US20110114132A1

US20110114132A1 - Method for operating a ware washer and ware washer

Info

Publication number: US20110114132A1
Application number: US12/621,200
Authority: US
Inventors: Klaus Padtberg; Frank A. Bondarowicz; Alan J. Varacins; Harald Disch
Original assignee: Premark FEG LLC
Current assignee: Premark FEG LLC
Priority date: 2009-11-18
Filing date: 2009-11-18
Publication date: 2011-05-19
Also published as: WO2011062790A2; WO2011062790A3

Abstract

A ware washer, which is designed as a programmable machine or as a conveyor ware washer, has at least one pump, at least one line system connected to the pump, and at least one nozzle system connected to the line system and having at least one nozzle, a liquid being supplied at least intermittently to the at least one nozzle via the line system. A sensor device connected to a control device is provided for detecting a profile of the volumetric flow rate of the liquid in the line system and for comparing the detected flow rate profile with a predetermined flow rate profile. The control device is designed, in the event of a deviation of the detected flow rate profile from the predetermined flow rate profile, automatically either to carry out a regulating action on the operation of the ware washer as a function of the size and the time gradient of a difference between the predetermined flow rate profile and the detected flow rate profile or to issue a fault warning via an optical and/or acoustic interface or to issue a fault warning to a remote maintenance station via a remote control interface.

Description

TECHNICAL FIELD

The invention relates to a method for operating a ware washer and to a ware washer, in particular commercial dishwasher or utensil ware washer, which is designed as a programmable machine or as a conveyor ware washer.
The invention is aimed particularly at a method for operating a ware washer which is designed as a programmable machine or as a conveyor ware washer and which has at least one pump, a line system connected to the pump and at least one nozzle connected to the line system, wherein a liquid is supplied at least intermittently to the at least one nozzle via the line system while the ware washer is in operation.
Furthermore, the invention relates to a ware washer which is designed as a programmable machine or as a conveyor ware washer and which has at least one pump, a line system connected to the pump and at least one nozzle connected to the line system, wherein liquid is supplied at least intermittently to the at least one nozzle via the line system.

BACKGROUND

Programmable machines are manually loadable and unloadable ware washers. The programmable machines (called “box-type ware washers” or else “batch dish washers”) may be rack-type push-through ware washers, also called hood ware washers (“hood-type ware washers”), or front loaders (“front loader ware washers”). Front loaders may be built-under machines (“under counter machines”), table top machines (“top counter machines”) or free-standing ware washers with front loading (“free standing front loaders”).
A ware washer designed as a programmable machine usually has a treatment chamber for the cleaning of wash ware. As a rule, beneath the treatment chamber, a washing tank is arranged, in which liquid can flow out of the treatment chamber as a result of gravity. Located in the washing tank is washing liquid which is usually water, to which, if appropriate, detergent can be supplied.
Furthermore, a ware washer designed as a programmable machine has a washing system with a washing pump and with a line system connected to the washing pump and having washing nozzles. The washing liquid located in the washing tank can be conveyed from the washing pump to the washing nozzles via the line system and sprayed through the washing nozzles in the treatment chamber onto the wash ware to be cleaned. The sprayed washing liquid subsequently flows back into the washing tank.
Conveyor ware washers are, in particular, belt-type conveyor ware washers (“flight-type ware washers”) or rack-type conveyor ware washers (“rack conveyor ware washer”). Conveyor ware washers are usually employed in the commercial sector.
In contrast to programmable machines in which the wash ware to be cleaned remains at a fixed location in the machine during cleaning, in conveyor ware washers a transport of the wash ware through various treatment zones of the conveyor ware washer takes place.
A conveyor ware washer usually has at least one prewashing zone and at least one main washing zone which is arranged downstream of the prewashing zone or prewashing zones, as seen in the direction of transport of the wash ware. As a rule, at least one postwashing zone and at least one final rinse zone following the postwashing zone or postwashing zones are arranged downstream of the main washing zone or main washing zones, as seen in the direction of transport. As seen in the direction of transport, either the wash ware received directly on the conveyor belt or the wash ware held by racks usually runs in the direction of transport through an entry tunnel, the following prewashing zone or prewashing zones, main washing zone or main washing zones, postwashing zone or postwashing zones, final rinse zone or final rinse zones and a drying zone into an exit section.
Said washing zones of the conveyor ware washer are assigned in each case a washing system which has a washing pump and a line system (washing line system) which is connected to the washing pump and via which liquid is supplied to the spray nozzles of the washing zone. The washing liquid supplied to the spray nozzles is sprayed in the respective washing zone onto the wash ware which is transported by a transport device of the conveyor ware washer through the respective washing zones. Each washing zone is assigned a tank in which sprayed liquid is received and/or in which liquid for the spray nozzles of the respective zones is provided.
In the conveyor ware washers conventionally known from the prior art, final rinse liquid in the form of fresh water, which may be pure or mixed with further additives, such as, for example, rinsing agent, is sprayed onto the wash ware via the spray nozzles of the final rinse zone. At least part of the sprayed final rinse liquid is transported from zone to zone, opposite to the direction of transport of the wash ware, via a cascade system.
The sprayed final rinse liquid is captured in a tank (postwashing tank) of the postwashing zone, from which tank it is conveyed, via the washing pump of the washing system belonging to the postwashing zone, to the spray nozzles (postwashing nozzles) of the postwashing zone. Washing liquid is rinsed off from the wash ware in the postwashing zone. The liquid which in this case occurs flows into the washing tank of the at least one main washing zone which precedes the postwashing zone, as seen in the direction of transport of the wash ware. Here, the liquid is usually provided with a detergent and sprayed onto the wash ware via the nozzles (washing nozzles) of the main washing zone by means of a pump system (washing pump) belonging to the washing system of the main washing zone. In so far as no further main washing zone is provided, the liquid subsequently flows from the washing tank of the main washing zone into the prewashing tank of the prewashing zone. The liquid in the prewashing tank is sprayed onto the wash ware via the prewashing nozzles of the prewashing zone by means of a pump system belonging to the washing system of the prewashing zone, in order to remove coarse impurities from the wash ware.
Conventionally, ware washers are equipped with rinsing pumps which supply the line system of the final rinse zone with the final rinse liquid to be sprayed. This ensures, in particular, a virtually constant volume flow of the final rinse liquid in the final rinse zone. It is also conceivable, however, to utilize the on-site line pressure, for example the pressure of the fresh water supply, in order to deliver the final rinse liquid to the line system of the final rinse zone. In this last-mentioned instance, an activatable valve may be provided between the line system and the spray nozzles of the final rinse zone, so that a temporary or complete interruption in the supply of final rinse liquid to the spray nozzles can be achieved.
Irrespective of whether the ware washer is designed as a programmable machine or as a conveyor ware washer, commercial ware washers therefore usually comprise at least one pump and/or a valve which ensure/ensures a virtually constant volume flow of the washing liquid or final rinse liquid for the duration of a washing or final rinse process in the treatment chamber (in the case of programmable machines) or in the respective treatment zone (in the case of conveyor ware washers). The respective pumps and/or valves on the line system are switched on and off by means of a control device (machine control) belonging to the ware washer.
However, various operating states of the ware washer, operating errors, insufficient cleaning of the systems or an incorrect installation of washing or final rinse arms (for example, after the cleaning of these) may lead to a deviation in the defined water circulation capacity (flow rate) or to a deviation in the desired washing pressure or desired rinsing pressure or desired nozzle pressure and, consequently, to a change in the washing performance.
The desired washing pressure of commercial ware washers lies in a range of approximately 0.1 to 0.8 bar, depending on the type of machine and its size. The desired final rinse pressure of commercial ware washers is likewise dependent on the type and size of the machine, but usually lies in a range of 0.2 to 0.8 bar. The washing liquid volume flow in commercial built-under machines is approximately 100 to 200 l/min, and in belt-type conveyor ware washers is approximately 400 to 800 l/min. The circulated washing liquid volume flows of hood-type and rack-type conveyor ware washers are between these. In what are known as commercial “Batch Type Dishwasher” machines or programmable machines, a final rinse water quantity of approximately 1.5 to 3.5 l per cycle is consumed. In continuous final rinse processes, as, for example, in conveyor ware washers, the volume flow of the final rinse liquid is approximately 2 to 8 l/min.
The publication EP 1 278 449 B1 relates to a domestic ware washer which has a washing system with an intermittently activated circulation pump and with two rotating spray arms. Furthermore, to detect a fluid pressure prevailing at the pump inlet, a sensor device is provided which is connected to a control device of the ware washer and optionally to an indicator. By the fluid pressure prevailing at the pump inlet being detected, it can be ascertained whether the spray arms of the ware washer are functioning properly. In particular, it can be ascertained whether the free rotatability of the spray arms is blocked, on account of pieces of crockery in the treatment chamber. If such an instance occurs, the intermittent operation of the circulation pump is changed correspondingly so that a predetermined washing result can be achieved.
The publication WO 2004/096006 A2 relates to a ware washer with a washing liquid circuit which is provided with a pressure sensor. It is possible via the pressure sensor to detect whether the hydrostatic pressure of the washing liquid circulating in the washing liquid circuit undershoots a prefixed threshold value. This occurs, for example, when a filter provided in the washing liquid circuit becomes clogged. In such an instance, there is the risk that the wash ware to be cleaned is not treated sufficiently. In order to counteract this, it is proposed to equip the ware washer with an additional washing liquid circuit which is cut in, as required, so that the washing liquid can ultimately be sprayed onto the wash ware with a predetermined desired nozzle pressure.
A method for operating a circulation pump in a program-controlled ware washer is known from the publication DE 197 50 266 A1. The circulation pump is activated intermittently so that pressure fluctuations can be introduced into the washing liquid in a directed manner. This is intended to promote the water flow at a screen, provided in a washing liquid circuit, with the effect of screen cleaning and dirt discharge. In order to prevent the situation where the deliberately introduced instability in the pressure profile is reduced on account of a loading of the washing liquid with foam or on account of the degree of contamination of the washing liquid, there is provision for, with the aid of a pressure sensor, detecting the pressure profile in the circulated washing liquid and, in particular, the absence of pressure fluctuations or of specific measurable pressure peaks. If such an instance occurs, instability is caused in the pressure profile due to an abrupt reduction in the pump rotational speed.
The publication EP 1 008 324 A1 relates to a method for the cleaning of wash ware in a ware washer, in which washing liquid in a washing liquid circuit is sprayed onto a wash ware to be cleaned. In the washing liquid circuit, a pressure sensor is provided, via which the pressure profile of the pump pressure is detected. By means of the detected pressure profile, it is determined whether air is unintentionally sucked in by means of the circulation pump and is therefore in an unstable hydraulic state. In such an instance, the circulation pump of the ware washer is temporarily switched off or throttled.

