours and 45 minutes if Cumulative Wash Cycle Time is less than 90 minutes after 3 hours and 45 of the Intelligent Wash Period, a Blue “Change Wash Water” LED on the control panel 10 of the machine illuminates flashing, the Standard Logic (discussed below) is canceled and the wash pump 20 of the machine restarts (if it has been stopped by the Standard Logic), or continues operating (if it has not been stopped by the Standard Logic). In addition, the condition warning light 15 under the control panel 10 turns on flashing to notify managers and crew members to perform a last unload of the wash tank 30 before the wash period ends. The flashing rate increases from slower to faster, until a period of 15 minutes prior to the end of the Intelligent Wash Period. Once 15 minutes have elapsed, or if the Stop button on the control panel 10 is pressed, the wash pump 20 shuts down, the condition warning light is turned on solid by the control system, and the blue “Change Wash Water” LED on the control LED on the control panel 10 is turned on solid by the control system, until the wash tank 30 is drained and refilled as is discussed above. If the wash tank 30 is not drained after a period of time, the system goes into an overnight deep cleaning mode, as discussed in FIG. 2a.

As is discussed in further detail in FIG. 2a, a preferred embodiment of the instant invention includes an improper fill alert to alert operators if the wash tank 30 reaches a high limit level in an amount of time that is less than a preset minimum. If the wash tank 30 reaches a high limit level in an amount of time that is less than the preset minimum an Improper Wash Tank Fill Error and a forced water change are triggered. The embodiment shown also includes a full tank alert that alerts operators as the wash tank 30 approaches a full state. Once the Wash Tank High Limit is reached, and no Fill Error has been triggered, the Start Wash Action button is active and can be pressed to initiate the Standard Logic (discussed in detail in FIG. 2a).

Sanitizer Logic (discussed in detail in FIG. 2b) is initiated upon power up of the system and is also utilized once the wash tank high limit is reached, thus any time the sanitizer tank 50 is filled, the improper fill logic, full tank alert logic, and change sanitizer alert logic will run. When the sanitizer tank 50 first begins to fill, a sanitizer tank improper fill alert timer starts as when the sanitizer water level reaches the low level sensor. Preferably, this improper fill alert timer is set at a point between 2 and 40 minutes. If the sanitizer water level reaches the high limit sensor in an amount of time that is less than the set point of the improper fill alert timer, an improper sanitizer tank fill error will be triggered. If the sanitizer water reaches the high limit sensor in an amount of time that is greater than the set point of the improper fill alert timer, no error will be triggered. If an improper sanitizer tank fill error is triggered, a water change is forced and the pump 20 shuts down and is locked out until the sanitizer water level is drained below the low level sensor.

A sanitizer tank 50 full tank alert timer also starts when the sanitizer water level reaches the low level sensor. This full tank alert timer is preferably set at a point between 2 and 40 minutes. When the full tank alert timer reaches the set point, an indicator is activated to indicate that the sanitizer tank 50 is approaching a “full” state. When the high limit sensor is reached, another indicator is activated to indicate that the sanitizer tank 50 has reached a “full” state and that immediate action is required. The sanitizer tank full tank alert indicator is cancelled by pressing the stop/idle button.

After the sanitizer tank 50 has reached a “full” state without triggering any errors, a sanitizer batch use period timer starts. Preferably, the batch use period timer is set at a point between 120 and 240 minutes. After the batch use period timer reaches its set point, an indicator is activated to indicate that the sanitizer water will be required to be changed soon. The indicator is activated for a period of time, between 10 and 30 minutes, preferably 15 minutes, after which another indicator is activated to indicate that the sanitizer batch use period is over and the sanitizer water must be changed. The pump 20 shuts down and is locked out until the sanitizer water level is drained below the low level sensor, unless the adjacent wash tank 30 has been drained. In the event that the wash tank 30 high level limit sensor 80 indicates that the wash tank 30 is not full, then the pump 20 will not shut down and lock out. When the sanitizer water level is drained below the low level sensor, the improper fill error and/or batch use period timer are also cleared and reset.

