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.

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.