SUMMARY

The set problem on which the present invention is based is to ascertain potential deviations in the water circulation capacity or potential deviations in the flow rate and automatically react correspondingly, in order to counteract the deviation in the water circulation capacity.
In particular, the invention is to achieve the object of providing a ware washer designed as a programmable machine or a conveyor ware washer which has a washing system with a washing pump, with a line system connected to the washing pump and with washing nozzles, potential malfunctions of the ware washer which have or may have an adverse influence on the treatment result being ascertained as early as possible. After potential malfunctions have been ascertained, countermeasures are to be automatically initiated, by means of which a deviation in the defined water circulation capacity or a change in the washing performance can be compensated as early as possible.
Furthermore, the object of specifying a corresponding method for operating such a ware washer is to be achieved.
The solution according to the invention is distinguished in that potential deviations in the volumetric flow rate are detected, using suitable flow sensors, and deviations are communicated via fault warnings to the customer or to the ware washer operator or via a remote control interface to the manufacturing company or to the competent remote maintenance system or are counteracted by means of a change of process parameters.
A suitable flow sensor is a device for sensing the rate of fluid flow. Typically a flow sensor is the sensing element used in a flow meter, or flow logger, to record the flow rate of fluids. As is true for all sensors, absolute accuracy of a measurement requires a functionality for calibration. There are various kinds of flow sensors and flow meters, including some that have a vane that is pushed by the fluid, and can drive a rotary potentiometer, or similar device.
In this case, the invention is based on the recognition that, in a situation where the desired flow rate in the line system is overshot immediately after a pump is switched on, this points to a leak in the line system. By contrast, a high overshooting of the desired flow rate is an indication of a faulty installation of the washing or final rinse arms. If the flow rate lies below the desired flow rate, this is an indicator of blockages in the lines or nozzles.
In particular, according to the invention, there is provision, with the aid of a flow sensor, for detecting the profile of the flow rate of the liquid in the line system and comparing it with a predetermined flow rate profile (the ideal desired flow rate profile, in the fault-free operation of the machine). If there is a deviation in the detected flow rate profile from the predetermined ideal flow rate profile, at least one of the following steps is selected and executed automatically as a function of the type of deviation:

- i) a regulating action is carried out on the operation of the ware washer; and/or
- ii) a fault warning is issued via an optical and/or acoustic interface of the ware washer; and/or
- iii) a warning is issued to a remote maintenance station via a remote control interface of the ware washer.

The type of deviation of the detected flow rate profile from the predetermined (ideal) flow rate profile is determined, in particular, by the answers to the following questions:

- i) does the detected flow rate profile lie below or above the ideal flow rate profile?
- ii) does the deviation in the detected flow rate profile from the predetermined (ideal) flow rate profile decrease over time or does it remain constant?
- iii) does the deviation occur only during continuous operation or is a deviation present even at the commencement of the operation of the ware washer?

In the solution according to the invention, therefore, first the type of deviation of the detected flow rate profile from the predetermined (ideal) flow rate profile is determined. Thus, a conclusion as to the cause of the deviation of the detected flow rate profile from the predetermined (ideal) flow rate profile and therefore a conclusion as to the cause of the deviation can be drawn. It is subsequently established whether the deviation, detected via the flow rate profile, may lead to a change in the washing or final rinse performance of the ware washer. Should this be the case, a check is made as to whether there is a possibility of carrying out a regulating action on the operation of the ware washer, so that the potential change in the washing or final rinse performance can be compensated.
Simultaneously with or alternatively to this, as a function of the determined cause of the deviation from the defined water circulation capacity and from in the defined desired flow rate respectively, an optical and/or acoustic fault warning is issued to the machine operator, so that the latter can undertake corresponding measures. This is the case particularly when an operating error is the cause of the deviation from the defined water circulation capacity.
If, by contrast, it is determined that the assistance of external servicing personnel is required in order to eliminate the fault, a corresponding fault warning is issued to a remote maintenance station automatically by the system via a remote control interface of the ware washer. This may be the case, for example, when an insufficient cleaning or final rinse performance of the washing or final rinse system or an incorrect installation of the washing or final rinse arms or a leak in the line system is the cause of the deviation from the defined water circulation capacity and from the defined desired pressure, respectively.
The remote maintenance of ware washers is gaining increasing importance in the support of the hardware and software of ware washers. Due to the ever greater interlinking of the control devices of ware washers via the Internet, to the set-up of in-house intranets and to conventional telecommunication pathways (ISDN, telephone), the possibilities of direct support assistance are extended. Not least because of the possibilities for making savings in travel costs and better resource utilization (personnel and technology), remote maintenance products are used in order to lower costs in businesses. Remote maintenance programs enable the servicing engineer sitting at a distance to have direct access to the control device of the ware washer to be maintained and to carry out corresponding actions.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described in more detail below with reference to the drawings in which:

FIG. 1 shows diagrammatically a ware washer, designed in the form of a programmable machine, according to a preferred embodiment of the invention;

FIG. 2 shows diagrammatically a conveyor ware washer according to a further preferred embodiment of the invention;

FIG. 3 shows diagrammatically the set-up of a washing system for a conveyor ware washer according to the invention or a ware washer according to the invention designed as a programmable machine;

FIG. 4 a to f show diagrammatic flow rate profiles to explain the principle of the detection of disturbing influences with the aid of the flow rate prevailing in the washing system; and

FIG. 5 a to f show diagrammatic flow rate profiles to explain the principle of the detection of disturbing influences with the aid of the flow rate prevailing in the final rinse system.

