Patent Application
20140332094
In numerous industries, such as, for example only, in performing mechanical or repair services and operations in automobile service centers, manufacturing facilities, machine shops, garages and the like, there exists a need to clean component mechanical parts prior to repair, inspection, or replacement. Generally, such parts have been exposed to various contaminants such as dirt, oil, grease and the like, which must be removed for effective repair or service. In the prior art, a variety of washing devices and techniques have been used to provide the requisite cleaning of the components as needed. One such technique includes the use of a parts washer assembly in which cleaning solution is dispensed and used to wash contaminated parts.
Typical parts washers with which the subject matter of the present invention is useful are parts washers of the type described in U.S. Pat. Nos. 3,522,814, 4,049,551, 4,261,378, 5,598,861, 5,720,308, 6,874,512, 7040,161, 7,740,711, 7,875,127, and 8,016,946, each of which is incorporated by reference in its entirety herein. These patents generally describe parts washers wherein a sink is positioned atop a barrel-type reservoir and in which a submersible pump in the reservoir circulates cleaning liquid from the reservoir to the interior of a sink in which parts are disposed for washing. While the washing is being carried out, cleaning liquid continually drains from an opening in the bottom of the sink back into the reservoir.
Over the years, the most successful parts washers have been those that can be readily and economically serviced. Servicing has consisted of changing the cleaning liquid, the filter, if any, and a general machine clean-up. In use, cleaning liquid used in a parts washer becomes increasingly dirty until its ability to clean is compromised by the presence of dispersed contaminants and/or soluble oils and greases. Service may also include replacing the entire heater and/or pump module and any control mechanisms connected thereto as a result of operational failure.
The present invention involves the discovery that earlier parts washers, however successful, have several disadvantages. First, the parts washers are not easily field serviceable. If one component of the control and/or pump assembly fails, the entire unit must be replaced. For example, the pump is the source of a majority of problems related to operability. Many pump failures are the result of a failure in the electrical motor such as a short circuit. The pump and/or motor housings are usually plastic and commonly attached to a distal end of a conduit used to route power control wires for the pump motor. A metallic fitting interfaces the conduit to the pump and/or motor housing. Cracks develop in the housing at the interface as a result of pump vibrations and the surrounding environment. As a result of this disadvantage, the pump and/or motor often fails and the entire unit must be replaced. Consequently, costs to the vendor and ultimately the customer are constantly increased.
In addition, the pump assembly in earlier parts washers were housed in the tank of cleaning solution either submerged or sometimes floating in the solution. The moisture and vapors of the cleaning solution presents an environment that can accelerate the degradation of the materials of the different components and can lead to increased frequency of operational failure.
Another disadvantage of many earlier parts washers is that there is often no protection against current leakage. This disadvantage is especially true with respect to parts washers that use aqueous cleaning solutions that can conduct electricity. This situation results in an increased likelihood of injury should an operator come into contact with an energized component.
Therefore, there is a need for an improved parts washer assembly having a configuration that allows for improved serviceability that may include increased modularity. A need also exists for a parts washer assembly with a configuration that increases the operational life of the multiple elements of the parts washer assembly. A further need exists for a parts washer assembly that provides additional safety to the users thereof.
In one embodiment, a parts washer assembly containing a volume of cleaning solution and a receptacle disposed on top of a tank holding the cleaning solution may comprise a control unit disposed on top of the tank and covering a portion of an opening of the tank and a pump assembly including a motor and extension wherein the motor is located above the control unit and the extension extends into the tank of cleaning solution.
In another embodiment, the control unit of the parts washer assembly may further include at least one connection point located outside of the tank.
In another embodiment, the control unit of the parts washer assembly may also include at least one connection point located outside of the tank and a motor that is connected to the connection point.
In another embodiment, the parts washer assembly as described above also includes a ground fault interrupter (GFI) or ground fault circuit interrupter (GFCI) unit. In this embodiment the GFCI unit includes a unique electrical connector configuration complimentary to a power cord of the parts washer assembly.
In still another embodiment, the parts washer assembly described above further includes a heating assembly connected to the pump assembly.
In yet another embodiment, the control unit of the parts washer assembly further comprises a shell including a connection surface, a flange extending downward from the shell, and at least one connection point located on the connection surface. In this embodiment, the connection point is located outside the tank and the flange of the control unit extends downward into the tank.
The following disclosure as a whole may be best understood by reference to the provided detailed description when read in conjunction with the accompanying drawings, drawing description, abstract, summary, detailed description, background, and other headings, where included. Identical reference numerals when found on different figures identify the same elements of a functionally equivalent element. The elements listed in the abstract are not referenced but nevertheless refer by association to the elements of the detailed description and associated disclosure.
