U.S. patent application number 13/021682 was filed with the patent office on 2011-10-06 for intelligent wash period with load/unload alert and idle mode, system and methods for washing machine.
Invention is credited to JOHN W. CANTRELL, MARK CHURCHILL.
Application Number | 20110240061 13/021682 |
Document ID | / |
Family ID | 44355817 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110240061 |
Kind Code |
A1 |
CANTRELL; JOHN W. ; et
al. |
October 6, 2011 |
INTELLIGENT WASH PERIOD WITH LOAD/UNLOAD ALERT AND IDLE MODE,
SYSTEM AND METHODS FOR WASHING MACHINE
Abstract
The present general inventive concept relates to a condition
alert and/or operator instructing system, control system and
control methods for a pot and pan, or other similar washing
machine. A method of washing wares in a continuous motion style
washing machine is provided. A wash period is provided. A
cumulative wash cycle time, of a plurality of individual wash
cycles within the wash period, is monitored. The wash period is
expanded or increased beyond a base period if the cumulative wash
cycle time is less than a maximum cumulative wash cycle condition
value. The wash period is contracted or reduced if the cumulative
wash cycle time reaches a maximum cumulative wash cycle condition
value during the wash period.
Inventors: |
CANTRELL; JOHN W.; (Leawood,
KS) ; CHURCHILL; MARK; (Grain Valley, MO) |
Family ID: |
44355817 |
Appl. No.: |
13/021682 |
Filed: |
February 4, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61301517 |
Feb 4, 2010 |
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61307828 |
Feb 24, 2010 |
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61326529 |
Apr 21, 2010 |
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61326687 |
Apr 22, 2010 |
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61385555 |
Sep 23, 2010 |
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Current U.S.
Class: |
134/25.2 |
Current CPC
Class: |
A47L 2401/09 20130101;
A47L 2501/26 20130101; A47L 15/16 20130101; A47L 15/0028 20130101;
A47L 2501/01 20130101; A47L 15/0092 20130101; A47L 2401/20
20130101; A47L 2501/02 20130101; A47L 2401/10 20130101; A47L
2401/22 20130101; A47L 2301/04 20130101 |
Class at
Publication: |
134/25.2 |
International
Class: |
A47L 15/42 20060101
A47L015/42 |
Claims
1. A method of washing wares in a continuous motion style washing
machine, said method comprising the steps of: activating a wash
pump by a control system to circulate a fluid within a wash tank of
the washing machine; starting by said control system a wash period
when the wash pump is activated; starting by said control system a
wash cycle and a wash cycle timer during said wash period; ending
said wash cycle and initiating an unload/load alert via the control
system when said wash cycle timer reaches a wash cycle timer
condition value; initiating an unload/load period via the control
system; beginning a new wash cycle during said wash period and
resetting and restarting said wash cycle timer after the
unload/load period is completed.
2. The method as claimed in claim 1 further comprising the step of
monitoring the wash water quality during said wash period.
3. The method as claimed in claim 2 further comprising the steps
of: deactivating the wash pump and locking out by said control
system operation of the wash pump based upon said water quality
either exceeding or falling below of a preset condition value; and
requiring draining of said wash tank prior to initiation of a new
wash period.
4. The method as claimed in claim 3 wherein said step of requiring
draining of said wash tank requires draining said wash tank to a
level below a fluid level sensor.
5. The method as claimed in claim 3 further comprising the steps
of: deactivating the wash pump and locking out by said control
system operation of the wash pump based upon a cumulative wash
cycle timer reaching a cumulative wash cycle timer condition value;
and requiring draining of said wash tank prior to initiation of a
new wash period.
6. The method as claimed in claim 5 wherein said step of requiring
draining of said wash tank requires draining said wash tank to a
level below a fluid level sensor.
7. The method as claimed in claim 3 further comprising the step of
deactivating the wash pump and locking out by said control system
operation of the wash pump if a cumulative wash cycle timer fails
to meet a minimum cumulative wash cycle timer condition value
within a predetermined period of time.
8. The method as claimed in claim 1 further comprising the step of
adding said wash cycle timer condition value for each wash cycle to
a cumulative wash cycle timer.
9. The method as claimed in claim 8 comprising the step of ending a
wash period upon said cumulative wash cycle timer meeting a
predetermined condition.
10. The method as claimed in claim 1 further comprising the steps
of: deactivating the wash pump and locking out by said control
system operation of the wash pump based upon a cumulative wash
cycle timer meeting a cumulative wash cycle timer condition value;
and requiring draining of said wash tank prior to initiation of a
new wash period.
11. The method as claimed in claim 10 wherein said step of
requiring draining of said wash tank requires draining said wash
tank to a level below a fluid level sensor.
12. The method as claimed in claim 5 further comprising the step of
deactivating the wash pump and locking out by said control system
operation of the wash pump if a cumulative wash cycle timer fails
to meet a minimum cumulative wash cycle timer condition value
within a predetermined period of time.
13. The method as claimed in claim 1 further comprising the step of
resetting said wash cycle timer and a cumulative wash cycle timer
upon initiation of a new wash period.
14. The method as claimed in claim 1 wherein said unload/load alert
comprises a visual alert.
15. The method as claimed in claim 14 wherein said visual alert
includes a light operably connected to said control system, said
light being mounted at a position and focused in a direction that
illuminates a location below a washing machine operator's direct
line of site and wherein a source of illumination is outside of the
operator's direct line of sight.
16. The method as claimed in claim 1 wherein said unload/load alert
comprises an audible alert.
17. The method as claimed in claim 1 wherein said wash pump remains
activated during said unload/load period.
18. The method as claimed in claim 1 wherein said wash pump is
deactivated or placed into an idle mode during said unload/load
period.
19. The method as claimed in claim 18 further comprising the steps
of: providing by said control system an option to delay a step of
locking out operation of said wash pump for at least one finite
time period; and locking out operation of said wash pump by said
control system after the at least one finite time period has
concluded.
20. The method as claimed in claim 1 wherein said step of starting
a wash period includes starting a wash period timer after said step
of activating a wash pump.
21. The method as claimed in claim 1 wherein said wash pump is
deactivated or placed into an idle mode during said wash
period.
22. The method as claimed in claim 21 further comprising the steps
of: providing by said control system an option to delay a step of
locking out operation of said wash pump for at least one finite
time period; and locking out operation of said wash pump by said
control system after the at least one finite time period has
concluded.
23. The method as claimed in claim 1 further comprising the steps
of: providing by said control system an option to delay a step of
locking out operation of said wash pump for at least one finite
time period; and locking out operation of said wash pump by said
control system after the at least one finite time period has
concluded.
24. The method as claimed in claim 1 wherein said step of
activating a wash pump by a control system to circulate a fluid
within a wash tank of the washing machine occurs after a step of
satisfying a fluid level sensor.
25. The method as claimed in claim 1 wherein said step of
initiating an unload/load period via the control system is
accomplished by an operator.