DETAILED DESCRIPTION

FIG. 1 shows a diagrammatic longitudinal sectional view of an example of a conveyor ware washer 50. The conveyor ware washer 50 according to the illustration in FIG. 1 has a prewashing zone 51 and a main washing zone 52 which is arranged downstream of the prewashing zone 51, as seen in the direction of transport T of the wash ware (not illustrated in FIG. 1). In the conveyor ware washer 50 illustrated in FIG. 1, a postwashing zone 53 and a final rinse zone 54 following the postwashing zone 53 are arranged downstream of the main washing zone 52, as seen in the direction of transport T. As seen in the direction of transport T, either wash ware received directly on the conveyor belt 58 or wash ware held by baskets runs in the direction of transport T through an entry tunnel 55, through the following prewashing zone 51, the main washing zone 52, the postwashing zone 53, the final rinse zone 54 and through a drying zone 56 into an exit section 57.
Said treatment zones 51, 52, 53, 54 of the conveyor ware washer 50 are assigned in each case spray nozzles 13-1, 13-2, 13-3, 13-4, via which liquid is sprayed onto the wash ware which is transported by the conveyor belt 58 through the respective treatment zones 51, 52, 53, 54. At least each washing zone (prewashing zone 51, main washing zone 52, postwashing zone 53) is assigned a tank (washing tank 14-1, 14-2, 14-3), in which sprayed liquid is received and/or in which liquid for the spray nozzles 13-1, 13-2, 13-3 of the respective zones 51, 52, 53 is provided.
The prewashing zone 51, the main washing zone 52 and the postwashing zone 53 of the conveyor ware washer 50 according to the embodiment illustrated in FIG. 1 have in each case a washing system 10-1, 10-2, 10-3. Each washing system 10-1, 10-2, 10-3 is composed of a washing pump 11-1, 11-2, 11-3, and a line system 12-1, 12-2, 12-3 connected to the washing pump 11-1, 11-2, 11-3 and of the spray nozzles 13-1, 13-2, 13-3 connected to the line system 12-1, 12-2, 12-3.
Further, a control device 20 is provided which serves (inter alia) for suitably activating the respective washing pumps 11-1, 11-2, 11-3 of the washing systems 10-1, 10-2, 10-3 during a washing process, in order at least intermittently to supply liquid via the associated line system 12-1, 12-2, 12-3 to the spray nozzles 13-1, 13-2, 13-3 of the nozzle system belonging to the respective washing system 10-1, 10-2, 10-3.
In particular, in the conveyor ware washer 50 illustrated in FIG. 1, final rinse liquid in the form of fresh water, which may be mixed with further additives, such as, for example, rinsing agent, is sprayed onto the wash ware, not illustrated in FIG. 1, via the spray nozzles 13-4 of the final rinse zone 54 which are arranged above and below the conveyor belt 58. As illustrated in FIG. 1, laterally arranged spray nozzles 13-5 may also be provided in the final rinse zone 54.
Part of the sprayed final rinse liquid is transported from zone to zone, opposite the direction of transport T of the wash ware, via a cascade system. The remaining part is conducted directly into the prewashing tank 14-1 via a valve 59 and a bypass line 100.
The sprayed final rinse liquid is captured in the tank (postwashing tank 14-3) of the postwashing zone 53, from which tank it is conveyed to the spray nozzles 13-3 (postwashing nozzles) of the postwashing zone 53 via the washing pump 11-3 belonging to the washing system 10-3 of the postwashing zone 53. Washing liquid is rinsed off from the wash ware in the postwashing zone 53. The liquid which in this case occurs flows into the washing tank 14-2 of the main washing zone 52, is usually provided with a detergent and is sprayed onto the wash ware, with the aid of a washing pump 11-2 belonging to the washing system 10-2 of the main washing zone 52, via the spray nozzles 13-2 (washing nozzles) of the washing system 10-2 belonging to the main washing zone 52.
The liquid subsequently flows from the washing tank 14-2 of the main washing zone 52 into the prewashing tank 14-1 of the prewashing zone 51. The liquid in the prewashing tank 14-1 is sprayed onto the wash ware, by means of a washing pump 11-1 belonging to the washing system 10-1 of the prewashing zone 51, via the spray nozzles 13-1 (prewashing nozzles) of the washing system 10-1 belonging to the prewashing zone 51, in order to move coarse impurities from the wash ware.
Each washing system 10-1, 10-2, 10-3 of the conveyor ware washer 50 according to FIG. 1 has a sensor device 30 connected to the control device 20. The sensor devices 30 serve for detecting a profile of the flow rate of the liquid (washing liquid) which is conveyed to the corresponding spray nozzles 13-1, 13-2, 13-3 in the respective line system 12-1, 12-2, 12-3 of the associated washing system 10-1, 10-2, 10-3 with the aid of the associated washing pump 11-1, 11-2, 11-3. The detected flow rate profile is subsequently compared with a predetermined desired flow rate profile which is filed in a storage device 21 belonging to the control device 20.
In the conveyor ware washer 50 illustrated in FIG. 1, the control device 20 is designed, in the event of a deviation of the detected flow rate profile from the predetermined flow rate profile either automatically to carry out, as a function of the size and time gradient of a difference between the predetermined flow rate profile and the detected flow rate profile, a regulating action on the washing process proceeding in the respective treatment zone 51, 52, 53, or to issue a fault warning via an optical and/or acoustic interface 22 or to issue a fault warning to a remote maintenance station via a remote control interface 23. How this takes place in particular is stated later with reference to the graphs according to FIGS. 4 a to 4 f.
FIG. 2 illustrates a diagrammatic longitudinal sectional view of a ware washer 40 designed in the form of a programmable machine. The ware washer 40 designed as a programmable machine has a treatment chamber 41 for the cleaning and final rinse of wash ware, not illustrated in FIG. 2. Beneath the treatment chamber 41, a tank 14-4 is arranged, in which liquid can flow back out of the treatment chamber 41 as a result of gravity. The tank 14-4 may be covered at the transition to the treatment chamber 41 with the aid of a screen, not illustrated in FIG. 2.
In the tank 14-4, liquid is located, which is usually water, to which, if appropriate, detergent or rinsing agent can be supplied automatically in a controlled way by a detergent or rinsing agent metering device, not illustrated in FIG. 2. The liquid can be conveyed via a line system 12-5 to washing nozzles 13-7 by a washing pump 11-5 belonging to a washing system 10-4 of the ware washer 40 and can be sprayed through these washing nozzles 13-7 in the treatment chamber 41 onto the wash ware to be cleaned. The sprayed liquid subsequently flows back into the tank 14-4. A discharge line 42 with a drain pump 43 may be connected to the lower end of the tank 14-4, in order to empty the tank 14-4, as required.
Like the conveyor ware washer 50 illustrated in FIG. 1, the ware washer 40 according to FIG. 2, designed as a programmable machine, has, furthermore, a control device 20. This control device 20 serves (inter alia) for suitably activating the washing pump 11-5 of the washing system 10-4 while the ware washer is in operation, in order at least temporarily to supply liquid to the washing nozzles 13-7 via the line system 12-5.
Furthermore, the washing system 10-4 of the ware washer 40 according to FIG. 2, designed as a programmable machine, has a sensor device 30 connected to the control device 20. As in the conveyor ware washer 50 according to the illustration in FIG. 1, the sensor device 30 serves for detecting a profile of the hydrostatic flow rate of the liquid (washing liquid) which is conveyed to the washing nozzles 13-7 in the line system 12-5 of the washing system 10-4 with the aid of the washing pump 11-5. Likewise, in the embodiment according to FIG. 2, the detected flow rate profile is subsequently compared with a predetermined desired flow rate profile which is filed in the storage device 21 belonging to the control device 20.
In functional terms, the control device 20 provided in the ware washer 40 according to FIG. 2, designed as a programmable machine, is identical to the control device which is used in the conveyor ware washer 50 according to FIG. 1. For this reason, there is no need at this juncture for a detailed description of the functioning of the control device 20. Instead, reference is made in this regard to the following statements relating to FIGS. 3 and 4.
