A MULTISTAGE CLEANING APPARATUS AND METHOD

Abstract: A multistage apparatus having a parts washing unit (21) that utilizes bioremediation to clean the cleaning fluid, said unit further having two internal chambers (27 and 28) for holding the cleaning fluid and bioremediation agents. The multistage washing apparatus further includes a cleaning fluid reservoir (22) for refilling the parts washer (21) and a plurality of satellite stations including a hand washer (23), a bench top washer (24), a brake washer (25) and a second parts washer (26). The cleaning fluids contained in each of the satellite stations are transferred to the parts washer (21) for cleaning by the bioremediation agents.

Description: A MULTISTAGE CLEANING APPARATUS AND METHOD FIELD OF THE INVENTION This invention relates (1) to apparatus and methods for cleaning, particularly to methods and apparatus for washing and cleaning human body parts such as skin of hands and non-biological articles e.g. parts of machines; and (2) to methods and apparatus for recycling the fluids used for such washing or cleaning. BACKGROUND OF THE INVENTION There are many industries that have the problem of cleaning parts that have become dirty and in having persons working with the parts clean their hands and bodies as well. Such industries include automotive repair and metal fabrication. Additionally, there are other fields in which technicians' hands become dirty or otherwise contaminated and thus need to be cleaned. Various solutions to these problems are known. These solutions, however, generally address the problems as separate and district. That is, the methods and apparatus for cleaning the non-biological parts are not necessarily used in conjunction with, or complementary to, the methods and apparatus used for washing hands. This results in wasting time and resources, including increased cost for water, increased cost for soaps and hand cleaners, and excess loads on waste water treatment systems. SUMMARY OF THE INVENTION The present invention offers an improvement in the methods and apparatus for cleaning items such as non-biological parts, articles and human skin, by incorporating such operations into a multistage system. In an embodiment of the invention there is provided a multistage washing apparatus including a satellite washing unit, a second washing unit, and a controller. Fluid is used for cleaning. The satellite unit, or first unit is in fluid association with the second washing unit so that fluid from the satellite unit can be transferred to the second washing unit. The controller is associated with the satellite unit and the second washing unit to control the transfer of such fluid; the second washing unit having a holding tank, in which biological agents for cleaning the fluid can be placed. A satellite unit is a unit appending to another main or base unit. In another embodiment of the invention there is provided a multistage cleaning system including a plurality of satellite cleaning stations and a base cleaning station. The satellite cleaning stations include a fluid reservoir, basin and a cleaning fluid. At least one of the satellite cleaning stations is a hand washing station. The base cleaning station includes a fluid reservoir, a basin, cleaning fluid and a holding tank containing biological agents capable of cleaning the fluid in the base cleaning station. In a further embodiment of the invention there is provided a process for cleaning which process includes obtaining a cleaning fluid, using that cleaning fluid to clean a item, monitoring the use of the cleaning fluid, at a predetermined point transferring the cleaning fluid to a cleaning apparatus, using the cleaning fluid in the cleaning apparatus to clean the items, and cleaning the cleaning fluid while it is in the cleaning apparatus, so the fluid is available for recycling. In yet a further embodiment of the invention there is provided a process for cleaning including obtaining a cleaning fluid having about a neutral pH, using the cleaning fluid for hand washing, determining that the cleaning fluid is no longer clean enough for hand washing purposes, transferring the cleaning fluid to a parts washer, using the cleaning fluid in the parts washer to clean articles, and cleaning the cleaning fluid in the parts washer with biological agents. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic flow diagram of a multistage washing apparatus. FIG. 2 is a schematic diagram of an example of a multistage washing apparatus and process. FIG. 3 A and 3B are schematics of an integrated circuit board that can be used to control the washing apparatus and process depicted in FIG 2. FIG. 4 is a schematic of an alternative example of a multistage washing apparatus and process. DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1 there is shown a schematic generally illustrating a multistage washing apparatus. The apparatus has a satellite (a first) washing unit 1, a second or base washing unit 2 and a control unit 3 (a controller). The control unit, although shown in the figure as being separate from the satellite unit, preferably may be incorporated into the satellite unit or the second washing unit. The satellite unit may be, for example, a hand washing station, a brake washing station, a bench top parts washer, or another parts washer for light cleaning work such as removing dust rather than grease. This station uses a cleaning fluid such as, for example, water, solvents, solvent free cleaning fluids, and aqueous cleaning fluids. Preferably, the cleaning fluid is both safe to the hands and skin, effective to remove grease, oil and other dirt to be removed from the items to be cleaned, and compatible with bacteriological or other living agents that can assist in the cleaning of the fluid through bioremediation. Preferably the cleaning fluid would have a neutral pH. A presently preferred cleaning fluid is obtainable from ZYMO ® International, of Duluth Georgia, under the trade name Surfzyme, ® and is a water based cleaning fluid. Generally, the cleaning fluid is used in the satellite unit for light cleaning, such as washing hands or parts that do not have a high level of dirt. As the cleaning fluid in the first washing unit, the satellite unit, becomes dirty, the fluid is then be transferred to the second washing unit for further uses and to be cleaned by biological agents, if necessary. The second washing unit may be a parts washer or other cleaning device for heavier cleaning applications, including solvent based, aqueous based, water based non-bioremediation and bioremediation parts washers. Preferably the second unit is a bioremediation parts washer and has the capability to hold and use bacteriological agents to clean the fluid through bioremediation. Although not shown in FIG. 1, additional satellite units can also be employed, and these units can be used in parallel or serially. In other words, the fluids from the satellite units can be sent directly to the second washing unit, or the fluid from one satellite unit can be sent to a second satellite unit and so on until the fluid is finally sent to the second washing unit. An example of a satellite cleaning unit is a hand washer, is to where reference is to human hand skin. This unit has a self-contained vessel with power (e.g., 12 volts) for heating and recirculation of the fluid. The hand washing unit is used by technicians or mechanics to wash their hands to remove oil, grease, and other dirt, soil or contaminants. The cleaning fluids from this unit are than manually transferred, when dirty, or at predetermined intervals, to a second washing unit. This transfer may also take place automatically by the control unit. The hand washing unit may also have the ability to be refilled automatically, which refilling operation may also be controlled and regulated by the control unit. The use of this process and system reduces the amount of time technicians or mechanics spend in the washroom washing their hands. Generally, these individuals must leave their workstation and go to the washroom for cleaning their hands. It has been estimated that this can take as much as 30 to 40 minutes out of an 8-hour work day. By having a hand washing unit located at or near their workstations, this lost or down time could be reduced. An example of the second washing unit is a parts washer. Because the fluid from the hand washer is then used in the parts washer, where it can be cleaned through bioremediation, the costs of operating the parts washer are greatly reduced. Little or no additional cleaning fluid is needed to replace the fluid that is lost in the parts washer through evaporation, dragout, or biodegradation, because such lost fluid is replaced by the fluid from the hands washer. Further, by not discarding the fluid used for hand washing (soap and water is normally discarded down the drain) this process and system reduces the effluent and the associated costs to clean it. The control unit controller monitors, controls and regulates the operation parameters of the multistage washing apparatus. The control unit generally consists of a microprocessor, but may be any other of the older types of controllers known to the art. Although a single control unit is shown and is preferred, multiple control units may also be employed including multiple units that work in conjunction with a main control unit. One of the operation parameters that the control unit may either monitor or perform is the transfer of fluid from one washing unit to the next. This may be done either entirely automatically, such as based on time, dirt level of the fluid, or usage of the fluid, or manually with the controller only monitoring and recording the transfers. For example, the controller can monitor and control such parameters as: temperature; fluid levels; alarms (e.g., fluid levels, fluid temperatures, fluid usage); pumps and motors; time; total usage; and