26. The method as claimed in claim 1 wherein said unload/load
period is completed by an operator manually ending the unload/load
period via an input to the control system.
27. The method as claimed in claim 1 wherein said unload/load
period is completed automatically by said control system based upon
a preset condition value.
28. The method as claimed in claim 1 further comprising the step of
repeating said ending, initiating and beginning steps until the
wash period is completed.
29. A method of washing wares in a continuous motion style washing
machine, said method comprising the steps of: providing a wash
period; monitoring a cumulative wash cycle time comprised of a
plurality of individual wash cycles within said wash period;
expanding said wash period if said cumulative wash cycle time is
less than a maximum cumulative wash cycle condition value; and
contracting said wash period if said cumulative wash cycle time
reaches said maximum cumulative wash cycle condition value during
said wash period.
30. The method as claimed in claim 29 wherein said expanding step
comprises continuing operation of a wash pump until said cumulative
wash cycle time reaches said maximum cumulative wash cycle
condition value.
31. The method as claimed in claim 30 wherein said expanding step
further comprises the step of deactivating the wash pump if a wash
period timer reaches a maximum wash period condition value.
32. The method as claimed in claim 29 wherein said contracting step
comprises deactivating a wash pump when said cumulative wash cycle
time reaches said maximum cumulative wash cycle condition
value.
33. The method as claimed in claim 29 wherein said expanding step
is not performed if said cumulative wash cycle time is less than a
minimum cumulative wash cycle condition value within a
predetermined period of time.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority pursuant to 35 U.S.C.
119(e) to co-pending U.S. Provisional Patent Application Ser. No.
61/301,517, filed Feb. 4, 2010, U.S. Provisional Patent Application
Ser. No. 61/307,828, filed Feb. 24, 2010, U.S. Provisional Patent
Application Ser. No. 61/326,529, filed Apr. 21, 2010, U.S.
Provisional Patent Application Ser. No. 61/326,687, filed Apr. 22,
2010, and U.S. Provisional Patent Application Ser. No. 61/385,555,
filed Sep. 23, 2010, the entire disclosures of which are
incorporated herein by reference.
FIELD
[0002] The present general inventive concept relates to a condition
alert and/or operator instructing system, control system and
control methods for a pot and pan, or other similar washing
machine. More specifically, the present general inventive concept
is concerned with a washing machine intelligent wash period with
unload/load alert and idle mode.
BACKGROUND
[0003] Pot and pan washing machines, of the type used in
restaurants, institutions and other eating facilities often involve
a large wash tank or basin in which water or other cleaning fluid
is circulated to provide a continuous motion rolling wash action
for the pots and pans and other "wares" (i.e. pots, pans, utensils,
flatware/silverware, etc.). One such continuous motion style pot
and pan washing machine is described in U.S. Pat. No. 4,773,436
issued to Cantrell et al., the entire disclosure of which is
incorporated herein by reference. The machine of Cantrell includes
a wash tank with multiple jets evenly spaced apart at an elevated
position along the rear wall of the wash tank. The tank is filled
with fluid (i.e. water, detergent, etc.) to a level above the
position of the jets. Pots and pans are placed in the wash tank,
and a wash pump is activated to draw fluid from within the wash
tank and direct it through the jets to create a jet stream. Each
jet directs its jet stream toward the bottom wall of the wash tank,
the bottom wall then deflects the jet stream upward and towards the
front wall of the tank. The front wall then deflects the upward
moving jet stream towards the rear wall of the tank, and the rear
wall deflects the jet stream downward and back towards the front
wall along the bottom wall. The combination of deflections of the
jet stream from the bottom, front and rear walls provides a rolling
washing action within the wash tank. Typically, the rolling wash
action is continuous through the washing cycle of the machine, and
wares are loaded and unloaded during the washing cycle as they are
deemed clean by an operator of the machine. In this manner,
multiple loads of wares are cleaned during a single washing
cycle.
[0004] Although the prior art pot and pan washing machine disclosed
in U.S. Pat. No. 4,773,436 provides an exceptional wash action,
many of the components discussed above hinder the overall
efficiency and performance of the machine. The inventions disclosed
in U.S. application Ser. Nos. 09/947,484; 09/947,485; and
10/744,666, the entire disclosures of which are incorporated herein
by reference, provide components that greatly increase the overall
efficiency and performance of the machine, including improvements
to the intake and discharge manifolds, jets, pump and system
assembly methods. In addition, International Patent Application
PCT/US09/59600, the entire disclosure of which is incorporated
herein by reference, provides a condition warning system, control
system and control methods for a pot and pan washing machine that
addresses a number of disadvantages in typical condition warning
systems, control systems and control methods for such machines.
Notwithstanding, none of the prior art machines, systems or methods
provide a simple and/or effective mechanism for quickly and easily
instructing or providing guidance to the typically unskilled and/or
untrained personnel (operators, crew members, etc.) that tend to
operate these types of machines in commercial eating facilities.
Therefore, it would be beneficial to provide a system and method
that alerts operators of conditions requiring operator action
and/or that easily instructs, or communicates to, the operator as
to the specific action that must be taken.
[0005] In addition, prior art machines typically include a preset
wash period, in which the machine will operate. After the wash
period time is expired, the operator is forced to drain and refill
the wash tank with clean washing fluid. This is intended to ensure
that the machine is not operated once the cleaning fluid has too
high of a soil load in which too much soil from items being cleaned
emulsifies in the wash fluid and the fluid is no longer able to
clean. In many prior art machines the wash period is either factory
set, or adjustable by a machine technician within a predetermined
range. The adjustable range does globally accommodate
establishments of various average soil loads. For example, if one
establishment typically has a higher than average soil load, the
wash period can be set by the technician to be shorter, within the
range. Likewise, if an establishment typically has a lower than
average soil load, the wash period can be set by the technician to
be longer, within the range. Nevertheless, this global setting does
not allow an establishment to actively adjust the wash period to
account for varying soil loads that may be encountered at different
times within the establishment. For example, between noon to 6 PM
an establishment may have a relatively high soil load, and a much
lower soil load after 6 PM, when business is much slower. Thus, the
global wash period setting may be too long and result in wash fluid
that has too high of a soil load to effectively clean, during the
high volume period, and may be too short and result in wash fluid
that is still able to clean being prematurely drained during lower
volume periods. Therefore, it would be beneficial to provide a
system and method that allow for varying degrees of soil loads
encountered at various times within an establishment.
