The present invention relates to a ware separation apparatus in a warewasher and has particular, although not exclusive, relevance for use as an apparatus for selectively removing wares from a conveyor.

In large kitchens such as those found in hotels or hospitals there is a need to rapidly clean very large quantities of dining ware. In these high-volume environments, it is prohibitively time consuming to wash the objects (wares) by hand, and so the process is typically automated using a warewasher system.

Warewasher systems process large numbers of objects, such as crockery or dining trays, to clean the objects of debris such as food waste, liquid waste, napkins, yoghurt pots, receipts, and the like. Objects that enter the machine are often separated into different transport lanes or storage areas. For example, this may be done so that a ware can be routed to a corresponding washing area optimised for washing that particular type of ware, or so that a particular ware may be stored in a tank for soaking. In low-capacity warewasher systems, objects may be manually separated by a user. High capacity warewasher systems on the other hand are highly complex machines able to process hundreds to thousands of objects per hour, and may separate objects automatically.

There is often a need to selectively remove wares from a transport lane, such as a conveyor, and to transport the removed wares to another area of a warewasher. This may be needed, for example, when an object is incompatible with a particular stage of a warewasher. A specialised wash stage of a warewasher may be ineffective at cleaning a particular type of ware, or there may be a risk of damage to the ware or the machinery. One possible solution to this problem is to provide a system such as a vertical conveyor or robotic arm to remove wares from the conveyor. However, such separation systems often require large amounts of space in which to operate, which is a particularly undesirable characteristic when the warewasher is installed in a kitchen environment where the available space is limited. Moreover, such systems are relatively complex, and may significantly increase the cost of the warewasher system.

The present invention seeks to provide an apparatus for transferring wares from a conveyor in a warewasher system, and a method of transferring wares from a conveyor in a warewasher system, for addressing or at least partially ameliorating one or more of the above issues.

In a first aspect the invention provides an apparatus for transferring wares from a conveyor in a warewasher system to another area of the warewasher system, the apparatus comprising: a conveyor comprising a plurality of ware conveying members, wherein the conveyor has a ware transfer area in which the plurality of members are configurable in: a ware conveying configuration for transporting wares on a surface of the members through the warewasher system; and a ware transfer configuration for transferring wares from the conveyor, through a gap provided between the members, to another area of the warewasher system; and means for configuring the plurality of members in the ware conveying configuration when a ware is to be conveyed through the ware transfer area and for configuring the plurality of members in the ware transfer configuration when a ware is to be transferred to another area of the warewasher system.

Each member may comprise a flexible cord (or tape).

When the cords are in the ware conveying configuration, at least two of the plurality of cords may be generally parallel to one another, and may be arranged to convey wares in a direction generally perpendicular to a longitudinal axis of the cords.

When the plurality of cords are in the ware transfer configuration, at least one of the plurality of cords may have at least one longitudinal section which is not parallel to a corresponding longitudinal section of at least one other of the plurality of cords.

The means for configuring the plurality of cords may be configured to move at least one of the plurality of cords to alter a separation, of a respective portion of each of at least two cords of the plurality of cords, in the ware transfer area, between a first separation distance and a second separation distance, that is different to the first separation distance, to respectively change the configuration of the plurality of cords between the ware conveying configuration and the ware transfer configuration.

The second separation distance may be greater than the first separation distance.

The means for configuring the plurality of cords may be configured to move at least two of the plurality of cords to alter the separation.

The first separation distance may be less than a corresponding dimension of a ware to be conveyed by the conveyor and the second separation distance may be greater than the corresponding dimension of the ware to be conveyed by the conveyor, whereby when a ware is in the ware transfer area and the means for configuring changes the configuration of the plurality of cords from the ware conveying configuration to the ware transfer configuration, the ware in the transfer area will pass between two of the cords.

The configuring means may comprise at least one cord repositioning element for engaging with at least one cord of the plurality of cords, wherein the at least one cord repositioning element may be movable between a first arrangement and a second arrangement whereby to change the configuration of the plurality of cords between the ware conveying configuration and the ware transfer configuration.

The at least one cord repositioning element may comprise at least one pulley wheel. The at least one cord repositioning element may comprise at least one pair of pulley wheels arranged for engaging with at least one cord of the plurality of cords. The at least one cord repositioning element may comprise a first pair of pulley wheels for engaging with a first cord of the plurality of cords, and a second pair of pulley wheels for engaging with a second cord of the plurality of cords.