It remains to be stated that both the ware washer 40 according to FIG. 2, designed as a programmable machine, and the conveyor ware washer 50 according to FIG. 1 in each case have at least one washing system, also designated below simply as the “washing system 10”, which comprises an associated washing pump (also designated below simply as the “washing pump 11”), an associated line system (also designated below simply as the “line system 12”) connected to the washing pump 11, and also associated washing nozzles (also designated below simply as the “washing nozzles 13”) connected to the line system 12 and integrated in washing arms 15-1 and 15-2. In the ware washer 40 according to FIG. 2, designed as a programmable machine, the washing system 10-4 is based on the washing pump 11-5, the washing line system 12-5 and the washing nozzles 13-7. In the conveyor ware washer 50 according to FIG. 1, at least the prewashing zone 51, the main washing zone 52 and the postwashing zone 53 are provided in each case with a corresponding washing system 10-1, 10-2, 10-3. These washing systems 10-1, 10-2, 10-3 have in each case a washing pump 11-1, 11-2, 11-3, a line system 12-1, 12-2, 12-3 connected to the washing pump 11-1, 11-2, 11-3, and spray nozzles 13-1, 13-2, 13-3 connected to the line system 12-1, 12-2, 12-3 and designated below as “washing nozzles 13”.
FIG. 3 illustrates a detailed and diagrammatic view of a preferred embodiment of a washing system 10 which may be used, for example, in the conveyor ware washer 50 illustrated in FIG. 1 or in the ware washer 40 illustrated in FIG. 2 and designed as a programmable machine.
In the washing system 10 according to FIG. 3, liquid (washing liquid) is routed in a circuit by a washing pump 11 from a tank 14 via a line system 12 to washing nozzles 13 which are installed in upper and lower washing arms 15-1, 15-2. In a ware washer (for example, according to FIG. 2) designed as a programmable machine, the washing arms 15-1, 15-2 having the washing nozzles 13 are arranged in the treatment chamber 41 shown in FIG. 2, so that the washing liquid can be conveyed out of the tank 14 via the line system 12 to the washing nozzles 13 by the washing pump 11 and sprayed through the washing nozzles 13 in the treatment chamber onto the wash ware to be cleaned (cf. FIG. 2).
In a conveyor ware washer 50 (for example, according to FIG. 1), the washing system 10 illustrated in FIG. 3 may be provided in at least one of the respective washing zones (prewashing zone 51, main washing zone 52, postwashing zone 53). It is, of course, also conceivable not (only) to use the washing system 10 according to FIG. 3 in one of the washing zones 51, 52, 53, but also in the final rinse zone 54 of the conveyor ware washer 50.
Regardless of the question of in which of the respective treatment zones of a conveyor ware washer the washing system 10 according to the illustration in FIG. 3 is used, in the conveyor ware washer, and also in the ware washer designed as a programmable machine, the washing liquid is sprayed through the washing tank 14 onto the wash ware via the washing nozzles 13 with the aid of the washing pump 11.
In contrast to a ware washer 40 (cf. FIG. 2) designed as a programmable machine, by contrast, in a conveyor ware washer the sprayed washing liquid, after being sprayed, does not, or at least does not completely, flow back into the washing tank 14 of the associated washing system 10. Instead, as already indicated, conveyor ware washers are usually equipped with a cascade system, via which at least part of the sprayed washing liquid is transported from treatment zone to treatment zone opposite to the direction of transport T of the wash ware. The remaining part of the sprayed washing liquid may be conducted directly into the prewashing tank 14-1, for example, via a valve 59 and a bypass line 100 (cf. FIG. 1).
The washing system 10 illustrated in FIG. 3 has at least one flow sensor 31 which belongs to the sensor device 30 already mentioned and which is arranged either at the outlet of the washing pump 11 (cf. ref. 1), upstream of the washing arms 15-1, 15-2 in a line system 12 (cf. ref. 2), between two washing arms 15-1, 15-2 in a line system 12 (cf. ref. 3) or in the washing arms 15-1, 15-2 themselves in the immediate vicinity of the washing nozzles 13 (cf. ref. 4 and ref. 5). The at least one flow sensor 31 is designed to detect the profile of the volumetric flow rate Q_Iin the washing liquid. The flow rate Q_Ito be detected by the flow sensor 31 is generated in the line system 12 when the washing pump 11 is activated during the washing process, in order preferably to ensure a virtually constant water circulation capacity.
The washing pump 11 of the washing system 10 illustrated in FIG. 3 is switched on and off via a control device 20, illustrated in FIG. 1 or FIG. 2, of the ware washer 40, 50 (cf. FIGS. 1 and 2). Furthermore, with the aid of the control device 20, the rotational speed of the washing pump 11 of the washing system 10 and therefore the water circulation capacity can advantageously be set.
As already indicated, the at least one flow sensor 31 of the washing system 10 belongs to a sensor device 30 which is connected to the control device 20. With the aid of the control device 20, the profile, detected by the flow sensor 31, of the flow rate Q_Iin the washing liquid is supplied to the control device 20.
FIG. 4 a illustrates in a diagrammatic and idealized way an “ideal” (desired) flow rate profile Q_Swhich is detected by means of the sensor device 30 and which is generated in the washing system 10 during fault-free operation of the ware washer 40, 50.
The switch-on of the washing pump 11, for example on commencement of the washing process, takes place at a time point t₀in the illustration according to FIG. 4 a. The desired flow rate Q_Sis a volumetric flow rate which is fixed for a selected operating state of the ware washer 40, 50 and at which the washing performance required for the operating state of the ware washer 40, 50 is achieved.
As illustrated in FIG. 4 a, in fault-free operation of the ware washer 40, 50 the flow rate Q_Iof the washing liquid in the washing system 10 has adjusted out after the time t₁at the desired flow rate Q_Sfixed for the set treatment program. If the flow rate detected by means of the at least one flow sensor 31 of the sensor device 30 does not deviate from the desired flow rate Q_Sover a time interval Δt₁, then there are no machine-side problems.
The (first) time interval Δt₁serves, in the embodiment illustrated in FIG. 4, as a time window for determining whether a fault-free operation of the ware washer 40, 50 is present or not. Within the first time interval Δt₁, the flow rate Q_Iin the washing system 10 is measured continuously with the aid of the at least one flow sensor 31. It is also conceivable, however, that, within the time interval Δt₁, the hydrostatic flow rate Q_Iis measured by predetermined time points or events, and the measured flow rate values are subsequently interpolated, in order to obtain a profile of the flow rate in the time interval Δt₁.
Preferably, the time interval Δt₁has a set length, which may be a predetermined or predeterminable (e.g., manufacturer, service person or operator programmable or settable) length, the start of the time interval Δt₁being fixed by a time point t₁at which the washing pump 11 is switched on or activated during the washing process in such a way that the washing liquid is supplied to the at least one washing nozzle 13 via the line system 12. As illustrated in FIG. 4 a, the start of the time interval Δt₁lies at a time point t₁directly after the expiry of an adjustment time of the flow rate Q_Igenerated in the line system 12 after the switch-on of the washing pump 11. However, it is, of course, also conceivable to select the start of the time interval Δt₁at another time point.
The ideal flow rate Q_Sto be expected in fault-free operation of the ware washer 40, 50 is filed in the control device 20 of the ware washer 40, 50, specifically preferably for each treatment program of the ware washer 40, 50, if different treatment programs are provided for this and if different water circulation capacities and desired flow rates are required for the washing processes of the respective treatment programs, respectively. It is, of course, also conceivable, however, that the ideal flow rate profiles Q_Sto be expected in fault-free operation of the ware washer are not filed in the control device 20 itself, but in a storage device 21 connected to the control device 20, in which case the control device 20 can have access to the storage device 21, as required, in order to read out the flow rate profile Q_Sideal for the washing process to be carried out.