SUMMARY
[0006] The present general inventive concept provides a method of
washing wares in a continuous motion style washing machine. In one
embodiment, the method includes the following steps. A wash pump is
activated by a control system to circulate fluid within a wash tank
of the washing machine during a wash period. The wash period begins
with the first activation of the pump to follow the wash tank being
filled with fluid. When the pump is activated, whether for the
first or any subsequent time following the wash tank being filled
with fluid, the control system simultaneously starts a wash cycle
timer. A unload/load period is initiated when the wash cycle timer
reaches a predetermined wash cycle timer condition value. A
unload/load alert is initiated simultaneously with the beginning of
the unload/load period. A wash cycle timer condition value is added
to a cumulative wash cycle timer. The wash cycle timer is reset and
restarted upon completion of the unload/load period. The steps of
initiating the unload/load period (and accompanying unload/load
alert) and resetting and restarting the wash cycle timer are
repeated until the cumulative wash cycle timer reaches a
predetermined cumulative wash cycle timer condition value. When the
cumulative wash cycle timer reaches the cumulative wash cycle timer
condition value, the wash pump is deactivated and locked. The wash
tank is required to be drained and refilled in order to unlock and
reactivate the wash pump and begin a new wash period. In some
embodiments, the method further includes a step of resetting the
wash cycle timer and the cumulative wash cycle timer upon
initiation of the new wash period.
[0007] In some embodiments, the unload/load alert is a visual alert
and/or an audible alert. In some embodiments, the visual alert
includes a light connected to the control system and the light is
mounted at a position and focused in a direction that illuminates a
location below a washing machine operator's direct line of site and
the source of illumination is outside of the operator's direct line
of sight.
[0008] In some embodiments, the step of initiating a unload/load
period further includes activating (for receipt of operator input)
an unload/load control button connected to the control system and
completing the unload/load period upon receipt of the operator
input (via the unload/load control button). In some embodiments,
the method further comprises starting an unload/load timer upon a
first input of the active unload/load control button by an operator
and completing the unload/load period upon the first to occur of:
(a) a second input of the active unload/load control button by the
operator, or (b) the unload/load timer meeting a predetermined
unload/load timer condition value.
[0009] In some embodiments, the wash pump remains activated during
the unload/load period. In other embodiments, the wash pump is
deactivated or placed into an idle mode during the unload/load
period. In some embodiments, the method further includes the step
of deactivating the wash pump and locking out the wash pump if the
cumulative wash cycle timer fails to meet a minimum cumulative wash
cycle timer condition value within a predetermined period of time.
In other embodiments, the method further includes the step of
deactivating the wash pump and locking out the wash pump if the
cumulative wash cycle timer fails to meet the cumulative wash cycle
timer condition value within a predetermined maximum wash period.
In some embodiments, the method further includes providing an
option to delay the step of locking out operation of the wash pump
for at least one additional finite time period and locking out
operation of the wash pump after the at least one additional finite
time period has concluded.
[0010] In another aspect, the present general inventive concept
provides a method of washing wares in a continuous motion style
washing machine. The method includes the following steps. A wash
period is provided. A cumulative wash cycle time, which is a
plurality of individual wash cycles within the wash period, is
monitored. The wash period is expanded or extended if the
cumulative wash cycle time is less than a maximum cumulative wash
cycle condition value. The wash period is contracted or reduced if
the cumulative wash cycle time reaches the maximum cumulative wash
cycle condition value during the wash period.
[0011] The foregoing and other objects are intended to be
illustrative of the invention and are not meant in a limiting
sense. Many possible embodiments of the invention may be made and
will be readily evident upon a study of the following specification
and accompanying drawings comprising a part thereof. Various
features and subcombinations of invention may be employed without
reference to other features and subcombinations. Other objects and
advantages of this invention will become apparent from the
following description taken in connection with the accompanying
drawings, wherein is set forth by way of illustration and example,
an embodiment of this invention and various features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A preferred embodiment of the invention, illustrative of the
best mode in which the applicant has contemplated applying the
principles, is set forth in the following description and is shown
in the drawings and is particularly and distinctly pointed out and
set forth in the appended claims.
[0013] FIG. 1 is a pot and pan washing machine of an embodiment of
the present general inventive concept.
[0014] FIG. 2 (FIGS. 2a and 2b) is one embodiment of operation and
control logic of a control system relating to alerts and
instructions for unloading and loading of the pot and pan washing
machine of FIG. 1.
DETAILED DESCRIPTION
[0015] As required, a detailed description of an embodiment of the
present general inventive concept is disclosed herein; however, it
is to be understood that the disclosed embodiment is merely
exemplary of the principles of the general inventive concept, which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present general inventive concept in virtually
any appropriately detailed structure.
[0016] The present general inventive concept provides a condition
alert and/or operator instructing system, control system and
control methods for a pot and pan, or other similar washing
machine. An embodiment of the present general inventive concept is
discussed herein in connection with the pot and pan washing
machine, and its condition warning and control systems, disclosed
in PCT/US09/59600. Nevertheless, it will be appreciated that the
system and methods of the present general inventive concept may be
utilized in connection with pot and pan washing machines, such as
those described in any of U.S. Pat. No. 4,773,436, or U.S.
application Ser. Nos. 09/947,984, 09/947,484, 10/744,666 and
PCT/US09/59600, as well as with any other washing machines, or
various combinations of washing machine components now known or
hereinafter developed without departing from the spirit and scope
of the present general inventive concept.
[0017] A method of washing wares in a continuous motion style
washing machine is provided. The method includes the following
steps. A wash tank of the washing machine is filled with a fluid. A
fluid level sensor identifies when the fluid level in the wash tank
has reached a prescribed threshold fluid level. After the fluid
reaches the threshold fluid level, a wash pump is activated via a
control system to circulate the fluid within the wash tank of the
washing machine. A wash period timer is initiated when the wash
pump is activated for the first time after satisfying the fluid
level sensor. In some embodiments, the wash period timer is
initiated before the wash pump is activated, for example as soon as
the fluid level sensors indicate that the fluid has sufficiently
drained. In some embodiments, the wash period timer is initiated
after the wash pump has been activated, for example upon input from
an operator via the control panel. In a preferred embodiment, the
wash period timer is initiated simultaneously with the activation
of the wash pump. A wash cycle and a wash cycle timer are also
simultaneously initiated via the control system. When the wash
cycle timer reaches a predetermined wash cycle timer condition
value, the wash cycle is ended and an unload/load alert is
initiated via the control system. Preferably, the predetermined
wash cycle timer condition value is within the range of 10 and 30
minutes. In response to the unload/load alert, an operator
initiates an unload/load period via the control system or the
unload/load period is automatically initiated based on a preset
condition value. Preferably, the preset condition value is in the
range of 5 to 30 minutes. The unload/load period ends either
manually via operator input to the control system or automatically
based on a preset condition value. Preferably, the preset condition
value is in the range of 5 to 30 minutes. When the unload/load
period ends, a new wash cycle and wash cycle timer are initiated.
Throughout the repeating wash cycles, unload/load alerts, and
unload/load periods, the overall wash period timer, that is
initiated when the wash pump is activated for the first time
following satisfying the fluid level sensor, remains
uninterrupted.
[0018] The method optionally additionally includes the step of
monitoring the quality and/or various characteristics of the
fluid/wash water throughout the overall wash period. In some
embodiments, the quality and/or various characteristics of the wash
water is monitored periodically, such as between each wash cycle.