The configuring means may comprise at least one cord engaging element for maintaining respective sections of the plurality of cords, outside the ware transfer area, in a generally parallel configuration when the cords are in the ware removal configuration. The at least one cord engaging element may comprise at least one pulley wheel.

The at least one cord engaging element may comprise at least one pair of pulley wheels arranged for engaging with at least one cord of the plurality of cords.

The at least one cord engaging element may comprise a first pair of pulley wheels for engaging with a first cord of the plurality of cords, and a second pair of pulley wheels for engaging with a second cord of the plurality of cords.

The at least one cord engaging element may comprise a plurality of cord engaging elements arranged in a fixed configuration relative to one another to cause, in operation when the means for configuring changes the configuration of the plurality of cords from the ware conveying configuration to the ware transfer configuration, at least one cord of the plurality of cords to bend around the plurality of cord engaging elements to maintain the respective sections of the plurality of cords outside the ware transfer area in the generally parallel configuration. The tension of at least one of the plurality of cords may be controlled by a cord tensioning means.

The ware may be at least one of a dining tray, item of crockery, service tray or item of cookware.

In a second aspect the invention provides a method of transferring wares from a conveyor in a warewasher system to another area of the warewasher system, wherein the conveyor comprises a plurality of ware conveying members, and the conveyor has a ware transfer area in which the plurality of members are configurable in a ware conveying configuration and a ware transfer configuration, the method comprising: configuring the plurality of members in the ware conveying configuration when a ware is to be conveyed through the ware transfer area; transporting wares on a surface of the members through the warewasher system when the plurality of members are in the ware conveying configuration; configuring the plurality of members in the ware transfer configuration when a ware is to be transferred to another area of the warewasher system; and transferring wares from the conveyor, through a gap provided between the members, to another area of the warewasher system when the plurality of members are in the ware transfer configuration.

Each feature disclosed in this specification (which term includes the claims) and/or shown in the drawings may be incorporated in the invention independently (or in combination with) any other disclosed and/or illustrated features. In particular but without limitation the features of any of the claims dependent from a particular independent claim may be introduced into that independent claim in any combination or individually.

Embodiments of the invention will now be described by way of example only with reference to the attached figures in which:

Figure 1 shows a simplified schematic diagram of a ware separation system;

Figure 2a shows a simplified schematic diagram of a ware separation apparatus in a first configuration;

Figure 2b shows a simplified schematic diagram of the ware separation apparatus in a second configuration; and

Figure 3 shows a simplified block diagram of a control unit. Overview

Figure 1 shows, for illustrative purposes, a simplified schematic diagram of an exemplary ware separation system, generally at 100. The system 100 comprises a conveyor 10, a ware separation stage 20 and a ware receiving area 30.

The conveyor 10 comprises a plurality of ware conveying members which, in the illustrated example comprise a pair of flexible cords 1 , a pair of conveyor walls 5, and a conveyor floor 6. In normal operation the flexible cords are generally parallel to one another at a distance that is less then a corresponding dimension of a ware, such as a dining tray 4 in the present example, that the conveyor 10 is configured to carry. Accordingly, in operation, the ware can be placed on the conveyer 10 in an appropriate orientation in which the ware is supported by the upper surface of the pair of flexible cords 1 , and can be transported by the conveyor 10 in the direction indicated by arrow A, into the ware separation stage 20. The conveyor walls 5 and conveyor floor 6 act as a guard to prevent items from the surface of the trays 4 from falling into other areas of the warewasher during transportation. However, it will be appreciated that the conveyor walls 5 and floor 6 need not necessarily be provided.

Figures 2a and 2b show an exemplary configuration of the ware separation stage 20. As described in more detail later, the ware separation stage 20, in this example, comprises a set of four fixed axis pulley wheels 2 and a corresponding set of four moveable axis pulley wheels 3.

The moveable axis pulley wheels 3 are operable to move between a ware conveying configuration illustrated in Figure 2a, and a ware separating configuration illustrated in Figure 2b.