The ideal flow rate profile Q_Sin the washing system 10 which is to be expected in fault-free operation of the ware washer 40, 50 is preferably filed previously in the control device 20 or storage device 21. It is, of course, also conceivable, however, that the ideal flow rate profile Q_Sis a flow rate profile which has been detected by the sensor device 30 during an earlier washing process and filed in the control device 20 or in the storage device 21. The advantage of this alternative is that, with the aid of the solution according to the invention, it is possible to detect whether or not a particularly slowly occurring deviation of the detected flow rate profile arises in the course of time, as seen over a plurality of washing processes, and this may serve as an indicator of, for example, the degree of contamination of the washing nozzles 13 or as an indicator of the degree of contamination of a filter device provided, if appropriate, in the washing system.
After the flow rate profile Q_Idetected over the time interval Δt₁by the sensor device 30 has been supplied to the control device 20, a comparison takes place between the detected flow rate profile Q_Iand the ideal flow rate profile Q_Swhich is filed, for example, in the control device 20 and which is to be expected in fault-free operation of the ware washer 40, 50. If a deviation of the detected flow rate profile Q_Ifrom the expected flow rate profile Q_Sarises, an analysis of the deviation takes place automatically in order to determine the cause of this and to bring about appropriate countermeasures.
It must be remembered, in this case, that, in determining whether a deviation from the ideal flow rate profile Q_Sis present or not, a certain deviation range has to be taken into account. Preferably, in this case, the control device 20 should be designed in such a way that it finds a deviation from the ideal flow rate profile Q_Sand therefore an operation of the ware washer 40, 50 which is not fault-free, only when the deviation of the detected flow rate profile Q_Ifrom the predetermined flow rate profile Q_Sovershoots or undershoots a predetermined or predeterminable (e.g., manufacturer, service person or operator programmable or settable) threshold value S₀.
It is, of course, also conceivable that the flow rate profile Q_Idetected by the sensor device 30 is averaged, filtered, smoothed or otherwise processed before comparison with the predetermined (ideal) flow rate profile Q_S.
In the evaluation of the detected flow rate profile Q_I, and particularly in the comparison of the detected (and, if appropriate, processed) flow rate profile Q_Iwith the predetermined ideal flow rate profile Q_S, it is determined whether a deviation from the ideal flow rate profile Q_Sis present or not. However, the present invention is not restricted only to ascertaining the deviation from the ideal flow rate profile Q_S; on the contrary, according to the invention, there is provision, in the presence of a deviation of the detected flow rate profile Q_Ifrom the predetermined flow rate profile Q_S, for evaluating the type of deviation so that a conclusion as to the disturbing influence responsible for this deviation can be drawn. In the embodiment illustrated, the type of deviation of the detected flow rate profile Q_Ifrom the ideal flow rate profile Q_Sis to be understood as being, in particular, the size and time gradient of a difference between the predetermined flow rate profile Q_S(as minuend) and the detected flow rate profile Q_I(as subtrahend). In particular, not only is the amount of the deviation relevant, but also the question as to whether the detected flow rate Q_Iis higher than or lower than the predetermined flow rate Q_S, and how the time behaviour of the flow rate profile Q_Iappears.
It is described in detail below, with reference to the illustrations according to FIGS. 4 a to 4 f, how, in a preferred embodiment of the invention, a conclusion can be drawn as to different disturbing influences on the basis of the type of deviation of the detected flow rate profile Q_Ifrom the ideal flow rate profile Q_Sillustrated, for example, in FIG. 4 a. In this case, FIGS. 4 a to 4 f illustrate in a diagrammatic and idealized way flow rate profiles which have been detected with the aid of the sensor device 30 in a preferred embodiment of the invention.
In this case, it must be remembered that, in the illustrations according to FIGS. 4 b to 4 d, the time interval Δt₁(first time interval Δt₁) serves as a time window for detecting the actual flow rate profile Q_I. In the case of the flow rate profiles Q_Iillustrated, the first time interval Δt₁commences at the time point t₁immediately after the expiry of an adjustment time of the flow rate generated in the line system 12 by the washing pump 11 being switched on. The end of the first time interval Δt₁is defined by the time point t₂. The time point t₂is preferably selected in such a way that a sufficient number of flow rate measurements can be carried out in the first time interval Δt₁so that reliable evidence of the flow rate Q_Iactually prevailing in the washing system 10 can be obtained. The time point t₂depends, in particular, on the sensing rate achievable by the sensor device 30 or the at least one flow sensor 31 and on the accuracy desired for the detected flow rate profile Q_I.
As already indicated, the graph according to FIG. 4 a illustrates the flow rate profile Q_S, such as can be expected in fault-free operation of the washing system 10. This flow arte profile Q_Sconstitutes the ideal or predetermined flow rate profile. A deviation from this arises when a fault occurs during operation, that is to say during the washing phase in the washing system 10. In the graphs according to FIGS. 4 b to 4 f, the ideal desired flow rate profile Q_Sis illustrated once again as a dashed curve profile for clearer understanding.
The basic flow rate profile Q_Iillustrated in the graph according to FIG. 4 b is a flow rate profile which is detected with the aid of the sensor device 30 when a minor leak is present in the washing system 10. As illustrated, in the time window (first time interval Δt₁) taken into account, the detected flow rate Q_Iin the washing system 10 lies slightly above the desired flow rate Q_S. In the instance illustrated in FIG. 4 b, that is to say when the detected flow rate profile Q_Ilies continuously below the predetermined flow rate profile within the time window (first time interval Δt₁) to be taken into account, and when the amount of the difference between the predetermined flow rate profile Q_Sand the detected flow rate profile Q_Ilies continuously within a range between a first fixed threshold value S₁and a second fixed threshold value S₂, a minor leak in the washing system 10 is concluded automatically with the aid of the control device 20. In this case, a corresponding fault warning is generated automatically by the control device 20 and is issued via the optical and/or acoustic interface 22 of the ware washer 40, 50, in order to draw the attention of the operator of the ware washer 40, 50 to the (minor) leak in the washing system 10.
Alternatively or additionally to this, it is conceivable that the control device 20 also automatically generates a corresponding fault warning and communicates this directly to a remote maintenance station (remote maintenance service) via the remote control interface 23 of the ware washer 40, 50.
As a reaction to the fault warning issued via the optical/acoustic interface 22 and/or via the remote control interface 23, appropriate measures can then be introduced by the ware washer operator or the remote maintenance station in order to compensate the effect of the detected leak on the washing performance of the ware washer 40, 50.
The graph according to the illustration in FIG. 4 c is a basic flow rate profile Q_Iwhich occurs in the event of a major leak in the washing system 10 or in the event of incorrect or neglected installation of the washing arms 15-1, 15-2 or in the event of an absence of washing arm cleaning caps. As illustrated in FIG. 4 c, during the time window (first time interval Δt₁) to be taken into account, only a relatively high flow rate is generated in the washing system 10, which lies below the second threshold value S₂and well above the desired flow rate Q_Sand does not approach the desired flow rate Q_Sover the time interval Δt₁.