In other embodiments, the quality and/or various characteristics of
the wash water is monitored continuously. Water monitors and
related sensors are well known in the art and are readily available
as "off-the-shelf" components. Some of the qualities and/or
characteristics that may be monitored include: detergent levels,
sanitizer levels, acidity-basicity (pH levels), salinity,
conductivity, turbidity, viscosity, foreign particles levels, and
flow rate. When the water monitor detects that the fluid quality
and/or characteristic has exceeded, fallen below of, or outside an
acceptable range for (depending upon the condition being monitored)
a predetermined threshold condition value, the wash pump is
deactivated and locked out by the control system. The wash pump can
not be reactivated until the wash tank is drained, as detected by
the fluid level sensor (i.e. low fluid level sensor). When the
fluid level sensor detects that the wash tank has been drained, the
wash pump is reset and may be reactivated after the wash tank is
refilled with fluid, as detected by the fluid level sensor (i.e.
high fluid level sensor). As discussed above, a new overall wash
period timer is initiated when the wash pump is activated for the
first time after satisfying the fluid level sensor.
[0019] The method optionally additionally includes the step of
adding each of the repeating wash cycle timer condition values to a
cumulative wash cycle timer. When the cumulative wash cycle timer
reaches a predetermined threshold value, the wash pump is
deactivated and locked out by the control system. Preferably, the
predetermined threshold value is between 90 and 240 minutes. The
cumulative wash cycle timer is reset when the wash tank is drained,
as determined by the fluid level sensor(s), and a new overall wash
period may be initiated when the wash tank is refilled, as
determined by the fluid level sensor(s). In some embodiments, the
method further includes a step of resetting the wash cycle timer
and the cumulative wash cycle timer upon initiation of the new wash
period.
[0020] In some embodiments, the unload/load alert is a visual alert
and/or an audible alert. In some embodiments, the visual alert
includes a light connected to the control system and the light is
mounted at a position and focused in a direction that illuminates a
location below a washing machine operator's direct line of site and
the source of illumination is outside of the operator's direct line
of sight.
[0021] In some embodiments, the step of initiating a unload/load
period further includes activating, for receipt of operator input,
an unload/load control button connected to the control system. The
unload/load period ends upon receipt of the operator input (via the
unload/load control button). In some embodiments, the method
further comprises starting an unload/load timer upon a first input
of the active unload/load control button by an operator and
completing the unload/load period upon the first to occur of: (a) a
second input of the active unload/load control button by the
operator, or (b) the unload/load timer meeting a predetermined
unload/load timer condition value. Preferably, predetermined
unload/load timer condition value is in the range of 5 to 30
minutes.
[0022] In some embodiments, the wash pump remains activated during
the unload/load period. In other embodiments, the wash pump is
deactivated or placed into an idle mode during the unload/load
period. In some embodiments, the method further includes the step
of deactivating the wash pump and locking out the wash pump if the
cumulative wash cycle timer fails to meet a cumulative wash cycle
timer condition value within a predetermined maximum wash period of
time. For example, the cumulative wash cycle timer condition value
may be set between 90 minutes and 240 minutes and the predetermined
maximum wash period of time may be set between 3 hours 40 minutes
and 6 hours. If the cumulative wash cycle timer condition value is
set to 90 minutes and the predetermined maximum wash period of time
is set at 5 hours 45 minutes, but the cumulative wash cycle timer
fails to reach 90 minutes before the predetermined maximum wash
period of time reaches 5 hours 45 minutes, the control system shuts
down the pump anyway, regardless of the cumulative wash cycle
timer, forcing a fluid change.
[0023] In other embodiments, the method further includes the step
of deactivating the wash pump and locking out the wash pump if the
cumulative wash cycle timer fails to meet a minimum cumulative wash
cycle timer condition value within a predetermined period of time.
This prevents a situation in which operators are not utilizing the
unload/load feature to maximize time between draining a refilling
the wash tank. For example, the minimum cumulative wash cycle timer
condition value is 90 minutes and predetermined standard wash
period is 4 hours. If the cumulative wash cycle timer fails to
reach 90 minutes before the wash period reaches 3 hours 45 minutes,
the control system shuts down the pump anyway at 4 hours,
regardless of the cumulative wash cycle timer, forcing a fluid
change. In some embodiments, the method further includes providing
an option to delay the step of locking out operation of the wash
pump for at least one additional finite time period and locking out
operation of the wash pump after the at least one additional finite
time period has concluded. For example, the one additional finite
time period may be 15 minutes.
[0024] In another aspect, the present general inventive concept
provides a method of washing wares in a continuous motion style
washing machine. The method includes the following steps. A wash
period is provided, initially set at four (4) hours. A cumulative
wash cycle time, which is a plurality of individual wash cycles
within the wash period, is monitored. The wash period is expanded
or extended if the cumulative wash cycle time is less than a
maximum cumulative wash cycle condition value. The wash period is
contracted or reduced if the cumulative wash cycle time reaches the
maximum cumulative wash cycle condition value during the wash
period. Preferably, the maximum cumulative wash cycle condition
value is set between 90 minutes and 240 minutes.
[0025] Referring to FIG. 1, a pot and pan washing machine of an
embodiment of the present general inventive concept is shown. In
the embodiment of FIG. 1, the pot and pan washing machine utilizes
the same or similar control system as is described in
PCT/US09/59600. The condition warning light 15 described in
PCT/US09/59600 is included in the embodiment shown in FIG. 1, shown
below the control panel 10. In one embodiment, a condition
warning/alert light 15 is alternatively or additionally located
remotely from the washing machine, such as below a drive-through
counter, or other similar location away from the washing
machine.
[0026] The pot and pan washing machine in FIG. 1 includes wash tank
30, rinse tank 40, and sanitizer tank 50 connected together in a
single unit via non-welded field joint 34. The unit also includes
soiled end drain board 32, and clean end drain board 31 to direct
fluids into wash tank 30 and sanitizer tank 50, respectively. The
unit further includes backsplash 38, end splash 33 and channel rim
36. Wash tank 30 includes a plurality of jets along its rear wall
which direct fluid from wash pump 20 (controlled by control system)
into wash tank 30. An intake draws fluid back into wash pump 20 for
continuous motion within wash tank 30. Wash tank also includes
utensil basket 60 for washing utensils. In addition, wash tank 30
includes detergent injector 70 that is connected to a detergent
supply system which is controlled by control system. Wash tank also
includes fluid high and low sensors 80 connected to the control
system to detect when the fluid level in the tank is drained below
a minimum low level and raised above a minimum high level. In the
embodiment shown in FIG. 1, rinse tank 40 includes a pre-rinse
faucet 45 for rinsing items in the rinse sink 40. In a preferred
embodiment, rinse tank 40 also includes fluid level sensors that
operate in the same or similar manner as those in the wash tank 30.