When the moveable pulley wheels 3 are in the ware conveying configuration, the distance between the cords 1 in the ware separation stage 20 is small enough such that the lower surface of the dining tray 4 can engage with the upper surface of both of the cords 1 simultaneously. When a dining tray 4 is transported into the ware separation stage 20 by the conveyor 10, and the moveable pulley wheels 3 are in the ware conveying configuration, the dining tray 4 remains supported by upper surface of the cords 1 and is transported through the ware separation stage by the conveyor 10.

When the moveable pulley wheels 3 are in the ware separating configuration, the distance between the cords 1 in the ware separation stage 20 is greater than when then moveable pulley wheels 3 are in the ware conveying configuration. The distance between the cords 1 in the ware separating configuration is large enough such that the lower surface of the dining tray 4 can no longer engage with both of the cords 1 simultaneously. Thus, when a dining tray 4 is transported into the ware separation stage 20 by the conveyor 10, and the moveable pulley wheels 3 are in the ware separating configuration, the dining tray 4 can no longer be supported by the pair of cords 1 and falls between the cords 1 , through a corresponding opening 7 in the conveyor floor 6, into a ware receiving area 30.

In operation, when a tray 4 that is approaching the ware separation stage 20 is to remain on the conveyor 10 and pass through the ware separation stage 20, the moveable pulley wheels 3 remain in, or move into, the ware conveying configuration and the tray 4 remains supported by the pair of cords 1 as it passes through the ware separation stage 20. When a tray 4 is identified that is to be removed from the conveyor 10, the moveable pulley wheels 3 move into, or remain in, the ware separating configuration, causing the tray 4 to fall between the pair of cords 1 into the ware receiving area 30.

In summary, therefore, a ware separation system 100 is provided comprising a conveyor 10 and a ware separation stage 20. The system 100 provides a relatively compact and inexpensive apparatus for selectively removing wares from a conveyor 10. Beneficially, the system 100 does not require the use of relatively complex and expensive machinery, such as robotic arms, to selectively remove the wares from the conveyor 10. Moreover, since only a relatively small deflection of the cords 1 is required to allow a transported ware to fall into the ware receiving area 30, the system provides a particularly compact solution compared to other systems for separating wares, such as vertical conveyors.

Illustrative Examples

The ware separation system 100 will now be described in more detail, by way of example only, with reference to Figures 2a, 2b and 3.

The four moveable axis pulley wheels 3 are located in an internal region defined between the flexible cords 1 , and the fixed axis pulley wheels 2 are located externally to the internal region between the flexible cords.

Each of the fixed axis pulley wheels 2 is arranged, in this example, at a respective vertex of a quadrilateral (e.g. rectangular or square) shape. Each of one pair of the fixed axis pulley wheels 2 is arranged to engage with a first of the flexible cords 1 for rotation about its fixed axis as the that flexible cords moves during operation. Similarly each of the other pair of the fixed axis pulley wheels 2 is arranged to engage with the other flexible cord 1 for rotation about its fixed axis as that flexible cord 1 moves during operation.

Each of the moveable axis pulley wheels 3 is arranged, in this example, at a respective vertex of a quadrilateral (e.g. rectangular or square) shape. Each of one pair of the moveable axis pulley wheels 3 is arranged to engage with a first of the flexible cords for rotation about its fixed axis as that flexible cords moves during operation. Similarly each of the other pair of the fixed axis pulley wheels 2 is arranged to engage with the other flexible cord for rotation about its fixed axis as that flexible cord moves during operation.

As can be seen in Figure 2a, when the moveable pulley wheels 3 are in the ware conveying configuration, the distance between the cords 1 in the ware separation stage 20 is smaller than the length of the tray 4 in the direction that is perpendicular to the direction of transport of the conveyor 10. Therefore, when the moveable pulley wheels 3 are in the ware conveying configuration, the tray 4 remains supported by the cords 1 , and is transported through the ware separation stage 20 by the conveyor. When a moveable pulley wheel 3 moves from the ware conveying position to the ware separating position, the moveable pulley wheel 3 pushes the corresponding cord 1 away from the central axis of the conveyor 10, causing the cord 1 to bend around the corresponding fixed axis pulley wheel 2. When the moveable pulley wheels 3 are in the ware separating configuration, the distance between the cords 1 in the ware separation stage 20 is greater than the length of the tray 4 in the direction that is perpendicular to the direction of transport of the conveyor 10. Therefore, the lower surface of the tray 4 cannot simultaneously engage with the upper surface of both of the cords 1 , and the tray 4 falls between the cords 1 into the ware receiving area 30. Beneficially, the fixed axis pulley wheels 2 help to maintain the pair of cords 1 in a generally parallel ware-conveying arrangement outside of the ware separation stage 20, even when the moveable pulley wheels 3 are in the ware separating configuration.