The present invention is not limited to the particular details of the assemblies depicted, and other modifications and applications may be contemplated. Further changes may be made in the assemblies without departing from the true spirit of the scope of the disclosure herein involved. It is intended, therefore, that the subject matter in this disclosure should be interpreted as illustrative, not in a limiting sense.
One embodiment of the present disclosure is illustrated in
In the embodiment shown in
In this embodiment, parts washer assembly 100 additionally includes receptacle 106. Receptacle 106, in one example, is a steel sink. Receptacle 106 includes upward facing walls and a bottom such that a parts cleaning chamber is defined for the placement of parts that can be cleaned within parts washer assembly 100. Receptacle 106 may also include a downward extending collar 134 that extends below the bottom of receptacle 106 and interfaces with tank 104 such that receptacle 106 is retained in position relative to tank 104. As can be appreciated by one of ordinary skill in the art, receptacle 106 may additionally include lid 108, drain and dispenser assembly. In this example, lid 108 may be connected to the upward facing walls of receptacle 106 with hinges such that lid 108 can be raised and lowered during periods of use and non-use. Drain can be used to return cleaning solution to tank 104 that is used during the cleaning of parts with cleaning solution that is dispensed from dispenser assembly.
Further mounted to lid 108, in this example, is lamp 110 and lamp control 112. Lamp 110 may be any suitable light known to one of ordinary skill in the art. In one example a conventional, incandescent light bulb with a steel housing and goose-neck arm is used but other light sources and lamp configurations may also be used. Lamp control 112 includes lamp switch 114 that can be used to activate lamp 110 and may also be connected to control unit 300 for further functionality as will be explained later.
As shown in
GFCI unit 122, in one embodiment shown in exploded view in
As shown in
GFCI unit 122 may further include rear cover 412, back plate 408, and housing 406. These components form the structure of GFCI unit 122 and can, in one example, be constructed of a plastic material of suitable characteristics as known to one or ordinary skill in the art. The rear cover 412, back plate 408, and housing 406 enclose the internal circuitry and electric components of GFCI unit 122. In one embodiment, GFCI unit 122 includes reset mechanism 410. Reset mechanism 410 is the element of GFCI unit 122 that allows a user to restore electric connection to power output 402 if GFCI unit 122 disconnects electrical current in response to the detection of leaking current. In one example, reset mechanism 410 is a push button located on the top surface of housing 406. Any suitable reset mechanism can also be used.
As shown in the embodiments in
Referring back to
Motor 202, in one embodiment, is connected to extension 204. Extension 204 is the element of pump assembly 118 that transfers the motion produced by motor 202 to an impeller. In one example, extension 204 includes a steel drive shaft that spins in response to the motion of motor 202. Support bearings may also be included in extension 204. Any suitable type of support bearings can be used such that the drive shaft is sufficiently supported such that the axis of rotation of the drive shaft does not vary and the drive shaft does not wobble. Extension 204 may also include a sheath that surrounds the drive shaft in this example. At the end of extension 204, opposite motor 202, is plenum 212 and impeller housing 208. Plenum 212, in one embodiment is a cone-shaped component that can include an outer surface and an open bottom that allows cleaning solution to be guided into the intake of pump assembly 118 for delivery to dispenser assembly 138. Plenum 212 may also include, as shown in
Pump assembly 118, in one embodiment, may also include an impeller inside impeller housing 208 at the end of extension 204 opposite motor 202. The impeller may be configured as known to one of ordinary skill the art such that its motion induces movement of cleaning solution for delivery to the dispenser assembly. The impeller is surrounded by impeller housing 208. Impeller housing 208 protects the impeller and its configuration also assists in creating the negative pressure that induces movement of the cleaning solution. The impeller impeller housing 208, and plenum 212 can be made of any suitable material as known to one of ordinary skill in the art. In one example, impeller housing 208, impeller and plenum 212 are constructed of stainless steel, however, other suitable metals, plastics, composite materials, etc. may also be used.
As discussed earlier, motor 202 of pump assembly 118, in one embodiment, is positioned above tank 104 and behind receptacle 106. Also shown in
As shown in
As shown in the embodiment of
Further included in parts washer module 102, in one embodiment, is control unit 300. Control unit 300 is configured to provide power to the other components of parts washer module 102. Control unit 300 may also provide other functionality such as controlling the operation, cycling, or activation of pump assembly 118, lamp 110, heating assembly 124 or other elements that may be connected to control unit 300. Control unit 300 may provide this functionality automatically in accordance with predetermined operating parameters or in response to input from a user. Control unit 300, in one embodiment, may include lamp module 302, pump module 306, heater module 310, and power module 314. In other embodiments, the aforementioned modules may be combined physically or functionally within control unit 300 or may also be separated, physically or functionally, to provide additional levels of control and operation of parts washer assembly 100.