total time that a fluid has been in use in the particular washing unit as well as in the entire system. The controller and the apparatus can have variable temperature settings for the controller, and the apparatus can have variable temperature settings for the fluid. Thus, different temperatures can be set and maintained for each washing unit, and for particular times. For example, the temperature may be lower in the evening if the facility is not operational at night and then may be raised prior to the start of business the next day, so that the unit is warmed up and fully operational when the facility opens. The unit can also use this internal clock to operate recycle and transfer pumps at scheduled intervals or cause such operations to be performed based upon a combination of parameters such as time and usage. The control unit can also convert between USA and metric units and is operable and convertible between 110V, 220V and other voltages commonly found in industrial facilities in the USA and throughout the world, such as by the use of a 110V or 220V DIP switch. This allows the washing units to be operable at these voltages. The unit can further have an EPROM or other device that permits the unit to retain any settings, stored data, and control parameters in the event of a power loss. An additional and alternative feature of the control unit is to incorporate a bar code scanner or other similar inventory control device so that the parts that are being washed can be monitored and compared to the fluid life of the units. This permits the facility to obtain valuable data as to the stages, location and numbers of washing units that should be in the washing system, as well as, the order in which certain parts are to be washed in those units. This data enables each facility to maximize its usage of fluid and the time that it takes for cleaning. Although many types of fluid level monitors are known, ranging from a simple toilet float-like device to conductivity sensors, it is preferred that when using fluids in conjunction with oil, grease and biological agents that the level sensor be a pressure type sensor with possibly a Teflon wrap. The Teflon wrap prevents adhesion of microorganisms and other material (e.g., oil and grease) to the sensor. Optimally the control unit has the ability to monitor, control or regulate at least 5 variable temperature settings, at least 5 variable pump cycle times, fluid monitoring with continuous digital level readouts, hi/lo fluid level alarms, transfer of fluid to or from an external vessel, 110V or 220V DIP switch settings and an time. Preferably the control unit operates displays or readouts (either located on the control unit, the washing units or at some other location where it is convenient for such displays to be located, e.g., the computers of the operations personnel). These displays or readouts preferably include fluid levels, temperature, pump operation, pump cyclitime and self- diagnostics. EXAMPLES The following examples provide embodiments of the invention. Example 1. A Multistage Washing Apparatus and Process. FIG. 2 is a schematic diagram of an example of a multistage washing apparatus and process. The multistage washing apparatus has a parts washing unit 21 that utilizes bioremediation to clean the cleaning fluid. Such units are commercially available from ZYMO ® International, under the trade name ZYMO ® , from Chemfree, of Norcross, Georgia, under the trade name Smartwasher ® , and from Kleerflo, of Minnesota, under the trade name Kleerflo. The parts washing unit 21 further has two internal chambers 27 and 28 for holding cleaning fluid and bioremediation agents. The multistage washing apparatus further has a cleaning fluid reservoir 22 for refilling the parts washer 21, and several satellite stations including a hand washer 23, a bench top washer 24, a brake washer 25 and another parts washer 26, for lighter cleaning. In operation, as the cleaning fluids in the satellite stations become dirty, they have to be transferred to the parts washer 21 for use (as well as to be cleaned). These transfers are accomplished either manually or automatically. In the case of the present example, it is contemplated that the transfer from the brake washer 25, the bench top washer 24 and the hand washer 23 occur manually, while the transfer from the parts washer 26 occurs automatically. The refilling of the parts washer 21 from the reservoir 22, as well as the transfer of the fluid from chambers 27 and 28, occurs automatically. Alternatively, the fluid from the satellite units may be transferred to reservoir 22. A schematic of an example of circuit boards that can be used to control this multistage washing apparatus are shown in FIG. 3A and 3B. Two circuit boards are used with this system. A sensor board shown schematically in FIG. 3 A and a main board shown schematically in FIG. 3B. These boards are separate to enable the calibration of sensing devices