When the moveable pulley wheels 3 move into the ware separating configuration, the movement of the cords 1 away from the central axis of the conveyor 10 causes an increase in the tension in each of the cords 1. A tensioner system, not shown in the figures, may be provided to maintain the tension in each of the cords 1 at a relatively constant value. For example, the tensioner system may provide more slack in each of the cords 1 when the moveable pulley wheels 3 are in the ware separating configuration than when the moveable pulley wheels 3 are in the ware conveying configuration.

The ware receiving area 30 may comprise a storage area for storing the trays 4 that are removed from the conveyor 10. Alternatively, the ware receiving area 30 may comprise a separate conveyor or any other suitable transport means for transporting the removed trays 4 to another area of the warewasher. For example, the ware receiving area may comprise an arrangement of moveable horizontal panels arranged to engage with a corresponding surface or edge of a ware. In operation, a ware may be transferred from the conveyor 10 and engage with a set of the horizontal panels, and the horizontal panels may move generally downwards to transport the ware away from the conveyor 10. Another set of the horizontal panels may then move into an arrangement for receiving the next ware that is transferred from the conveyor 10. The movement of the horizontal panels may be driven by a motor. Alternatively, the horizontal panels may be combined with a pulley arrangement, whereby a brake is released to allow movement of the horizontal panels after a ware has been transferred from the conveyor to the horizontal panels.

In the present example the ware separation stage 20 is controlled by a control unit 8. Figure 3 shows a simplified block diagram of the control unit 8. In this example, the control unit 8 comprises a separation stage interface 81 , a transceiver circuit 82, a controller 84 and a memory 85.

Software stored in the memory 85 includes, among other things, an operating system 86, a communication control module 87 and a ware identification module 88. It will be appreciated that whilst, for ease of understanding, the controller 84 is described as operating under the control of a number of discrete software modules, the functionality attributed to these modules may be built into the overall operating system 86 or as separate code in such a way that the modules may not be discernible as discrete entities.

The transceiver circuit 82 is operable to transmit signals to, and to receive signals from, the separation stage 20 via the separation stage interface 81. The operation of the transceiver circuit 82 is controlled by a controller 84 in accordance with the software stored in the memory 85. The communication control module 87 controls communication with the separation stage 20. For example, the communication control module 87 may send instructions for the moveable pulley wheels 3 to be moved into the ware separating configuration when a tray 4 is to be removed from the conveyor.

The ware identification module 88 identifies a ware that is present on the conveyor 10, and determines if that ware should be removed from the conveyor 10. For example, the ware identification module 88 may receive, from a vision system not shown in the figures, an image of the surface of the conveyor that is prior to the ware separation stage 20. The ware identification module may determine that a ware in the image is to be removed from the conveyor 10 in the ware separation stage 20, or may determine that the ware is to remain on the conveyor 10 and pass through the ware separation stage 20. The determination may be based on, for example, an identified dimension of the ware, or an identified class of the ware. Alternatively, the ware identification module 88 may identify an object such as a mobile phone or wallet on the surface of the ware, and determine that the ware should be removed from the conveyor based on presence of the identified object. It will be appreciated that the ware identification module 88 may determine whether a ware 4 should be removed from the conveyor 10 using any other suitable determination method, such as by using information about the weight of the ware 4.

Modifications and alternatives

An exemplary system and apparatus for selectively removing wares from a conveyor 10 has been described above in detail. As those skilled in the art will appreciate, a number of modifications and alternatives can be applied in the above examples and variations whilst still benefiting from the inventions embodied therein.

