Patent Application
20110297238
The invention generally relates to material dispensing systems. More specifically, the invention relates to methods and systems of operating and controlling material dispensing systems.
As washing machines (e.g., dish washing machines, clothes washing machines, etc.) have become more sophisticated, systems have been implemented to automatically feed such machines with detergents, sanitizers, rinse aids, and the like, which may be produced in liquid, condensed, compressed, granulated, and/or powdered form. Such materials may be automatically delivered to a variety of types of washing machines, and their concentration monitored by a permanently installed sensor. Generally, such sensors must be maintained and cleaned to ensure proper operation.
In one embodiment, a method of determining one or more operational parameters of a washing system having a wash tank to which water and material are added includes establishing a communication link between a sensor and a controller. The sensor is positioned in the wash tank and transmits a signal indicative of a material concentration to the controller, which receives the signal. The method also includes adding material to water in the wash tank, monitoring the material concentration while material is being added, and stopping the material addition upon the material concentration reaching a predetermined material concentration. Additionally, the method includes determining, by the controller, an operational parameter indicative of the amount of material that is needed to reach the predetermined material concentration.
In another embodiment, the invention provides a system for determining one or more operational parameters of a washing system having a wash tank to which water and material are added. The system includes a sensor and a dispensing device having a controller. The sensor is positioned in the wash tank and generates a signal indicative of a material concentration. The dispensing device dispenses a metered amount of material into the wash tank. The controller receives the signal from the sensor, determines the material concentration in the wash tank, and determines a correlation between the material concentration and the amount of material that is dispensed into the wash tank.
In another embodiment, a method of determining one or more operational parameters of a washing system having a wash tank to which water and material are added includes receiving, by a controller, from a sensor, a signal indicative of a material concentration in the wash tank. The method also includes supplying the wash tank with a metered amount of material, the material being added until a desired material concentration is achieved in the wash tank. Additionally, the method includes recording, by the controller, an operational parameter indicative of the amount of material required to achieve the desired material concentration.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
Embodiments of the invention relate to systems and methods of determining a quantity of material that is provided to a wash tank of a washing system. Embodiments of the invention also relate to determining a correlation between a quantity of material that is provided to a wash tank and a material concentration in the wash tank. In an embodiment, a dose (or number of doses) of material is added to the wash tank while a sensor monitors the concentration of material in the wash tank. Upon the material concentration reaching a predetermined amount, a controller determines the number of doses, and, correspondingly, the amount of material that was added to the wash tank to achieve the desired material concentration. Such data can be compiled during a training mode and used to control future washing system operations. It is to be appreciated that embodiments herein do not require the sensor to be permanently installed in the wash tank, thereby potentially reducing upkeep and maintenance associated with the sensor.
The dispensing system 100 also includes a water intake conduit 140 that is controlled by a solenoid valve 145. The water intake conduit 140 and solenoid valve 145 are utilized to introduce water into the receptacle 110. For example, in some embodiments, when the solenoid valve 145 is energized, water from the water intake conduit 140 is allowed to enter the receptacle 110. Alternatively, when the solenoid valve 145 is de-energized, water is prevented from entering the receptacle 110. In other embodiments, a valve mechanism other than the solenoid valve 145 may be used.
A water solution outlet conduit 150 is also in communication with the receptacle 110. For example, the outlet conduit 150 allows water to exit the receptacle 110. In some embodiments, as described in greater detail below, water is mixed with dispensed material prior to exiting the receptacle 110 through the outlet conduit 150. In the embodiment shown in
In some embodiments, as described in greater detail below, the dispensing system 100 can also include electronic components such as a controller and one or more conductivity sensors. For example, in one embodiment, one or more conductivity sensors are positioned in the receptacle 110 to monitor the conductivity of the receptacle 110 (and the liquid disposed therein).
As shown in
Referring to
The water supply 310 provides water to the tank 305 and the dispensing system 315. As such, the water supply 310 may have one or more associated valves (e.g., solenoid valves) to control the supply of water to the tank 305 and the dispensing system 315. In such embodiments, the valves may be controlled by the dispensing system 315 or another control system. As described in greater detail below, water may be supplied to the tank 305 to fill the tank (e.g., an initial fill operation) or to supplement water that is removed from the tank 305.