In this case, that is to say when the detected flow rate value lies continuously above the predetermined flow rate profile Q_Sand the amount of the difference between the predetermined flow rate profile Q_Sand the detected flow rate profile Q_Iis continuously greater than the second fixed threshold value S₂, a major leak in the washing system 10 is concluded automatically by the control device 20 and a corresponding fault warning is issued preferably via the optical and/or acoustic interface 22 of the ware washer 40, 50 in order to draw the attention of the operator of the ware washer 40, 50 to a major leak in the washing system 10.
So that a differentiation can be made as to whether the washing flow rate deviation in the washing system detected in the scenario according to FIG. 4 c is the result of a leak or the result of an incorrect installation of at least one of the washing arms 15-1, 15-2 or the result of the absence of washing arm cleaning caps, it is basically conceivable to provide suitable washing arm position sensors, via which corresponding warnings are issued if at least one of the washing arms 15-1, 15-2 is installed incorrectly or if washing arm cleaning caps are absent. In this development, a major leak in the washing system 10 is present when the detected flow rate profile Q_Ilies continuously above the predetermined flow rate profile Q_Swithin the first time interval Δt_Iand the amount of the difference between the predetermined flow rate profile Q_Sand the detected flow rate profile Q_Iis continuously greater than the second fixed threshold value S₂, and when the washing arm position sensors issue no fault warning.
The graph according to the illustration in FIG. 4 d shows in a diagrammatic and idealized way the basic flow rate profile Q_Iwhich is established in the washing system 10 when one or more clogged washing nozzles 13 are present. As illustrated in FIG. 4 d, in the event of such a fault the flow rate Q_Iin the washing system 10 lies continuously below the desired flow rate Q_Sduring the time window Δt_Ito be taken into account.
In this case, that is to say when the detected flow rate profile Q_Ilies continuously below the predetermined flow rate profile Q_Sand the amount of the difference between the predetermined flow rate profile Q_Sand the detected flow rate profile Q_Iis continuously greater than a fixed threshold value S₀characteristic of the presence of a deviation, the presence of a blockage in the washing system 10 is concluded automatically by the control device 20. Consequently, a corresponding fault warning is issued automatically, preferably via the optical and/or acoustic interface 22, in order to indicate to the operator of the ware washer 40, 50 that, for example, at least one washing nozzle 13 has to be cleaned.
It is conceivable in this case, that evidence as to the degree of blockage or the number of nozzles to be cleaned can also be obtained by means of the amount of the deviation of the detected flow rate profile Q_Ifrom the predetermined flow rate profile Q_S.
The invention is not restricted only to evaluating the detected (actual) flow rate profile Q_Iin the washing system 10 by means of a predetermined (ideal) flow rate profile Q_Sat the commencement of the washing process, that is to say within the first time interval Δt_I, so that conclusions as to possible disturbing influences can be drawn. On the contrary, the solution according to the invention also covers the detection and evaluation of the actual flow rate profile Q_Iduring a second time interval Δt₂. The second time interval Δt₂may lie in any desired range during the washing process.
In the illustrations according to 4 a to 4 f, therefore, the flow rate profile Q_Iis not only evaluated in the first time interval Δt₁, which preferably lies immediately after the expiry of the adjustment time of the flow rate generated in the line system 12 by the washing pump 11 being switched on, but also in the second time interval Δt₂, wherein in the graphs illustrated this second time interval Δt₂commences at the end of the first time interval Δt₁(at the time point t₂) and preferably lasts as long as the washing pump 11 is running.
Possible flow rate profiles, from which disturbances or faults occurring during the washing process become clear, are dealt with below with reference to the graphs according to the illustrations in FIGS. 4 e and 4 f.
The graph according to the illustration in FIG. 4 e is a basic flow rate profile Q_Iin the event of leakage occurring during the washing process. The graph shows that no faults have occurred during the first time interval Δt₁. In the second time interval Δt₂, the start of which is defined by the time point t₂(end point of the first time interval Δt₁), the detected flow rate Q_Iin the washing system 10 falls continuously at the time point t₃. In this case, that is to say when the measured flow rate Q_Ifalls continuously within the second time interval Δt₂from a time point t₃lying in the time window Δt₂, the occurrence of a leakage in the washing system 10 is concluded automatically, preferably after an upper threshold value is overshot.
The graph according to the illustration in FIG. 4 f shows the basic flow rate profile Q_Iwhich is established when a blockage occurs in the washing system 10 during continuous washing operation (that is to say, within the second time interval Δt₂). This is the case, for example, when individual washing nozzles 13 become at least partially blocked during the continuous operation of the ware washer 40, 50. In this case, that is to say when the measured hydrostatic flow rate Q_Idecreases continuously from a time point t₃during the second time interval Δt₂or during the continuous operation of the ware washer 40, 50, a blockage of the washing system 10 occurring only during the continuous operation of the ware washer 40, 50 is concluded automatically. Consequently, a corresponding fault warning is issued automatically, preferably via the optical and/or acoustic interface 22, in order to draw the attention of the operator of the ware washer 40, 50 to this disturbing factor.
In a case when, within a time interval Δt₁, Δt₂during which the flow rate profile is detected, the measured volumetric flow rate Q_Iis reduced due to a blockage in the washing system 10 (cf. FIGS. 4 d and 4 f), the process can be affected as follows: in a ware washer 40 designed as a programmable machine, the running time of the treatment program shall be increased, preferably in proportion to the detected flow rate drop. On the other hand, however, in a ware washer 50 designed as a conveyor ware washer, the speed at which the washing items to be treated are transported through the ware washer 50 shall be decreased preferably in proportion to the detected flow rate drop thereby increasing the treatment time of the washing items in the conveyor ware washer.
In the above-described embodiment of the solution according to the invention, a ware washer 40, 50 is assumed which has at least one washing pump (washing pumps 11-1, 11-2, 11-3 in the conveyor ware washer 50 shown in FIG. 1 and washing pump 11-5 in the ware washer 40 shown in FIG. 2 and designed as a programmable machine) and at least one washing nozzle 13-1, 13-2, 13-3, 13-7 which is connected to the washing pump 11-1, 11-2, 11-3, 11-5 via a line system 12-1, 12-2, 12-3, 12-5 and to which a washing liquid is supplied during a washing process by the washing pump 11-1, 11-2, 11-3, 11-5 being activated, during the washing process the profile Q_Iof the flow rate of the washing liquid in the line system 12-1, 12-2, 12-3, 12-5 being detected and being compared with a predetermined flow rate profile Q_S.
Alternatively or additionally to this, however, it is also conceivable, during a final rinse process, to detect the profile Q_Iof the flow rate of the final rinse liquid supplied to the nozzles 13-4, 13-5, 13-6 provided for final rinse and to compare it with a predetermined flow rate profile Q_S.
In this case, it must be remembered that the conveyor ware washer 50 illustrated, for example, in FIG. 1 has a final rinse pump 11-4 and final rinse nozzles 13-4, 13-5 connected to the final rinse pump 11-4 via the line system 12-4. During a final rinse process, final rinse liquid is supplied to the final rinse nozzles 13-4, 13-5 by the final rinse pump 11-4 being activated. In order to achieve a situation where, during the final rinse process, the profile Q_Iof the flow rate of the final rinse liquid in the line system 12-4 can be detected and compared with a predetermined flow rate profile Q_S, in the conveyor ware washer 50 illustrated in FIG. 1 a sensor device 30′ is provided, having at least one pressure sensor 31′ which may be arranged, for example, at the outlet of the final rinse pump 11-4 or in the line system 12-4 in the immediate vicinity of the final rinse nozzles 13-4, 13-5. The at least one pressure sensor 31′ is designed to detect the profile of the volumetric flow rate Q_Iin the final rinse liquid. The flow rate Q_Ito be detected by the flow sensor 31′ is generated in the line system 12-4 when the final rinse pump 11-4 is activated during the final rinse process.