If the wash tank 30 is full and the sanitizer water is not filled within a period of time, between 10 and 30 minutes, an indicator is activated indicating that the sanitizer tank 50 must be filled immediately. Optionally, if the wash tank 30 is full and the sanitizer water is not filled within the period of time, the pump 20 is temporarily shut down and locked out until the sanitizer tank 50 reaches a “full” state.

The system includes all standard functionality and logic of the PS-200 system, available from POWER SOAK SYSTEMS, INC., and described in PS-200 documentation, the entire disclosure of which is incorporated herein by reference. The fluid heat system is active whenever the wash pump 20 is active. When the wash pump 20 is not running, the heat system is also shut down. Every new timer cancels out any previously running timer, with the exception of the intelligent wash period timer and the cumulative cycle timer, which are only cancelled out when the fluid level sensor determines that the fluid level has been drained. The stop button on the control panel 10, effectively becomes a “start idle mode” button during the intelligent wash period. The high fluid level sensor will not be read for a brief period of time, preferably five (5) minutes, after initiating idle mode. When any Full Tank Alert is active (wash tank 30, rinse tank 40, sanitizer tank 50, etc.), the stop/idle button on the control panel 10 temporarily changes functionality to a “cancel full tank alert” button. After the full tank alert is canceled by an operator selecting the stop button, the stop button returns to its normal function as a stop/idle button. In the event that multiple tanks (wash tank 30, rinse tank 40, sanitizer tank 50, etc.) simultaneously have full tank alerts, the full tank alert that started first will be cancelled first and the stop/idle button will need to be selected a subsequent time to cancel an subsequent full tank alerts, before the stop/idle button returns to normal stop/idle functionality.

Red and Blue colored alert lights 15 are located under the control panel 10 and illuminate and/or flash in sequence with the corresponding red change sanitizer indicator light and blue change wash water indicator light on the control panel 10. A green colored alert light 15 located under the control panel 10 is temporarily ceases flashing and/or sustained (solid) illumination whenever the red or blue colored alert lights are active, however, the logic continues to run. The blue colored change wash tank fluid alert light 15 and the red colored change sanitizer tank fluid alert light 15 are always dominant over the green colored unload/load alert light 15. Additionally, the blue colored change wash tank fluid alert light 15 is dominant over the red colored change sanitizer tank fluid alert light 15, when it is flashing. Unlike the alert lights below, the indicator lights on the control panel 10 continue their respective functions and messages, uninterrupted, and the logic of each function continues to run simultaneously.

Additional embodiments of operation and control logic of a control system of the present general inventive concept relating to alerts and instructions for unloading and loading of the pot and pan washing machine of FIG. 1 are provided in the following examples. It will be appreciated that additional operation and control logic may be included in the control system in combination with any of the following examples. In a preferred embodiment, the control logic includes one or more of the features discussed in PCT/US09/59600. Additionally, it will also be appreciated that the operation and control logic discussed in the examples below may each be incorporated alone, or in combination with one or more other of the examples below.

In all of the following examples, wash Action Start and Stop buttons are located on the control panel 10 of the pot and pan washing machine of FIG. 1. When the Start button is pressed, a standard wash period is initiated (as is further discussed in PCT/US09/59600). In general, the wash period, preferably four (4) hours, can only be cancelled or restarted by draining and refilling the wash tank 30. Once the wash period has expired, the pump 20 shuts down and is locked out, and a change wash water LED illuminates on the control panel 10 to indicate to the operator that the water must be changed in the wash tank 30. When the wash tank 30 is drained below a low level sensor, a new wash period begins.