As described above, the dispensing system 315 may be configured similarly to the dispensing system 100 shown in
Generally, the controller 320 is a suitable electronic device, such as, for example, a programmable logic controller (“PLC”), a computer, a microcontroller, a microprocessor, and/or other industrial/personal computing device. As such, the controller 320 may include both hardware and software components, and is meant to broadly encompass the combination of such components. The controller 320 is responsible for executing a variety of tasks and/or processes. For example, in some embodiments, the controller 320 determines when to actuate the water supply 310 (e.g., to fill or maintain the water level in the tank), as well as when to dispense material into the tank (e.g., to attain or maintain a pre-determined material concentration in the tank). Additionally, the controller 320 can, in some embodiments, execute a training mode or process (see, for example, the process shown with respect to
To carry out the tasks and/or processes, the controller 320 can communicate with a variety of components of the washing system 300. These communications may be wired or wireless. For example, to control the water supply, the controller 320 transmits a signal to the one or more valves associated with the water supply to turn the valves on or off. Additionally, to determine when to dispense material into the tank, the controller 320 receives and processes a signal from the sensor 325 positioned in the tank (as described in greater detail below). In other embodiments, the controller 320 may also be in communication with other components of the washing system 300 (e.g., other sensors, valves, and the like) and/or with external components interfaced with the controller 320. For example, in some embodiments, the controller 320 may be in communication with a server or other storage device, allowing the controller 320 to upload and/or communicate data (e.g., operational parameters) of the washing system.
The sensor 325 is positioned in the tank 305 and transmits a signal to the controller 320 indicative of a material concentration (e.g., the material concentration of the water in the tank 305). In some embodiments, the sensor 325 is mounted permanently within the tank 305. In other embodiments, the sensor 325 may be removed from the tank 305 after use. For example, as described with respect to
The sensor 325 can be configured to measure a variety of different parameters of the tank, which can be used to determine the concentration of material in the tank. For example, in some embodiments, the sensor 325 is a conductivity sensor that measures the conductivity of the water in the tank 305. That conductivity data is then used to determine the concentration of material in the tank 305. In other embodiments, the sensor 325 may be an alternative type of sensor whose signal can be used to determine a concentration of material in the tank 305. For example, the sensor 325 may be an infra-red (“IR”) sensor, an ultraviolet (“UV”) absorber, an oxidation-reduction potential (“ORP”) sensor, or other type of sensor.
In some embodiments, the sensor 325 also includes a temperature sensing capability. For example, in addition to transmitting a signal indicative of the conductivity of the tank 305, the sensor 325 can transmit a signal that is indicative of the temperature of the tank 305. The temperature data can then be used to provide a more accurate representation of the concentration of the material in the tank 305. Additionally or alternatively, the sensor 325 (or an additional sensor) can be used to measure the relative hardness of the water being added to the tank 305.
In some embodiments, the signal (or signals) from the sensor 325 is used to determine the material concentration in the tank 305. However, in other embodiments, the water supply 310 (and associated water supply valve) can be used to determine material concentration. For example, the material concentration in the tank 305 is reduced as fresh water is added. Thus, a correlation can be determined between the amount of water that is added to the tank 305 (or a time duration that the water supply valve is active) and the resulting material concentration in the tank 305.
In some embodiments, the material being added to the wash tank 305 is a detergent. In other embodiments, however, the dispensing system 315 may be adapted to dispense more than one type of material (e.g., a detergent, a sanitizer, a rinse aid, bleach, etc.). In such embodiments, several sensors 325 may be required to measure material concentrations for each material being added.
The embodiment described with respect to
After installation of the sensor 325 and establishment of a communication link between the sensor 325 and the dispensing system 315, a training mode or learning mode can be initialized (step 415). As described in greater detail with respect to
To initialize the training mode (step 415), a user may actuate an input (e.g., a switch, knob, pushbutton, or the like) on a control panel of the dispensing system 315. Actuation of the input then transmits a signal to the controller 320, thereby alerting the controller 320 to initialize the training mode. In another embodiment, the training mode may be initialized without a prompt from a user. For example, the training mode may be initialized automatically by the controller 320 upon establishing communication with the sensor 325. Alternatively or additionally, the training mode may be initialized by the controller 320 after a predetermined time duration has expired and/or after a predetermined number of washing system cycles.
After the training mode has been initialized, operational parameters of the washing system 300 can be established and stored. For example, an amount of material (e.g., a number of material doses) that is required to attain a material concentration during an initial fresh water fill of the tank 305 can be determined (step 420) (e.g., the process of
By monitoring and storing the operational parameters of the dispensing system 315, the operational parameters can be used for future operations of the washing system 300. For example, each fresh fill and subsequent use of the washing system 300 that is carried out after the training mode has been completed can implement the same operational parameters as were stored during the training mode. More specifically, if “X” doses of material were required to achieve the desired material concentration during a fresh fill, and “Y” doses of material were required over a certain time period (or, alternatively, for a certain amount of water), then each subsequent fresh fill and operation can use “X” and “Y” doses of material without having to monitor the material concentration. This can lead to reduced cost and general upkeep of the washing system 300, because the sensor 325 is not needed after the training mode is completed. Thus, the sensor 325 does not need to be permanently installed and maintained within the washing system 300. Since the sensor is not permanently installed, more expensive and sophisticated sensors can be utilized to carry out the training mode.