Sanitizer tank 50 also includes similar fluid level sensors 52, as
well as a sanitizer injector 54 that is connected to a sanitizer
supply system controlled by control system. The control system also
controls condition warning light 15, which is mounted below control
panel 10, underneath the soiled end drain board 32, and which
directs light onto the floor directly below the unit. The system
also optionally includes one or more instruction light 90. FIG. 1
includes five (5) instruction lights (90a, 90b, 90c, 90d, and 90e)
that are located along the channel rim 36 in front of the soiled
end drain board 32, wash tank 30, rinse tank 40, sanitizer tank 50,
and clean end drain board 31, respectively. Each instruction light
90 includes three upward pointing arrows 93 and a button 95. In
alternative embodiments, in addition to or in place of the soiled
end drain board 32, the machine may include a scrapper sink or
other similar feature. In further alternative embodiments, one or
more of the rinse tank 40 and sanitizer tank 50 may be replaced
with alternative features that provide similar functionality, such
as the rinse and/or sanitizer systems disclosed in U.S. patent
application Ser. No. 12/781,750, the entire disclosure of which is
incorporated herein by reference.
[0027] Referring to FIG. 2 (FIGS. 2a and 2b), one embodiment of
operation and control logic of a control system of the instant
invention relating to alerts and instructions for unloading and
loading of the pot and pan washing machine of FIG. 1 is shown. It
will be appreciated that additional operation and control logic may
be included in the control system in combination with that shown in
FIG. 2. For example, in a preferred embodiment, the control logic
includes one or more of the features discussed in PCT/US09/59600.
Referring to FIG. 2, Wash Action Start and Stop buttons that are
located on the control panel 10 of the pot and pan washing machine
of FIG. 1 are illustrated in the flow diagram. When the Start
button is pressed an Intelligent Wash Period (explained in detail
in FIG. 2a) timer is initiated. In general, the Intelligent Wash
Period can only be cancelled or restarted by draining and refilling
the wash tank 30. Once the Intelligent Wash Period has expired, the
pump 20 shuts down and within a period of 15 minutes following the
end of the period can be restarted for up to five separate
one-minute "mini-unload cycles" and a change wash water LED
illuminates on the control panel 10 (and alert light 15 under
panel) to indicate to the operator that the Intelligent Wash Period
is over and the water must be changed in the wash tank 30. After
the 15 minute window, the pump 20 is locked out and the fluid in
the wash tank 30 must be changed. When the wash tank 30 is drained
below a low level sensor 80, a new Intelligent Wash Period begins,
and/or a Wash Tank Improper Fill Error clears (if applicable). As
is shown in FIG. 2, after a Cumulative Wash Cycle Time reaches a
preset number of minutes (adjustable between 90 and 240 minutes),
or reaches 3 hours and 45 minutes if Cumulative Wash Cycle Time is
less than 90 minutes after 3 hours and 45 of the Intelligent Wash
Period, a Blue "Change Wash Water" LED on the control panel 10 of
the machine illuminates flashing, the Standard Logic (discussed
below) is canceled and the wash pump 20 of the machine restarts (if
it has been stopped by the Standard Logic), or continues operating
(if it has not been stopped by the Standard Logic). In addition,
the condition warning light 15 under the control panel 10 turns on
flashing to notify managers and crew members to perform a last
unload of the wash tank 30 before the wash period ends. The
flashing rate increases from slower to faster, until a period of 15
minutes prior to the end of the Intelligent Wash Period. Once 15
minutes have elapsed, or if the Stop button on the control panel 10
is pressed, the wash pump 20 shuts down, the condition warning
light is turned on solid by the control system, and the blue
"Change Wash Water" LED on the control LED on the control panel 10
is turned on solid by the control system, until the wash tank 30 is
drained and refilled as is discussed above. If the wash tank 30 is
not drained after a period of time, the system goes into an
overnight deep cleaning mode, as discussed in FIG. 2a.
[0028] As is discussed in further detail in FIG. 2a, a preferred
embodiment of the instant invention includes an improper fill alert
to alert operators if the wash tank 30 reaches a high limit level
in an amount of time that is less than a preset minimum. If the
wash tank 30 reaches a high limit level in an amount of time that
is less than the preset minimum an Improper Wash Tank Fill Error
and a forced water change are triggered. The embodiment shown also
includes a full tank alert that alerts operators as the wash tank
30 approaches a full state. Once the Wash Tank High Limit is
reached, and no Fill Error has been triggered, the Start Wash
Action button is active and can be pressed to initiate the Standard
Logic (discussed in detail in FIG. 2a).
[0029] Sanitizer Logic (discussed in detail in FIG. 2b) is
initiated upon power up of the system and is also utilized once the
wash tank high limit is reached, thus any time the sanitizer tank
50 is filled, the improper fill logic, full tank alert logic, and
change sanitizer alert logic will run. When the sanitizer tank 50
first begins to fill, a sanitizer tank improper fill alert timer
starts as when the sanitizer water level reaches the low level
sensor. Preferably, this improper fill alert timer is set at a
point between 2 and 40 minutes. If the sanitizer water level
reaches the high limit sensor in an amount of time that is less
than the set point of the improper fill alert timer, an improper
sanitizer tank fill error will be triggered. If the sanitizer water
reaches the high limit sensor in an amount of time that is greater
than the set point of the improper fill alert timer, no error will
be triggered. If an improper sanitizer tank fill error is
triggered, a water change is forced and the pump 20 shuts down and
is locked out until the sanitizer water level is drained below the
low level sensor.
[0030] A sanitizer tank 50 full tank alert timer also starts when
the sanitizer water level reaches the low level sensor. This full
tank alert timer is preferably set at a point between 2 and 40
minutes. When the full tank alert timer reaches the set point, an
indicator is activated to indicate that the sanitizer tank 50 is
approaching a "full" state. When the high limit sensor is reached,
another indicator is activated to indicate that the sanitizer tank
50 has reached a "full" state and that immediate action is
required. The sanitizer tank full tank alert indicator is cancelled
by pressing the stop/idle button.
[0031] After the sanitizer tank 50 has reached a "full" state
without triggering any errors, a sanitizer batch use period timer
starts. Preferably, the batch use period timer is set at a point
between 120 and 240 minutes. After the batch use period timer
reaches its set point, an indicator is activated to indicate that
the sanitizer water will be required to be changed soon. The
indicator is activated for a period of time, between 10 and 30
minutes, preferably 15 minutes, after which another indicator is
activated to indicate that the sanitizer batch use period is over
and the sanitizer water must be changed. The pump 20 shuts down and
is locked out until the sanitizer water level is drained below the
low level sensor, unless the adjacent wash tank 30 has been
drained. In the event that the wash tank 30 high level limit sensor
80 indicates that the wash tank 30 is not full, then the pump 20
will not shut down and lock out. When the sanitizer water level is
drained below the low level sensor, the improper fill error and/or
batch use period timer are also cleared and reset.