The final rinse pump 11-4 of the conveyor ware washer 50 illustrated in FIG. 1 is switched on and off via the control device 20 of the ware washer 50. Furthermore, with the aid of the control device 20, the rotational speed of the final rinse pump 11-4 and therefore the quantity of final rinse liquid supplied per unit time for the final rinse nozzles 13-4, 13-5 can advantageously be set.
On the other hand, it is, of course, also conceivable, in the ware washer 40 illustrated in FIG. 2 and designed as a programmable machine, during a final rinse process to detect the profile Q_Iof the flow rate of the final rinse liquid supplied to the final rinse nozzles 13-6 provided for final rinse and to compare it with a predetermined flow rate profile Q_S. In this case, it must be remembered that, in the embodiment, illustrated in FIG. 2, of the ware washer 40 designed as a programmable machine, a final rinse pump 11-6 is provided which is connected with its suction side to an outlet of a water heater (boiler) 60. The water heater 60 has an inlet connected to a fresh water supply line 61. The fresh water supply line 61 is connectable to further fresh water supply lines 63, 64 via a valve 62, so that either fresh water or fresh water with added rinse agent can be supplied to the water heater 60. The water heater 60 has a heating system, so that the liquid (pure fresh water or fresh water with added rinse agent) supplied via the inlet can be heated in accordance with a process flow.
Via the final rinse pump 11-6 connected with its suction side to the outlet of the water heater 60, the final rinse liquid optionally heated in the water heater 60 or unheated can be routed, for example during a final rinse phase, to the final rinse nozzles 13-6 via a final rinse line system 12-6. The final rinse nozzles 13-6 are arranged in the treatment chamber 41, in order to spray the final rinse liquid heated in the water heater 60 onto the wash ware in the treatment chamber 41. It is, of course, also conceivable, however, that the water heater 60 is supplied with pure fresh water, to which a rinse agent is added only after heating in the water heater 60.
The solution according to the invention is not restricted to the presence of a water heater 60. On the contrary, within the scope of the invention, the provision of a water heater 60 may even be dispensed with, so that, during a final rinse process, unheated final rinse liquid is conveyed to the final rinse nozzles 13-6 arranged in the treatment chamber 41 and is sprayed onto the wash ware.
In the embodiment, illustrated diagrammatically in FIG. 2, of the ware washer 40 designed as a programmable machine, the washing nozzles 13-7 and the final rinse nozzles 13-6 are in each case preferably arranged above and below the wash ware region and are directed toward the wash ware region of the treatment chamber 41. In particular, in the embodiment illustrated, a downwardly directed upper washing nozzle system and a likewise downwardly directed upper final rinse nozzle system, formed separately from this, and also an upwardly directed lower washing nozzle system and a likewise upwardly directed lower final rinse nozzle system, formed separately from this, are provided. It is, of course, also conceivable, however, to provide an upper and a lower washing nozzle system which serve jointly for the spraying of washing liquid (during a washing phase) and for the spraying of final rinse liquid (during a final rinse phase). Also, the washing nozzles 13-7 and/or the final rinse nozzles 13-6 may be arranged only at the top or only at the bottom, instead of at the bottom and top, or, instead or additionally, may also be arranged on one side of the treatment chamber 41 and be directed into the wash ware region transversely with respect to the treatment chamber 41.
During a final rinse process, in the embodiment, illustrated diagrammatically in FIG. 2, of the ware washer 40 designed as a programmable machine, final rinse liquid is supplied to the final rinse nozzles 13-6 by the final rinse pump 11-6 being activated. In order to achieve the situation where, during the final rinse process, the profile Q_Iof the flow rate of the final rinse liquid in the line system 12-6 can be detected and compared with a predetermined flow rate profile Q_S, in the ware washer 40 illustrated in FIG. 2 a sensor device 30″ is provided, having at least one flow sensor 31″ which may be arranged, for example, at the outlet of the final rinse pump 11-6 or in the line system 12-6 between the final rinse pump 11-6 and the final rinse nozzles 13-6. The at least one flow sensor 31″ is designed to detect the profile of the hydrostatic flow rate Q_Iin the final rinse liquid. The flow rate Q_Ito be detected by the flow sensor 31″ is generated in the line system 12-6 when the final rinse pump 11-6 is activated during the final rinse process.
The final rinse pump 11-6 of the ware washer 40 illustrated in FIG. 2 is switched on and off via the control device 20 of the ware washer 40. Furthermore, with the aid of the control device 20, the rotational speed of the final rinse pump 11-6 and therefore the quantity of final rinse liquid supplied per unit time to the final rinse nozzles 13-6 can advantageously be set.
FIGS. 5 a to 5 f illustrate flow rate profiles which were recorded, in the conveyor ware washer according to FIG. 1, with the aid of the sensor device 30′ or, in the ware washer 40 designed as a programmable machine, with the aid of the sensor device 30″ and which correspond respectively to the flow rate profile of the volumetric flow rate of the final rinse liquid in the line system 12-4 and to the flow rate profile of the volumetric flow rate of the final rinse liquid in the line system 12-6 during a final rinse process. The flow rate profiles illustrated in FIGS. 5 a to 5 f for the final rinse system largely correspond in profile and indication to the flow rate profiles in the washing system which are explained in FIGS. 4 a to 4 f. The observations explained there for the washing system may be transferred similarly to the final rinse system, and in this case the flow rate profiles of the liquids in the washing system may differ from those in the final rinse system, where appropriate, in their amplitudes (desired flow rate Q_S, detected flow rate Q_I, threshold values S₀, S₁, S₂).
The invention is not restricted to the embodiments shown by way of example in the drawings. On the contrary, the invention may be gathered from an overall consideration by a person skilled in the art of the patent claims and of the description of the exemplary embodiments.
Thus, it is, of course, conceivable that the start of the second time interval Δt₂illustrated in FIGS. 4 a to 4 f does not coincide with the end (time point t₂) of the first time interval Δt₁. In particular, it is conceivable that the second time interval Δt₂, like the first time interval Δt₁, commences even immediately after the expiry of the settling time of the flow rate which is generated in the washing system 10 when the washing pump 11 is switched on.
On the other hand, it is nevertheless conceivable that the profile of the flow rate Q_Iis detected with the aid of the sensor device 30, 30′, 30″, in that the flow rate is measured continuously during the entire washing and/or final rinse process, or in that the flow rate is measured at predetermined or predeterminable time points or events during the entire washing and/or final rinse process, and the measured flow rate values are interpolated.
The solution according to the invention makes it possible automatically to ascertain and evaluate a deviation of the flow rate profile Q_Iprevailing in the washing system and/or final rinse system from an ideal prefixed flow rate profile Q_S, in order to record disturbances or faults which are responsible for the flow rate deviation and which either are present even at the commencement of the washing process or first arise during the washing or final rinse process. Suitable measures are taken automatically as a function of the type of disturbance, in order either to maintain the desired washing performance of the ware washer or, if this is not possible, to maintain the operation of the ware washer, without entailing the risk of damage occurring on the ware washer.