Example 1

Simultaneous with the start of a 4 hour wash period, is the initiation of a unload/load alert timer by the control system. After a 20 minute period is measured by the unload/load alert timer, in which the wash pump 20 has been running, the alert light 15 (condition warning light) located under the control panel 10 shown in FIG. 1 is activated by the control system to flash. The flashing alert light 15 alerts an operator(s) of the machine that items should be unloaded/loaded in the wash tank 30. Once the alert light 15 is flashing, the control system initiates another timer, a cancel unload/load alert timer. After a 5 minute period of the cancel unload/load alert timer has expired, the control system activates a cancel unload/load alert button on the control panel 10. When the button is active, if it is depressed by an operator the unload/load alert timer is reset (and the timer restarted) and the flashing light is turned off by the control system. In the disclosed embodiment, the cancel unload/load alert button is active for a period of 10 minutes. After that time, the system goes into an idle mode in which wash action stops, heat is deactivated and the alert light 15 below the control panel 10 is illuminated solid (i.e. not flashing) by the control system. While in idle mode, pressing the start button on the control panel 10 brings the system back into the same operational state as it was after the unload/load alert reached 20 minutes (i.e. wash action and heat are reactivated, alert light flashing, cancel unload/load timer restarted at zero). Upon entering idle mode, the control system initiates an idle mode timer. After 15 minutes in idle mode, if no action is taken, the wash action and heat are reactivated by the control system and the system is brought back into the same operational state as it was after the unload/load alert reached 20 minutes (i.e. wash action and heat are reactivated, alert light flashing, cancel unload/load timer restarted at zero).

Example 2

The same unload/load process discussed in connection with Example 1 is combined with instructional steps that guide or instruct an operator (e.g. kitchen crew member) to properly unload/load the machine of FIG. 1. It will be appreciated that the steps discussed with respect to Example 2 can be used in combination with those discussed in Example 1, or can be used independent of the process of Example 1 (including, but not limited to the instruction steps of Example 2 being used in combination with the process of Example 3 discussed below).

When the unload/load alert timer reaches 20 minutes, the control system causes the alert light 15 under the control panel 10 to flash and initiates a cancel unload/load timer. At that point an instruction light 90e (in the embodiment shown in FIG. 1 the instruction light includes three illuminated and optionally flashing up arrows 93) located on the front rim of the clean drain board 31 of the machine shown in FIG. 1 is illuminated. This prompts the crew members to unload any items that are sitting on the clean drain board 31. A cancel unload clean drain board prompt button 95 (shown next to the arrow lights 93 in the embodiment of FIG. 1) begins flashing after a predetermined time has been measured by the cancel unload/load alert timer. Once that button 95 is flashing, it is “active” in that upon pressing the button 95 by a crew member, the control system causes the instruction light 90e for the clean drain board to turn off and then illuminates a similar instruction light 90d in front of the sanitizer tank 50. This instructs the crew members to unload the sanitizer tank 50. After a predetermined period of time, measured either by the cancel unload/load timer, or by a separate sub-timer, a cancel unload sanitizer tank prompt button 95 (next to the arrows 93) begins flashing and is active. Once that button 95 is pressed by a crew member, the control system turns off the sanitizer instruction light 90d and illuminates instruction lights 90b and 90c in front of the wash tank 30 and rinse tank 40, respectively. This instructs the crew members to unload the wash tank 30 and rinse the wares in the rinse tank 40. After a predetermined period of time, again measured either by the cancel unload/load timer, or by a separate sub-timer, a cancel unload wash tank and rinse ware prompt button 95 (next to the illuminated arrows 93 of either the wash tank light 90b or rinse tank light 90c) begins flashing and is active. Once one of those buttons 95 is pressed by a crew member, the control system turns off the wash tank and rinse tank instruction lights 90b and 90c and illuminates an instruction light 90a in front of the soiled drain board 32 and/or scrapper areas. This instructs crew members to pre-scrap and load soiled wares into the wash tank 30. After a predetermined period of time, again measured either by the cancel unload/load timer, or by a separate sub-timer, a cancel pre-scrap and load prompt button 95 (next to illuminated arrows 93) beings flashing and is active. Once that button 95 is pressed by a crew member, the unload/load alert timer is reset to zero and restarted for a new cycle of washing newly loaded wares.