[0032] If the wash tank 30 is full and the sanitizer water is not
filled within a period of time, between 10 and 30 minutes, an
indicator is activated indicating that the sanitizer tank 50 must
be filled immediately. Optionally, if the wash tank 30 is full and
the sanitizer water is not filled within the period of time, the
pump 20 is temporarily shut down and locked out until the sanitizer
tank 50 reaches a "full" state.
[0033] The system includes all standard functionality and logic of
the PS-200 system, available from POWER SOAK SYSTEMS, INC., and
described in PS-200 documentation, the entire disclosure of which
is incorporated herein by reference. The fluid heat system is
active whenever the wash pump 20 is active. When the wash pump 20
is not running, the heat system is also shut down. Every new timer
cancels out any previously running timer, with the exception of the
intelligent wash period timer and the cumulative cycle timer, which
are only cancelled out when the fluid level sensor determines that
the fluid level has been drained. The stop button on the control
panel 10, effectively becomes a "start idle mode" button during the
intelligent wash period. The high fluid level sensor will not be
read for a brief period of time, preferably five (5) minutes, after
initiating idle mode. When any Full Tank Alert is active (wash tank
30, rinse tank 40, sanitizer tank 50, etc.), the stop/idle button
on the control panel 10 temporarily changes functionality to a
"cancel full tank alert" button. After the full tank alert is
canceled by an operator selecting the stop button, the stop button
returns to its normal function as a stop/idle button. In the event
that multiple tanks (wash tank 30, rinse tank 40, sanitizer tank
50, etc.) simultaneously have full tank alerts, the full tank alert
that started first will be cancelled first and the stop/idle button
will need to be selected a subsequent time to cancel an subsequent
full tank alerts, before the stop/idle button returns to normal
stop/idle functionality.
[0034] Red and Blue colored alert lights 15 are located under the
control panel 10 and illuminate and/or flash in sequence with the
corresponding red change sanitizer indicator light and blue change
wash water indicator light on the control panel 10. A green colored
alert light 15 located under the control panel 10 is temporarily
ceases flashing and/or sustained (solid) illumination whenever the
red or blue colored alert lights are active, however, the logic
continues to run. The blue colored change wash tank fluid alert
light 15 and the red colored change sanitizer tank fluid alert
light 15 are always dominant over the green colored unload/load
alert light 15. Additionally, the blue colored change wash tank
fluid alert light 15 is dominant over the red colored change
sanitizer tank fluid alert light 15, when it is flashing. Unlike
the alert lights below, the indicator lights on the control panel
10 continue their respective functions and messages, uninterrupted,
and the logic of each function continues to run simultaneously.
[0035] Additional embodiments of operation and control logic of a
control system of the present general inventive concept relating to
alerts and instructions for unloading and loading of the pot and
pan washing machine of FIG. 1 are provided in the following
examples. It will be appreciated that additional operation and
control logic may be included in the control system in combination
with any of the following examples. In a preferred embodiment, the
control logic includes one or more of the features discussed in
PCT/US09/59600. Additionally, it will also be appreciated that the
operation and control logic discussed in the examples below may
each be incorporated alone, or in combination with one or more
other of the examples below.
[0036] In all of the following examples, wash Action Start and Stop
buttons are located on the control panel 10 of the pot and pan
washing machine of FIG. 1. When the Start button is pressed, a
standard wash period is initiated (as is further discussed in
PCT/US09/59600). In general, the wash period, preferably four (4)
hours, can only be cancelled or restarted by draining and refilling
the wash tank 30. Once the wash period has expired, the pump 20
shuts down and is locked out, and a change wash water LED
illuminates on the control panel 10 to indicate to the operator
that the water must be changed in the wash tank 30. When the wash
tank 30 is drained below a low level sensor, a new wash period
begins.
Example 1
[0037] Simultaneous with the start of a 4 hour wash period, is the
initiation of a unload/load alert timer by the control system.
After a 20 minute period is measured by the unload/load alert
timer, in which the wash pump 20 has been running, the alert light
15 (condition warning light) located under the control panel 10
shown in FIG. 1 is activated by the control system to flash. The
flashing alert light 15 alerts an operator(s) of the machine that
items should be unloaded/loaded in the wash tank 30. Once the alert
light 15 is flashing, the control system initiates another timer, a
cancel unload/load alert timer. After a 5 minute period of the
cancel unload/load alert timer has expired, the control system
activates a cancel unload/load alert button on the control panel
10. When the button is active, if it is depressed by an operator
the unload/load alert timer is reset (and the timer restarted) and
the flashing light is turned off by the control system. In the
disclosed embodiment, the cancel unload/load alert button is active
for a period of 10 minutes. After that time, the system goes into
an idle mode in which wash action stops, heat is deactivated and
the alert light 15 below the control panel 10 is illuminated solid
(i.e. not flashing) by the control system. While in idle mode,
pressing the start button on the control panel 10 brings the system
back into the same operational state as it was after the
unload/load alert reached 20 minutes (i.e. wash action and heat are
reactivated, alert light flashing, cancel unload/load timer
restarted at zero). Upon entering idle mode, the control system
initiates an idle mode timer. After 15 minutes in idle mode, if no
action is taken, the wash action and heat are reactivated by the
control system and the system is brought back into the same
operational state as it was after the unload/load alert reached 20
minutes (i.e. wash action and heat are reactivated, alert light
flashing, cancel unload/load timer restarted at zero).
Example 2
[0038] The same unload/load process discussed in connection with
Example 1 is combined with instructional steps that guide or
instruct an operator (e.g. kitchen crew member) to properly
unload/load the machine of FIG. 1. It will be appreciated that the
steps discussed with respect to Example 2 can be used in
combination with those discussed in Example 1, or can be used
independent of the process of Example 1 (including, but not limited
to the instruction steps of Example 2 being used in combination
with the process of Example 3 discussed below).
[0039] When the unload/load alert timer reaches 20 minutes, the
control system causes the alert light 15 under the control panel 10
to flash and initiates a cancel unload/load timer. At that point an
instruction light 90e (in the embodiment shown in FIG. 1 the
instruction light includes three illuminated and optionally
flashing up arrows 93) located on the front rim of the clean drain
board 31 of the machine shown in FIG. 1 is illuminated. This
prompts the crew members to unload any items that are sitting on
the clean drain board 31. A cancel unload clean drain board prompt
button 95 (shown next to the arrow lights 93 in the embodiment of
FIG. 1) begins flashing after a predetermined time has been
measured by the cancel unload/load alert timer. Once that button 95
is flashing, it is "active" in that upon pressing the button 95 by
a crew member, the control system causes the instruction light 90e
for the clean drain board to turn off and then illuminates a
similar instruction light 90d in front of the sanitizer tank 50.
This instructs the crew members to unload the sanitizer tank 50.