associated with the sensor board (but not shown in the schematic) to be calibrated in the factory before shipment to a customer's location. This calibration in the factory allows sensing devices to be easily installed or replaced in the field without the need for a skilled technician at the facility to calibrate them. The sensor board shown in FIG. 3 A shows the configuration for both the temperature sensor and the level sensor. In use it is to be understood that the board is configured for either one sensor or the other. Thus each sensor has its own sensor board. For the level sensor, which is based upon pressure, the sensor which comprises a Delrin tube, is inserted at 31. The signal from the sensor is amplified by a 1000 gain amplifier 32. The signal from amplifier 32 is then filtered by noise filter comprising resistors 33 and capacitor 34. The signal is then amplified by a two gain amplifier 35 and further filtered by a filter comprising resistor 36 and capacitor 37. The signal is then sent via plug 38 to the main board. The circuitry 39 consisting of a potentiometer is used to adjust the gain so that the board, and thus the sensor that is plugged into it, can be calibrated. The circuitry 313 is an offset to adjust the zero point for the sensors. For the temperature sensor, the sensor is plugged into plug 310. The temperature sensor, which is a solid state temperature sensor generates a current which is converted to a voltage by resistors 311 and 312. The signal is then filtered by the filters 33, 34 and amplified by amp 35. The signal is then further filtered by filter 36,37 and sent to the main board via plug 38. The gain adjusting circuitry 39 and the zeroing circuitry 313 are also used when the board is configured for the temperature sensor. The signal from the sensor board is received by the main board via plugs 41 on the main board (FIG. 3B). The main board has a test port 42. The main board has circuitry 62 to convert 1 lOVand 220V A/C power into the DC voltages that operate the boards. This comprises a plug 42a for connection to the AC power source, a switch for switching between 110V and 220V power sources, a transformer 42c, the fuse may also be located at a point around 42d, a regulator 42e that provides 5 volts DC, and a regulator 42g that provides 7.5 volts DC, which runs the sensor circuit. The line 42f has raw DC voltage of 10 volts. The board further comprises a grouping of plugs and switches 43 that are for connection to and control of the recirculation pump in the parts washer, a transfer pump from the reservoir, and a transfer pump ("Auxiliary Inputs" on the schematic) from the second light cleaning parts washer. The board also contains: a DIP switch 44, which settings are labeled on the drawing and which are incorporated herein by reference; a grouping of buttons 410, for controlling the readouts and setting the ranges of the readouts; a microprocessor 45; real-time circuitry and EPROM 46, circuitry to control a multiplex LED display 47; circuitry to control an alarm buzzer or horn 48, and circuitry to control a warning light 49, which indicates temperature and low fluid levels. Example 2. Another Multistage Washing Apparatus and Process Another example of a multistage washing apparatus and process is illustrated in FIG. 4. In this washing apparatus there is a satellite station 51, a controller 52 and a washing station with bioremediation capabilities 53. The apparatus has recirculation pumps 54 and 55, and a transfer pump 56. Satellite station 51 has a fluid reservoir 57 (which is shown external to the unit but can easily be incorporated into the unit so as not to be seen and to reduce the overall space of the unit), a holding reservoir 58 (shown in phantom lines), and a sink basin 59 (also shown in phantom lines). The fluid reservoir 57 has a heating element and sensor 510 and a fluid level sensor 511. The holding tank 58 has a fluid level sensor 517 and a heating element and sensor 519. The washing apparatus with bioremediation capabilities 53 has a fluid reservoir 512 (which is shown external to the unit but can easily be incorporated into the unit so as not to be seen and to reduce the overall space of the unit), a holding reservoir 515 (shown in phantom lines), and a basin 516 (also shown in phantom lines). The fluid reservoir 512 has a heating element and sensor 513 and a fluid level sensor 514. The holding tank 515, in which the bioremediation agent would be located would have a level sensor 518 and a heating element and sensor 520. The controller 52 monitors and controls the fluid levels and temperature in the reservoir tanks 57; and operates the transfer pump 56 and recirculation pumps 54 and 55 to the parameters set by the operators. Although the pumps and tanks are depicted as being outside of the cleaning unit, these pumps and tanks can be incorporated into the units themselves to provide a compact apparatus. This apparatus may also be portable or fixed.