Example 3

After a Wash Period Timer reaches 3 hours and 50 minutes (i.e. 3 hours and 50 minutes into the 4 hour wash period), a Blue “Change Wash Water” LED on the control panel 10 of the machine illuminates, the Standard Logic (discussed below) is canceled and the wash pump 20 of the machine restarts (if it has been stopped by the Standard Logic), or continues operating (if it has not been stopped by the Standard Logic). In addition, the condition warning light under the control panel 10 turns on solid (i.e. not flashing) to notify managers and crew members to perform a last unload of the wash tank 30 before the 4 hour wash period ends. Once ten minutes have elapsed, or if the Stop button on the control panel 10 is pressed, following the 3 hour 50 minutes (i.e. after the 4 hour period is completed), the wash pump 20 shuts down, the condition warning light is turned off by the control system, and the blue “Change Wash Water” LED on the control LED on the control panel 10 is operated to flash by the control system, until the wash tank 30 is drained and refilled as is discussed above.

Simultaneous with the start of a 4 hour wash period, is the initiation of the Standard Logic by the control system of the instant invention. Upon initiation, the Standard Logic of the control system initiates an unload/load alert timer, starts the wash pump 20 and activates the heat system for the wash tank 30. After a 15 minute period is measured by the unload/load alert timer, in which the wash pump 20 has been running, the alert light 15 (condition warning light), preferably located under the control panel 10 shown in FIG. 1, is activated by the control system to flash. The flashing alert light 15 alerts an operator(s) of the machine that items should be unloaded/loaded in the wash tank 30. In one embodiment, a remotely located alert light is also activated. Once the alert light 15 is flashing, the control system initiates another timer, a cancel unload/load alert timer, and simultaneously, the control system activates a cancel unload/load/idle alert button on the control panel 10. When the button is active, it is illuminated solid, and if it is depressed by an operator within 5 minutes time elapsing on the cancel unload/load alert timer, a unload/load 5 minute count down timer is initiated by the control system. Upon expiration of the 5 minute unload/load count down timer, the unload/load alert timer is reset (and the timer restarted) and the flashing alert light 15 is turned off by the control system. If the cancel unload/load/idle alert button is not pressed within 5 minutes time elapsing on the cancel unload/load alert timer, the system goes into an idle mode in which an idle mode timer is initiated, wash action stops, heat is deactivated and the alert light 15 below the control panel 10 is deactivated (turned off) by the control system. In addition, while in idle mode, the unload/load/idle button flashes quickly to indicate to an operator(s) that a “Cancel Idle Mode” is active in which pressing either the unload/load/idle button or the Start Wash Action button on the control panel 10 cancels the idle mode. When the idle mode is canceled, the control system brings the system back into the same operational state as it was after the unload/load alert reaches 15 minutes (i.e. wash action and heat are reactivated, alert light flashing, cancel unload/load timer restarted at zero and unload/load/idle button illuminated and active). Upon entering idle mode, the control system initiates an idle mode timer. After 15 minutes in idle mode, if no action is taken, the wash action and heat are reactivated by the control system and the system is brought back into the same operational state as it was after the unload/load alert reached 15 minutes (i.e. wash action and heat are reactivated, alert light flashing, cancel unload/load timer restarted at zero and unload/load/idle button illuminated and active).

Example 4

After a Wash Period Timer reaches 3 hours and 50 minutes (i.e. 3 hours and 50 minutes into the 4 hour wash period), a Blue “Change Wash Water” LED on the control panel 10 of the machine illuminates, the Standard Logic (discussed below) is canceled and the wash pump 20 of the machine restarts (if it has been stopped by the Standard Logic, or continues operating (if it has not been stopped by the Standard Logic. In addition, the condition warning light under the control panel 10 turns on solid (i.e. not flashing) to notify managers and crew members to perform a last unload of the wash tank 30 before the 4 hour wash period ends. Once ten minutes have elapsed, or if the Stop button on the control panel 10 is pressed, following the 3 hour 50 minutes (i.e. after the 4 hour period is completed), the wash pump 20 shuts down, the condition warning light is turned off by the control system, and the blue “Change Wash Water” LED on the control LED on the control panel 10 is operated to flash by the control system, until the wash tank 30 is drained and refilled as is discussed above.