After a predetermined period of time, measured either by the cancel
unload/load timer, or by a separate sub-timer, a cancel unload
sanitizer tank prompt button 95 (next to the arrows 93) begins
flashing and is active. Once that button 95 is pressed by a crew
member, the control system turns off the sanitizer instruction
light 90d and illuminates instruction lights 90b and 90c in front
of the wash tank 30 and rinse tank 40, respectively. This instructs
the crew members to unload the wash tank 30 and rinse the wares in
the rinse tank 40. After a predetermined period of time, again
measured either by the cancel unload/load timer, or by a separate
sub-timer, a cancel unload wash tank and rinse ware prompt button
95 (next to the illuminated arrows 93 of either the wash tank light
90b or rinse tank light 90c) begins flashing and is active. Once
one of those buttons 95 is pressed by a crew member, the control
system turns off the wash tank and rinse tank instruction lights
90b and 90c and illuminates an instruction light 90a in front of
the soiled drain board 32 and/or scrapper areas. This instructs
crew members to pre-scrap and load soiled wares into the wash tank
30. After a predetermined period of time, again measured either by
the cancel unload/load timer, or by a separate sub-timer, a cancel
pre-scrap and load prompt button 95 (next to illuminated arrows 93)
beings flashing and is active. Once that button 95 is pressed by a
crew member, the unload/load alert timer is reset to zero and
restarted for a new cycle of washing newly loaded wares.
Example 3
[0040] After a Wash Period Timer reaches 3 hours and 50 minutes
(i.e. 3 hours and 50 minutes into the 4 hour wash period), a Blue
"Change Wash Water" LED on the control panel 10 of the machine
illuminates, the Standard Logic (discussed below) is canceled and
the wash pump 20 of the machine restarts (if it has been stopped by
the Standard Logic), or continues operating (if it has not been
stopped by the Standard Logic). In addition, the condition warning
light under the control panel 10 turns on solid (i.e. not flashing)
to notify managers and crew members to perform a last unload of the
wash tank 30 before the 4 hour wash period ends. Once ten minutes
have elapsed, or if the Stop button on the control panel 10 is
pressed, following the 3 hour 50 minutes (i.e. after the 4 hour
period is completed), the wash pump 20 shuts down, the condition
warning light is turned off by the control system, and the blue
"Change Wash Water" LED on the control LED on the control panel 10
is operated to flash by the control system, until the wash tank 30
is drained and refilled as is discussed above.
[0041] Simultaneous with the start of a 4 hour wash period, is the
initiation of the Standard Logic by the control system of the
instant invention. Upon initiation, the Standard Logic of the
control system initiates an unload/load alert timer, starts the
wash pump 20 and activates the heat system for the wash tank 30.
After a 15 minute period is measured by the unload/load alert
timer, in which the wash pump 20 has been running, the alert light
15 (condition warning light), preferably located under the control
panel 10 shown in FIG. 1, is activated by the control system to
flash. The flashing alert light 15 alerts an operator(s) of the
machine that items should be unloaded/loaded in the wash tank 30.
In one embodiment, a remotely located alert light is also
activated. Once the alert light 15 is flashing, the control system
initiates another timer, a cancel unload/load alert timer, and
simultaneously, the control system activates a cancel
unload/load/idle alert button on the control panel 10. When the
button is active, it is illuminated solid, and if it is depressed
by an operator within 5 minutes time elapsing on the cancel
unload/load alert timer, a unload/load 5 minute count down timer is
initiated by the control system. Upon expiration of the 5 minute
unload/load count down timer, the unload/load alert timer is reset
(and the timer restarted) and the flashing alert light 15 is turned
off by the control system. If the cancel unload/load/idle alert
button is not pressed within 5 minutes time elapsing on the cancel
unload/load alert timer, the system goes into an idle mode in which
an idle mode timer is initiated, wash action stops, heat is
deactivated and the alert light 15 below the control panel 10 is
deactivated (turned off) by the control system. In addition, while
in idle mode, the unload/load/idle button flashes quickly to
indicate to an operator(s) that a "Cancel Idle Mode" is active in
which pressing either the unload/load/idle button or the Start Wash
Action button on the control panel 10 cancels the idle mode. When
the idle mode is canceled, the control system brings the system
back into the same operational state as it was after the
unload/load alert reaches 15 minutes (i.e. wash action and heat are
reactivated, alert light flashing, cancel unload/load timer
restarted at zero and unload/load/idle button illuminated and
active). Upon entering idle mode, the control system initiates an
idle mode timer. After 15 minutes in idle mode, if no action is
taken, the wash action and heat are reactivated by the control
system and the system is brought back into the same operational
state as it was after the unload/load alert reached 15 minutes
(i.e. wash action and heat are reactivated, alert light flashing,
cancel unload/load timer restarted at zero and unload/load/idle
button illuminated and active).
Example 4
[0042] After a Wash Period Timer reaches 3 hours and 50 minutes
(i.e. 3 hours and 50 minutes into the 4 hour wash period), a Blue
"Change Wash Water" LED on the control panel 10 of the machine
illuminates, the Standard Logic (discussed below) is canceled and
the wash pump 20 of the machine restarts (if it has been stopped by
the Standard Logic, or continues operating (if it has not been
stopped by the Standard Logic. In addition, the condition warning
light under the control panel 10 turns on solid (i.e. not flashing)
to notify managers and crew members to perform a last unload of the
wash tank 30 before the 4 hour wash period ends. Once ten minutes
have elapsed, or if the Stop button on the control panel 10 is
pressed, following the 3 hour 50 minutes (i.e. after the 4 hour
period is completed), the wash pump 20 shuts down, the condition
warning light is turned off by the control system, and the blue
"Change Wash Water" LED on the control LED on the control panel 10
is operated to flash by the control system, until the wash tank 30
is drained and refilled as is discussed above.
[0043] Simultaneous with the start of a 4 hour wash period, is the
initiation of the Standard Logic by the control system of the
instant invention. Upon initiation, the Standard Logic of the
control system initiates a unload/load alert timer, starts the wash
pump 20 and activates the heat system for the wash tank 30 and
chemical system (if applicable) to automatically dispense chemicals
such as soap, sanitizer, etc. into the wash tank 30. After a 20
minute period is measured by the unload/load alert timer, in which
the wash pump 20 has been running, the alert light 15 (condition
warning light) located under the control panel 10 shown in FIG. 1
is activated by the control system to flash. In a preferred
embodiment, the flash sequence includes three flashes and a pause.
The flashing alert light 15 alerts an operator(s) of the machine
that items should be unloaded/loaded in the wash tank 30. In one
embodiment, a remotely located alert light is also activated to
flash in a synchronized manner with the alert light 15 on the
machine. Simultaneously with the activation of the alert light(s)
discussed above, the control system activates a unload/load/idle
alert button on the control panel 10. When the button is active, it
flashes in sync with the alert light, and if it is depressed by an
operator, a unload/load process 10 minute count down timer is
initiated by the control system and the alert light(s) and
unload/load/idle button begin a different distinctive synchronized
flashing sequence. In a preferred embodiment, the flashing sequence
includes a single flash followed by a single pause. Upon expiration
of the 10 minute unload/load process count down timer, the
unload/load alert timer is reset (and the timer restarted) and the
flashing alert light(s) and flashing unload/load/idle button are
turned off by the control system.