In the above examples, the moveable pulley wheels 3 have been illustrated as pushing the cords 1 away from the central axis of the conveyor 10. Alternatively, an apparatus may be provided for pulling the cords 1 away from the central axis of the conveyor 10. For example, telescopic rods may be provided such that one end of a rod is attached to one of the cords 1 , and the other end of the rod is attached to a corresponding wall 5 of the conveyor. The telescopic rod may be attached to the cord 1 and wall 5 by any suitable coupling means, such as a hook. When the telescopic rod is in an extended configuration, the length of the rod is such that there is minimal deflection, or no deflection, of the cords 1 away from the centre of the conveyor. In operation, when the telescopic rod is in the extended configuration, a tray 4 transported by the conveyor 10 into the ware separation stage 20 remains on the upper surface of the cords 1 , and is transported through the ware separation stage 20. When the telescopic rod moves into a retracted configuration, the rod retracts (i.e. shortens in length), causing the cords 1 to be pulled away from the central axis of the conveyor 10. In operation, when the telescopic rod is in the retracted configuration, a ware transported into the ware separation stage 20 falls between the cords 1 into the ware receiving area 30. It will be appreciated that any other suitable apparatus for pulling or pushing at least one of the moveable cords, to alter the distance between the cords in the ware separation stage 20, may be provided.

In the above examples the ware separation stage 20 has been described as comprising a set four moveable pulley wheels 3 for moving both of the cords 1 away from the central axis of the conveyor 1. Alternatively, moveable pulley wheels may be provided on one side of the conveyor 10 only, such that only one of the cords 1 is moved away from the central axis of the conveyor 10 when the moveable pulley wheels 3 move into the ware separating configuration.

Although in the above examples the ware separation stage 20 has been described as comprising a set of four moveable pulley wheels 3, with two moveable pulley wheels 3 arranged to engage with each of the cords 1 , it will be appreciated that the number of moveable pulley wheels that engage with each of the cords 1 could instead be less than or greater than two. For example, a set of two (rather than four) moveable pulley wheels 3 may be provided, with a respective moveable pulley wheel 3 arranged to engage with each of the cords 1.

In the above examples the ware separation stage 20 has been described as comprising a set of moveable pulley wheels 3 and a set of fixed axis pulley wheels 2. Beneficially, the rotation of the pulley wheels about their respective axis, with the movement of the cord, reduces the friction between the pulley wheels and the cord 1. However, it will be appreciated that any other suitable apparatus for increasing the separation of the cords 1 in the ware separation stage 20, or for maintaining the parallel arrangement of the cords outside of the ware separation stage 20, may be provided. For example, instead of the fixed axis and/or moveable axis pulley wheels, vertical rods (that need not rotate) may be provided, in a similar arrangement to the pulley wheels, for pushing at least one of the cords 1 away from the central axis of the conveyor 10. In the above examples the moveable pulley wheels 3 have been described as moving from a ware conveying configuration to a ware separating configuration when a tray 4 is to be removed from the conveyor, to selectively remove trays 4 from the conveyor 10. Alternatively, the moveable pulley wheels may move from the ware separating configuration to the ware conveying configuration, to selectively allow trays 4 to remain on the surface of the conveyor 10. In other words, in normal operation, the default configuration may be either the ware conveying configuration or the ware separating configuration.

In the above examples the ware transported by, and selectively removed from, the conveyor 10 has been described as a dining tray 4. However, it will be appreciated that any other suitable wares such as service trays, cooking trays, dining plates, or other suitable items of dining ware or cookware may be transported by, and selectively removed from, the conveyor 10.

In the above examples the fixed axis pulley wheels 2 and the moveable pulley wheels 3 have been described as being engaged with a corresponding cord 1 when the moveable pulley wheels 3 are in the ware conveying configuration. Alternatively, the fixed axis pulley wheels 2 and the moveable pulley wheels 3 may be engaged with a corresponding cord 1 only when the moveable pulley wheels 3 are in the ware separating configuration, beneficially reducing the friction between the cords 1 and the pulley wheels. For example, the fixed axis pulley wheels 2 may be slightly offset, away from the central axis of the conveyor 10, such that a corresponding cord 1 only engages with the fixed axis pulley wheels when the cord 1 is bent by the moveable pulley wheels 3.

In the above examples the conveyor 10 has been described as comprising a pair of flexible cords 1. However, it will be appreciated that the conveyor 10 may comprise any other suitable means for transporting wares, such as a pair of flexible tapes. Moreover, whilst the use of cords is particularly advantageous, some of the benefits of being able to pass a ware vertically through a gap provided in the conveyor to a storage area, or to another ware transport mechanism, might also be achieved for a conveyor comprising rollers which are configured to move apart from one another to allow the wares to pass through the resulting gap.

Various other modifications will be apparent to those skilled in the art and will not be described in further detail here.