Simultaneous with the start of a 4 hour wash period, is the initiation of the Standard Logic by the control system of the instant invention. Upon initiation, the Standard Logic of the control system initiates a unload/load alert timer, starts the wash pump 20 and activates the heat system for the wash tank 30 and chemical system (if applicable) to automatically dispense chemicals such as soap, sanitizer, etc. into the wash tank 30. After a 20 minute period is measured by the unload/load alert timer, in which the wash pump 20 has been running, the alert light 15 (condition warning light) located under the control panel 10 shown in FIG. 1 is activated by the control system to flash. In a preferred embodiment, the flash sequence includes three flashes and a pause. The flashing alert light 15 alerts an operator(s) of the machine that items should be unloaded/loaded in the wash tank 30. In one embodiment, a remotely located alert light is also activated to flash in a synchronized manner with the alert light 15 on the machine. Simultaneously with the activation of the alert light(s) discussed above, the control system activates a unload/load/idle alert button on the control panel 10. When the button is active, it flashes in sync with the alert light, and if it is depressed by an operator, a unload/load process 10 minute count down timer is initiated by the control system and the alert light(s) and unload/load/idle button begin a different distinctive synchronized flashing sequence. In a preferred embodiment, the flashing sequence includes a single flash followed by a single pause. Upon expiration of the 10 minute unload/load process count down timer, the unload/load alert timer is reset (and the timer restarted) and the flashing alert light(s) and flashing unload/load/idle button are turned off by the control system.

If the Stop button on the control panel 10 is pressed at any time during the Standard Logic operation, the system goes into an idle mode in which an idle mode timer is initiated, wash action stops, heat is deactivated and the alert light 15 below the control panel 10 is deactivated (turned off) by the control system. In addition, while in idle mode, the unload/load/idle button on the control panel 10 flashes quickly to indicate to an operator(s) that a “Cancel Idle Mode” is active in which pressing the unload/load/idle button or the Start Wash Action button on the control panel 10 cancels the idle mode. When the idle mode is canceled, the control system brings the system back into the same operational state as it was after the unload/load alert reaches 20 minutes (i.e. wash action and heat are reactivated, alert light flashing, unload/load/idle button flashing and active). Upon entering idle mode, the control system initiates an idle mode timer. After 15 minutes in idle mode, if no action is taken, the “Cancel Idle Mode” becomes inactive. After 30 minutes in idle mode, if no action is taken, the wash action and heat are reactivated by the control system and the system is brought back into the same operational state as it was after the unload/load alert reached 20 minutes (i.e. wash action and heat are reactivated, alert light flashing, unload/load/idle button flashing and active).

Example 5

After a Wash Period Timer reaches 3 hours and 45 minutes (i.e. 3 hours and 45 minutes into the 4 hour wash period), a Blue “Change Wash Water” LED on the control panel 10 of the machine illuminates, the Standard Logic (discussed below) is canceled and the wash pump 20 of the machine restarts (if it has been stopped by the Standard Logic), or continues operating (if it has not been stopped by the Standard Logic). In addition, the condition warning light under the control panel 10 turns on solid (i.e. not flashing) to notify managers and crew members to perform a last unload of the wash tank 30 before the 4 hour wash period ends. Once 15 minutes have elapsed, or if the Stop button on the control panel 10 is pressed, following the 3 hour 45 minutes (i.e. after the 4 hour period is completed), the wash pump 20 shuts down, the condition warning light is turned off by the control system, and the blue “Change Wash Water” LED on the control LED on the control panel 10 is operated to flash by the control system, until the wash tank 30 is drained and refilled as is discussed above.