Claims: We Claim: 1. A multistage washing apparatus for use in washing human body parts and non-biological articles with a cleaning fluid, said apparatus comprising: (a) a first washing unit which is a satellite unit; (b) a second washing unit in fluid association with the satellite unit; said unit comprising a holding tank for placement of biological agents added to clean the cleaning fluid; (c) a controller associated with both the satellite washing unit and the second washing unit, said controller directing transfer of the cleaning fluid between the satellite unit and the second washing unit. 2. A multistage cleaning system comprising: (a) a plurality of satellite cleaning stations, said stations comprising: i. a fluid reservoir, ii. a basin, and iii. a cleaning fluid; and (b) a base cleaning station, said station comprising: i. a fluid reservoir, ii. a basin, and iii. a holding tank for containing biological agents and having cleaning fluid cleaned and circulating through the system 3. The multistage cleaning system of claim 2, wherein at least one of the satellite cleaning stations is a hand washing station. 4. The satellite unit of claim 1 further defined as a hand washing unit. 5. A method for cleaning human body parts and non-biological articles and parts, said method comprising: (a) contacting the human body parts or non-biological articles and parts with a cleaning fluid; (b) monitoring the cleaning fluid to determine when it needs to be cleaned; and (c) cleaning the cleaning fluid with biological agents so it can be recycled. 6. The method of claim 5, wherein the cleaning fluid is within the cleaning apparatus and wherein the cleaning fluid is cleaned within the apparatus. 7. The method of claim 5, wherein the cleaning fluid has about a neutral pH. 8. The method of claim 5, wherein the cleaning fluid is water based. 9. A multistage apparatus having a parts washing unit 21 that utilizes bioremediation to clean the cleaning fluid, said unit further having two internal chambers 27 and 28 for holding the cleaning fluid and bioremediation agents; the multistage washing apparatus further having a cleaning fluid reservoir 22 for refilling the parts washer 21 and a plurality of satellite stations including a hand washer 23, a bench top washer 24, a brake washer 25 and another parts washer 26, for lighter cleaning; said cleaning fluids in the satellite stations transferring to the parts washer 21 for use after the fluid becomes dirty and for cleaning of the fluid. 10. A multistage washing apparatus having a satellite station 51, a controller 52 and a washing station with bioremediation capabilities 53, said apparatus having recirculation pumps 54 and 55, and a transfer pump 56, said satellite station 51 having a fluid reservoir 57, a holding reservoir 58 a sink basin 59, said fluid reservoir 57 having a heating element and sensor 510 and a fluid level sensor 511, said holding tank 58 having a fluid level sensor 517 and a heating element and sensor 519. 11. The washing apparatus of claim 10 further defined as having a fluid reservoir 512, a holding reservoir 515, and a basin 516 ; said fluid reservoir 512 having a heating element and sensor 513 and a fluid level sensor 514, the holding tank 515 in which the bioremediation agent is located having a level sensor 518 and a heating element and sensor 520, said controller 52 monitoring and controlling the fluid levels and temperature in the reservoir tank 57; the apparatus operating the transfer pump 56 and recirculation pumps 54 and 55 to parameters set by the operators.

Inventors: AFFOLDER DAVID, WHITEMAN GEORGE R, AFFOLDER, DAVID, WHITEMAN, GEORGE, R.
Applicants: AFFOLDER DAVID, WHITEMAN GEORGE R, AFFOLDER, DAVID, WHITEMAN, GEORGE, R.
Application year: 1999
Main classification: B08B7
IPC codes: B08B3