In other embodiments, the operational parameters of the dispensing system 315 can be monitored and stored for use in a redundant or backup mode. For example, washing systems that include a permanently installed sensor may continually monitor the operational parameters, and not rely on stored operational parameters to operate. However, in the event of a sensor failure, the stored operational parameters can be utilized as a backup until the sensor can be repaired, replaced, or removed.
The first step in the process 500 is to set a desired material concentration level for the tank 305 of the washing system 300 (step 505). For example, a user can determine a concentration level that is required to effectively clean the articles positioned within the tank 305. The user can enter this desired concentration into the controller 320 using a user input included on the dispensing system 315. In some embodiments, step 505 is completed by an installation professional after the washing system 300 has been installed in a location. In other embodiments, step 505 can be completed manually by a washing system operator or automatically without user input.
Next, the tank 305 is filled with water (step 510) and material is dispensed into the tank 305 (step 515). In some embodiments, material is dispensed into the tank 305 using a dispensing system having a dispensing closure (such as the dispensing closure 115 shown in
After the tank 305 has achieved the desired material concentration, the conditions that produced the desired concentration are monitored and/or measured (step 530) and stored (step 535). For example, in some embodiments, the number of doses required to achieve the desired concentration are monitored and stored. Additionally, the temperature of the liquid in the tank 305 can be measured and stored. In other embodiments, the date and time that the process 500 was initialized are identified and stored. Other factors (e.g., the size of the tank 305 and/or the amount of water required to fill the tank 305, a washing system identification number, a water hardness variable, etc.) can also be monitored and stored with the material dose data.
The process 600 begins by initializing operation of the washing system 300 (step 605). Additionally, a timer is initialized (step 610). The duration of the timer may vary according to the location and intended use of the washing system 300. For example, in some embodiments, the washing system 300 is used to wash dishes in a restaurant that serves breakfast, lunch, and dinner. Accordingly, the duration of the timer may be long enough to capture the material dispensing variations associated with each of the meals. For example, relatively more material may be used to maintain the desired material concentration during peak meal times, and relatively less material may be used to maintain the material concentration during non-peak times. In other embodiments, the duration of the timer may be longer or shorter than an entire day (e.g., 1 hour, 4 hours, 8 hours, etc.). In this way, the timer can be optimized to the operational constraints of the setting in which the washing system 300 is installed (e.g., a restaurant, a cafeteria, a hotel, etc.). By employing a timer, the training mode can be automatically started and stopped without intervention by a user. In other embodiments, as described below, a user may manually start and stop the training mode. Accordingly, timer-related steps may be omitted from the process 600.
After the timer has been initialized (step 610), a check is made to verify that the timer has not yet elapsed (step 615). If the timer has not yet elapsed, the operational parameters of the washing system 300 are monitored (step 620). For example, for embodiments in which the washing system 300 is utilized as a dish washing machine (e.g., dishes are loaded into the tank 305 and washed), the material concentration of the tank 305 may be reduced due to soil being washed from the dishes and deposited in the tank 305. Additionally, fresh water may enter the tank 305 while the dishes are being rinsed, thereby reducing the material concentration. Accordingly, material may be added during operation of the washing system 300 to maintain the desired concentration level. In some embodiments, the amount of material that is added is tracked by monitoring the number of doses of material that are added. Additionally, the amount of time that passes between each material dose may be monitored.
Each of the monitored parameters (e.g., number of material doses, time between each dose, temperature of the liquid in the tank 305, water hardness in the tank, amount of water added to the tank 305, etc.) are also stored (step 625) in a memory associated with the controller 320. For example, each time that the dispensing system 315 dispenses material to achieve the desired concentration, the number of doses of material that are dispensed is stored (step 625). Additionally, the frequency at which the dispensing system 315 dispenses material is stored (step 625).
The operational parameters continue to be monitored and stored until the timer has elapsed. After the timer has elapsed, an indication can be provided that the training mode is complete (step 630). This indication may be audible or visual. For example, in some embodiments, a light included on the dispensing system 315 flashes after the training mode has been completed.
The embodiments described with respect to
Various features and embodiments of the invention are set forth in the following claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US08/75391 | 9/5/2008 | WO | 00 | 2/19/2010 |
| Number | Date | Country | |
|---|---|---|---|
| 60970632 | Sep 2007 | US |