Simultaneous with the start of a 4 hour wash period, is the initiation of the Standard Logic by the control system of the instant invention. Upon initiation, the Standard Logic of the control system initiates a unload/load alert timer (adjustable between 10, 15 and 20 minutes), starts the wash pump 20 and activates the heat system for the wash tank 30 and chemical system 70 and 54 (if applicable) to automatically dispense chemicals such as soap, sanitizer, etc. into the wash tank 30 and/or sanitizer tank 50. After a the adjustable wash cycle period measured by the unload/load alert timer is completed, in which the wash pump 20 has been running, the alert light 15 (condition warning light) located under the control panel 10 shown in FIG. 1 is activated by the control system to flash. In a preferred embodiment, the flash sequence includes three flashes and a pause. The flashing alert light 15 alerts an operator(s) of the machine that items should be unloaded/loaded in the wash tank 30. In one embodiment, a remotely located alert light is also activated to flash in a synchronized manner with the alert light 15 on the machine. Simultaneously with the activation of the alert light(s) discussed above, the control panel 10 activates a unload/load/idle alert button on the control panel 10. When the button is active, it flashes in sync with the alert light 15, and if it is depressed by an operator, a unload/load process (adjustable between 5, 10 and 15 minutes) count down timer is initiated by the control system and the alert light(s) and unload/load/idle button begin a different distinctive synchronized flashing sequence to indicate that an unload/load process is “in process”. In a preferred embodiment, the flashing sequence includes a single flash followed by a single pause. Upon expiration of the unload/load process count down timer, or if the unload/load button is pressed during the count down, the unload/load alert timer is reset (and the timer restarted) and the flashing alert light(s) and flashing unload/load/idle button are turned off by the control system.

If the Stop button on the control panel 10 is pressed at any time during the Standard Logic operation, the system goes into an idle mode in which an idle mode timer is initiated, wash action stops, heat is deactivated and the alert light 15 below the control panel 10 is deactivated (turned off) by the control system. In addition, while in idle mode, an unload/load/idle LED on the control panel 10 flashes quickly to indicate to an operator(s) that a “Cancel Idle Mode” is active in which pressing the Start Wash Action button on the control panel 10 cancels the idle mode. When the idle mode is canceled, the control system brings the system back into the same operational state as it was after the unload/load alert timer reaches the end of a wash cycle (i.e. wash action and heat are reactivated, alert light flashing, unload/load/idle button flashing and active). Upon entering idle mode, the control system initiates an idle mode timer. After a preset period (adjustable between 15, 30, 45 and 60 minutes) in idle mode, if no action is taken, the control system brings the system back into the same operational state as it was after the unload/load alert timer reaches the end of a wash cycle (i.e. wash action and heat are reactivated, alert light flashing, unload/load/idle button flashing and active).

In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described.

Although the foregoing detailed description of the present invention has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall with in the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Claims

1. A method of washing wares in a continuous motion style washing machine, said method comprising the steps of: activating a wash pump by a control system to circulate a fluid within a wash tank of the washing machine;starting by said control system a wash period when the wash pump is activated;starting by said control system a wash cycle and a wash cycle timer during said wash period;ending said wash cycle and initiating an unload/load alert via the control system when said wash cycle timer reaches a wash cycle timer condition value;initiating an unload/load period via the control system;beginning a new wash cycle during said wash period and resetting and restarting said wash cycle timer after the unload/load period is completed.

2. The method as claimed in claim 1 further comprising the step of monitoring the wash water quality during said wash period.

3. The method as claimed in claim 2 further comprising the steps of: deactivating the wash pump and locking out by said control system operation of the wash pump based upon said water quality either exceeding or falling below of a preset condition value; andrequiring draining of said wash tank prior to initiation of a new wash period.

4. The method as claimed in claim 3 wherein said step of requiring draining of said wash tank requires draining said wash tank to a level below a fluid level sensor.

5. The method as claimed in claim 3 further comprising the steps of: deactivating the wash pump and locking out by said control system operation of the wash pump based upon a cumulative wash cycle timer reaching a cumulative wash cycle timer condition value; andrequiring draining of said wash tank prior to initiation of a new wash period.

6. The method as claimed in claim 5 wherein said step of requiring draining of said wash tank requires draining said wash tank to a level below a fluid level sensor.

7. The method as claimed in claim 3 further comprising the step of deactivating the wash pump and locking out by said control system operation of the wash pump if a cumulative wash cycle timer fails to meet a minimum cumulative wash cycle timer condition value within a predetermined period of time.

8. The method as claimed in claim 1 further comprising the step of adding said wash cycle timer condition value for each wash cycle to a cumulative wash cycle timer.

9. The method as claimed in claim 8 comprising the step of ending a wash period upon said cumulative wash cycle timer meeting a predetermined condition.