[0044] If the Stop button on the control panel 10 is pressed at any
time during the Standard Logic operation, the system goes into an
idle mode in which an idle mode timer is initiated, wash action
stops, heat is deactivated and the alert light 15 below the control
panel 10 is deactivated (turned off) by the control system. In
addition, while in idle mode, the unload/load/idle button on the
control panel 10 flashes quickly to indicate to an operator(s) that
a "Cancel Idle Mode" is active in which pressing the
unload/load/idle button or the Start Wash Action button on the
control panel 10 cancels the idle mode. When the idle mode is
canceled, the control system brings the system back into the same
operational state as it was after the unload/load alert reaches 20
minutes (i.e. wash action and heat are reactivated, alert light
flashing, unload/load/idle button flashing and active). Upon
entering idle mode, the control system initiates an idle mode
timer. After 15 minutes in idle mode, if no action is taken, the
"Cancel Idle Mode" becomes inactive. After 30 minutes in idle mode,
if no action is taken, the wash action and heat are reactivated by
the control system and the system is brought back into the same
operational state as it was after the unload/load alert reached 20
minutes (i.e. wash action and heat are reactivated, alert light
flashing, unload/load/idle button flashing and active).
Example 5
[0045] After a Wash Period Timer reaches 3 hours and 45 minutes
(i.e. 3 hours and 45 minutes into the 4 hour wash period), a Blue
"Change Wash Water" LED on the control panel 10 of the machine
illuminates, the Standard Logic (discussed below) is canceled and
the wash pump 20 of the machine restarts (if it has been stopped by
the Standard Logic), or continues operating (if it has not been
stopped by the Standard Logic). In addition, the condition warning
light under the control panel 10 turns on solid (i.e. not flashing)
to notify managers and crew members to perform a last unload of the
wash tank 30 before the 4 hour wash period ends. Once 15 minutes
have elapsed, or if the Stop button on the control panel 10 is
pressed, following the 3 hour 45 minutes (i.e. after the 4 hour
period is completed), the wash pump 20 shuts down, the condition
warning light is turned off by the control system, and the blue
"Change Wash Water" LED on the control LED on the control panel 10
is operated to flash by the control system, until the wash tank 30
is drained and refilled as is discussed above.
[0046] Simultaneous with the start of a 4 hour wash period, is the
initiation of the Standard Logic by the control system of the
instant invention. Upon initiation, the Standard Logic of the
control system initiates a unload/load alert timer (adjustable
between 10, 15 and 20 minutes), starts the wash pump 20 and
activates the heat system for the wash tank 30 and chemical system
70 and 54 (if applicable) to automatically dispense chemicals such
as soap, sanitizer, etc. into the wash tank 30 and/or sanitizer
tank 50. After a the adjustable wash cycle period measured by the
unload/load alert timer is completed, in which the wash pump 20 has
been running, the alert light 15 (condition warning light) located
under the control panel 10 shown in FIG. 1 is activated by the
control system to flash. In a preferred embodiment, the flash
sequence includes three flashes and a pause. The flashing alert
light 15 alerts an operator(s) of the machine that items should be
unloaded/loaded in the wash tank 30. In one embodiment, a remotely
located alert light is also activated to flash in a synchronized
manner with the alert light 15 on the machine. Simultaneously with
the activation of the alert light(s) discussed above, the control
panel 10 activates a unload/load/idle alert button on the control
panel 10. When the button is active, it flashes in sync with the
alert light 15, and if it is depressed by an operator, a
unload/load process (adjustable between 5, 10 and 15 minutes) count
down timer is initiated by the control system and the alert
light(s) and unload/load/idle button begin a different distinctive
synchronized flashing sequence to indicate that an unload/load
process is "in process". In a preferred embodiment, the flashing
sequence includes a single flash followed by a single pause. Upon
expiration of the unload/load process count down timer, or if the
unload/load button is pressed during the count down, the
unload/load alert timer is reset (and the timer restarted) and the
flashing alert light(s) and flashing unload/load/idle button are
turned off by the control system.
[0047] If the Stop button on the control panel 10 is pressed at any
time during the Standard Logic operation, the system goes into an
idle mode in which an idle mode timer is initiated, wash action
stops, heat is deactivated and the alert light 15 below the control
panel 10 is deactivated (turned off) by the control system. In
addition, while in idle mode, an unload/load/idle LED on the
control panel 10 flashes quickly to indicate to an operator(s) that
a "Cancel Idle Mode" is active in which pressing the Start Wash
Action button on the control panel 10 cancels the idle mode. When
the idle mode is canceled, the control system brings the system
back into the same operational state as it was after the
unload/load alert timer reaches the end of a wash cycle (i.e. wash
action and heat are reactivated, alert light flashing,
unload/load/idle button flashing and active). Upon entering idle
mode, the control system initiates an idle mode timer. After a
preset period (adjustable between 15, 30, 45 and 60 minutes) in
idle mode, if no action is taken, the control system brings the
system back into the same operational state as it was after the
unload/load alert timer reaches the end of a wash cycle (i.e. wash
action and heat are reactivated, alert light flashing,
unload/load/idle button flashing and active).
[0048] In the foregoing description, certain terms have been used
for brevity, clearness and understanding; but no unnecessary
limitations are to be implied therefrom beyond the requirements of
the prior art, because such terms are used for descriptive purposes
and are intended to be broadly construed. Moreover, the description
and illustration of the inventions is by way of example, and the
scope of the inventions is not limited to the exact details shown
or described.
[0049] Although the foregoing detailed description of the present
invention has been described by reference to an exemplary
embodiment, and the best mode contemplated for carrying out the
present invention has been shown and described, it will be
understood that certain changes, modification or variations may be
made in embodying the above invention, and in the construction
thereof, other than those specifically set forth herein, may be
achieved by those skilled in the art without departing from the
spirit and scope of the invention, and that such changes,
modification or variations are to be considered as being within the
overall scope of the present invention. Therefore, it is
contemplated to cover the present invention and any and all
changes, modifications, variations, or equivalents that fall with
in the true spirit and scope of the underlying principles disclosed
and claimed herein. Consequently, the scope of the present
invention is intended to be limited only by the attached claims,
all matter contained in the above description and shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
[0050] Having now described the features, discoveries and
principles of the invention, the manner in which the invention is
constructed and used, the characteristics of the construction, and
advantageous, new and useful results obtained; the new and useful
structures, devices, elements, arrangements, parts and
combinations, are set forth in the appended claims.
[0051] It is also to be understood that the following claims are
intended to cover all of the generic and specific features of the
invention herein described, and all statements of the scope of the
invention which, as a matter of language, might be said to fall
therebetween.
* * * * *