Claims

1. A method for operating a ware washer which is designed as a programmable machine or as a conveyor ware washer having at least one pump, at least one line system connected to the pump, and at least one nozzle system connected to the line system and having at least one nozzle,

the method having the following method steps:

during the operation of the ware washer, a liquid is supplied at least intermittently to the at least one nozzle via the line system; and

the profile of the flow rate of the liquid in the line system is detected and is compared with a predetermined flow rate profile,

characterized,

in that, in the event of a deviation of the detected flow rate profile from the predetermined flow rate profile, at least one of the following steps is selected and executed automatically as a function of the size and the time gradient of a difference between the predetermined flow rate profile and the detected flow rate profile:

i) regulating action is carried out on the operation of the ware washer; and/or

ii) a fault warning is issued via an optical and/or acoustic interface of the ware washer; and/or

iii) a warning is issued to a remote maintenance station via a remote control interface of the ware washer.

2. The method as claimed in claim 1,

wherein the at least one pump is has a washing pump and the at least one nozzle is a washing nozzle which is connected to the washing pump via the line system and to which a washing liquid is supplied during a washing process via the washing pump being activated, and wherein, during the washing process, the profile of the volumetric flow rate of the washing liquid in the line system is detected and compared with the predetermined flow rate profile.

3. The method as claimed in claim 2,

wherein the ware washer has a final rinse pump and at least one final rinse nozzle which is connected to the final rinse pump via a final rinse line system and to which a final rinse liquid is supplied during a final rinse process by the final rinse pump being activated, and wherein, during a final rinse process, the profile of the volumetric flow rate of the final rinse liquid in the final rinse line system is detected and compared with the a predetermined final rinse flow rate profile.

4. The method as claimed in claim 2,

wherein the ware washer has a valve and at least one final rinse nozzle which is connected to the valve via a final rinse line system and to which a final rinse liquid is supplied during the final rinse process by the valve being opened, and

wherein, during the final rinse process, the profile of the volumetric flow rate of the final rinse liquid in the final rinse line system is detected and compared with a predetermined final rinse flow rate profile.

5. The method as claimed in claim 1,

wherein at least one of the steps i) to iii) is selected and executed automatically only when the deviation of the detected flow rate profile from the predetermined flow rate profile overshoots or undershoots a set threshold value.

6. The method as claimed in claim 1,

wherein the profile of the volumetric flow rate is detected in that the volumetric flow rate is measured continuously within at least one predetermined time interval, or in that the volumetric flow rate is measured at predetermined time points or events within at least one predetermined time interval, and the measured flow rate values are interpolated.

7. The method as claimed in claim 6,

wherein the time interval has a set length, and wherein the start of the time interval is fixed by a time point at which the pump is switched on or activated in such a way that the liquid is supplied via the line system to the nozzle system having the at least one nozzle.

8. The method as claimed in claim 7,

wherein the profile of the volumetric flow rate is detected in that the volumetric flow rate is measured continuously or at predetermined time points or events in a plurality of time intervals preferably directly contiguous to one another, the start of the first time interval lying at a time point preferably immediately after the expiry of a starting time of the flow rate generated in the line system by the pump being switched on.

9. The method as claimed in claim 1,

wherein, in a case when the detected flow rate profile lies continuously above the predetermined flow rate profile and the amount of the difference between the predetermined flow rate profile and the detected flow rate profile lies continuously within the range between a first fixed threshold value and a second fixed threshold value, a minor leak in the line system or nozzle system is concluded automatically, and

wherein a corresponding fault warning then is issued via the optical and/or acoustic interface; and/or

wherein a corresponding fault warning then is issued via the remote control interface.

10. The method as claimed in claim 9,

wherein, in a case when the detected flow rate profile lies continuously above the predetermined flow rate profile and the amount of the difference between the predetermined flow rate profile and the detected flow rate profile is continuously above the second fixed threshold value, a major leak in the line system or nozzle system is concluded automatically, and a corresponding fault warning is issued via the optical and/or acoustic interface.

11. The method as claimed in claim 1,

wherein, in a case when the detected flow rate profile lies continuously below the predetermined flow rate profile and the amount of the difference between the predetermined flow rate profile and the detected flow rate profile is continuously above a fixed threshold value, a blockage in the line system or nozzle system is concluded automatically, and a corresponding fault warning is issued via the optical and/or acoustic interface.

12. The method as claimed in claim 11,

wherein the at least one pump is has a washing pump and the at least one nozzle is a washing nozzle which is connected to the washing pump via the line system and to which a washing liquid is supplied during a washing process by the washing pump being activated, and wherein, during the washing process, the profile of the volumetric flow rate of the washing liquid in the line system is detected and compared with the predetermined flow rate profile.

13. The method as claimed in claim 12, wherein, if the ware washer is designed as a programmable machine, the running time of the treatment program is increased, preferably in proportion to the detected flow rate drop; or

wherein, if the ware washer is designed as a conveyor ware washer, the speed at which the washing items to be treated are transported through the ware washer is reduced preferably in proportion to the detected flow rate drop.

14. The method as claimed in claim 1,

wherein, in a case when, within a time interval during which the flow rate profile is detected, the measured volumetric flow rate increases continuously from a time point and overshoots a predetermined threshold value, the pump capacity of the pump is automatically adjusted down, preferably in inverse proportion to a detected flow rate rise.

15. The method as claimed in one of claim 1,

wherein, in a case when, within a time interval during which the flow rate profile is detected, the measured volumetric flow rate decreases continuously from a time point and undershoots a predetermined threshold value, a blockage occurring only during the continuous operation of the ware washer is concluded automatically, and a corresponding fault warning is issued via the optical and/or acoustic interface.

16. A ware washer, in particular commercial dishwasher or utensil ware washer, which is designed as a programmable machine or as a conveyor ware washer and has the following:

at least one pump;

at least one line system connected to the pump;

at least one nozzle system connected to the line system and having at least one nozzle, a liquid being supplied at least intermittently to the at least one nozzle via the line system; and

a sensor device connected to a control device, for detecting a profile of the volumetric flow rate of the liquid in the line system and for comparing the detected flow rate profile with a predetermined flow rate profile,

characterized,

in that the control device is designed, in the event of a deviation of the detected flow rate profile from the predetermined flow rate profile, automatically either to carry out a regulating action on the operation of the ware washer as a function of the size and the time gradient of a difference between the predetermined flow rate profile and the detected flow rate profile or to issue a fault warning via an optical and/or acoustic interface or to issue a fault warning to a remote maintenance station via a remote control interface.

17. The ware washer as claimed in claim 16,

wherein the ware washer has, furthermore, the following:

at least one valve;

at least one final rinse line system connected to the valve; and

at least one nozzle system connected to the line system and having at least one final rinse nozzle,

wherein the control device is designed, furthermore, for activating the valve in such a way that a liquid is supplied at least intermittently to the at least one final rinse nozzle via the final rinse line system, and

wherein the sensor device is designed, furthermore, for detecting a profile of the volumetric flow rate of the liquid in the final rinse line system and for comparing the detected flow rate profile with a predetermined final rinse flow rate profile.

18. The ware washer as claimed in claim 16,

wherein the control device is designed, furthermore, to carry out a regulating action on the operation of the ware washer or to issue a fault warning only when the deviation of the detected flow rate profile from the predetermined flow rate profile overshoots or undershoots a set threshold value.

19. The ware washer as claimed in claim 16,

wherein the sensor device has at least one flow sensor, and is designed to detect the profile of the volumetric flow rate in that the volumetric flow rate is measured continuously or at predetermined time points or events by means of the at least one flow sensor within a predetermined time interval, and, if appropriate, the measured flow rate values are interpolated.

20. The ware washer as claimed in claim 16,

wherein the at least one pump is ware washer has a washing pump and the at least one nozzle is a washing nozzle which is connected to the washing pump via the line system and to which a washing liquid is supplied during a washing process by the washing pump being activated, and wherein the sensor device connected to the control device is designed for detecting the profile of the volumetric flow rate of the washing liquid in the line system and for comparing the detected flow rate profile with the predetermined flow rate profile.

21. The ware washer as claimed in claim 16,

wherein the at least one pump is ware washer has a final rinse pump and the at least one nozzle is a final rinse nozzle which is connected to the final rinse pump via the line system and to which a final rinse liquid is supplied during a final rinse process by the final rinse pump being activated, and

wherein the sensor device connected to the control device is designed for detecting the profile of the volumetric flow rate of the final rinse liquid in the line system and for comparing the detected flow rate profile with the predetermined flow rate profile.