10. The method as claimed in claim 1 further comprising the steps of: deactivating the wash pump and locking out by said control system operation of the wash pump based upon a cumulative wash cycle timer meeting a cumulative wash cycle timer condition value; andrequiring draining of said wash tank prior to initiation of a new wash period.

11. The method as claimed in claim 10 wherein said step of requiring draining of said wash tank requires draining said wash tank to a level below a fluid level sensor.

12. The method as claimed in claim 5 further comprising the step of deactivating the wash pump and locking out by said control system operation of the wash pump if a cumulative wash cycle timer fails to meet a minimum cumulative wash cycle timer condition value within a predetermined period of time.

13. The method as claimed in claim 1 further comprising the step of resetting said wash cycle timer and a cumulative wash cycle timer upon initiation of a new wash period.

14. The method as claimed in claim 1 wherein said unload/load alert comprises a visual alert.

15. The method as claimed in claim 14 wherein said visual alert includes a light operably connected to said control system, said light being mounted at a position and focused in a direction that illuminates a location below a washing machine operator's direct line of site and wherein a source of illumination is outside of the operator's direct line of sight.

16. The method as claimed in claim 1 wherein said unload/load alert comprises an audible alert.

17. The method as claimed in claim 1 wherein said wash pump remains activated during said unload/load period.

18. The method as claimed in claim 1 wherein said wash pump is deactivated or placed into an idle mode during said unload/load period.

19. The method as claimed in claim 18 further comprising the steps of: providing by said control system an option to delay a step of locking out operation of said wash pump for at least one finite time period; andlocking out operation of said wash pump by said control system after the at least one finite time period has concluded.

20. The method as claimed in claim 1 wherein said step of starting a wash period includes starting a wash period timer after said step of activating a wash pump.

21. The method as claimed in claim 1 wherein said wash pump is deactivated or placed into an idle mode during said wash period.

22. The method as claimed in claim 21 further comprising the steps of: providing by said control system an option to delay a step of locking out operation of said wash pump for at least one finite time period; andlocking out operation of said wash pump by said control system after the at least one finite time period has concluded.

23. The method as claimed in claim 1 further comprising the steps of: providing by said control system an option to delay a step of locking out operation of said wash pump for at least one finite time period; andlocking out operation of said wash pump by said control system after the at least one finite time period has concluded.

24. The method as claimed in claim 1 wherein said step of activating a wash pump by a control system to circulate a fluid within a wash tank of the washing machine occurs after a step of satisfying a fluid level sensor.

25. The method as claimed in claim 1 wherein said step of initiating an unload/load period via the control system is accomplished by an operator.

26. The method as claimed in claim 1 wherein said unload/load period is completed by an operator manually ending the unload/load period via an input to the control system.

27. The method as claimed in claim 1 wherein said unload/load period is completed automatically by said control system based upon a preset condition value.

28. The method as claimed in claim 1 further comprising the step of repeating said ending, initiating and beginning steps until the wash period is completed.

29. A method of washing wares in a continuous motion style washing machine, said method comprising the steps of: providing a wash period;monitoring a cumulative wash cycle time comprised of a plurality of individual wash cycles within said wash period;expanding said wash period if said cumulative wash cycle time is less than a maximum cumulative wash cycle condition value; andcontracting said wash period if said cumulative wash cycle time reaches said maximum cumulative wash cycle condition value during said wash period.

30. The method as claimed in claim 29 wherein said expanding step comprises continuing operation of a wash pump until said cumulative wash cycle time reaches said maximum cumulative wash cycle condition value.

31. The method as claimed in claim 30 wherein said expanding step further comprises the step of deactivating the wash pump if a wash period timer reaches a maximum wash period condition value.

32. The method as claimed in claim 29 wherein said contracting step comprises deactivating a wash pump when said cumulative wash cycle time reaches said maximum cumulative wash cycle condition value.

33. The method as claimed in claim 29 wherein said expanding step is not performed if said cumulative wash cycle time is less than a minimum cumulative wash cycle condition value within a predetermined period of time.