In one embodiment, shown in
As described earlier, the top view of control unit 300, in one embodiment, generally follows a circular segment shape. Within this shape, control unit 300 may include one or more openings or slots 324. Slots 324 are defined by vertical walls in control unit 300 such that other elements of parts washer assembly 100 extend through control unit 300 if desired. Control unit 300 may also include retention elements by which other elements of parts washer module 102 can be removably connected to control unit 300 such as, but not limited to, pump assembly 118 and heating assembly 124 and tank 104.
Control unit 300 may additionally include, within shell 320, the electronic circuitry and other elements necessary to provide power to the elements of parts washer assembly and the desired functionality. Further to this end, control unit 300 may include lamp connection point 304, pump connection point 308, and power connection point 318. In one embodiment the connection points of control unit 300 are female plug adapters that allow the connection cords with mating male plug adapters attached thereto to be electrically connected to control unit 300. This type of configuration allows for the disconnection and re-connection of the various elements of parts washer assembly 100 from control unit 300 such that individual elements can be serviced or replaced individually. Also shown in this embodiment, lamp connection point 304, pump connection point 308, and power connection point 318 are disposed on a downward facing connection surface 326. As can be appreciated by one of ordinary skill the art and seen in
As shown in
The embodiments of control unit 300 that include separable modules or pieces provide the ability to service, replace, or update individual components of parts washer assembly 100 without the need to replace other elements. In addition, additional functionality can be added in a modular fashion depending on the needs of a user.
In addition to providing the modularity, ease of repair and increased service life of the components of parts washer assembly 100, control unit 300 additionally provides the added benefit of covering tank 104. By limiting the exposure of the volume of cleaning solution to the ambient conditions in which a parts washer assembly resides, evaporation of cleaning solution is reduced and an improvement in the air quality of a work environment is realized.
In still another embodiment as shown in
As shown in
Further included on cover plate 910, in this embodiment, is cord flange 810 and one or more rim flanges 812. Cord flange 810 can be a down-standing flange configured to substantially follow a cord of the circular top opening of tank 104. Cord flange 810 extends downward from a top surface of cover plate 910 down into tank 104 when cover plate 910 is in an installed position. Cord flange 810 provides added rigidity to cover plate 910 as well as preventing lateral movement of cover plate 910 relative to tank 104. Cover plate 910, in this embodiment, can also include one or more rim flanges 812. Rim flanges 812 can also be down-standing flanges extending downward from top surface of cover plate 910. In the embodiment shown in
Cover plate 910 may take other configurations and shapes that interface with the other components of parts washer assembly or with the other types of parts washer assemblies previously described as well as others. For example, cover plate 910 may include flanges or other surfaces that can interface with pump assembly 908 such that cover plate is connected to pump assembly 908. Cover plate 910 can be connected to pump assembly 908 via any suitable connection such as, but not limited to screws, bolts, rivets, welds, adhesive or the like. In other examples, cover plate 910 can be connected to control box 902, or heating unit 904. Connection of cover plate 910 to other components provides the benefit of preventing cover plate 910 from being dropped or from falling into tank 104. In other example alternate configurations of cover plate 910, tank 104 may be rectangular shaped and cover plate 910 can be configured to interface with this type of tank as known to one of ordinary skill in the art.
Cover plate 910 provides, among other, the advantages and benefits previously described relative to the other embodiments of control unit 300. These advantages include, but are not limited to, providing for modularity to assist in the repair and maintenance of parts washer assembly 900 as well as reducing evaporation of cleaning solution and improving the air quality of a work environment in which parts washer assembly 900 may be located.
As discussed, in one embodiment, parts washer assembly 900 may include control box 902. Control box 902 may include lamp connection point 926, pump connection point 928, power cord 930, and heating assembly output 912. As shown in this embodiment, lamp connection point 304 can be located on a bottom surface of control box 902. Pump connection point 308 can be located on a side surface of control box 902 and contiguous to pump assembly 908. Heating assembly output 912 can be a connection point but may also be, as shown in
Parts washer assembly 900, in one embodiment, may include pump assembly 908 as shown in
Further included on pump assembly 908, in this embodiment, is cage 916. Cage 916 can be configured to substantially surround motor 920 so as to protect motor 920 from damage. Also, since motor 920 can heat up during extended periods of operation, cage 916 prevents a user from touching motor 920 when it has become hot and assists in cooling the motor due to the increased surface area of cage 916. In one example, cage 916 is a cylindrically shaped element fixed in place around motor 920. Other types and shapes of cage 916, as known to one of ordinary skill in the art may also be used.
The embodiment of parts washer assembly 900, as shown in
The preceding detailed description is merely some examples and embodiments of the present disclosure and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from its spirit or scope. The preceding description, therefore, is not meant to limit the scope of the disclosure but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.
