Systems And Methods For Automatically Cleaning Converters With Heated Fluids

Abstract

A method of cleaning a converter, the method including the steps of: providing a heating unit for heating a cleaning fluid; providing a ring main for continuous circulation of heated cleaning fluid around the ring main; connecting the heating unit to the ring main; connecting the ring main to the converter to enable delivery of heated cleaning fluid to the converter; and providing a controllable cleaning fluid valve for delivery of a heated cleaning fluid, and providing a controllable rinsing fluid valve for delivery of a rinsing fluid; providing a controller for controlled delivery of a sequence of the rinsing fluid and the heated cleaning fluid to the converter upon recognition of a rinsing fluid delivery condition and a heated cleaning fluid delivery condition, respectively.

Claims

1-53. (canceled)

54. A method of cleaning ink from components of a converter configured for the manufacture of printed material, the method including the steps of: a. Providing a heating unit for heating a cleaning fluid; b. Providing a ring main for continuous circulation of heated cleaning fluid around the ring main; c. Connecting the heating unit to the ring main; d. Connecting the ring main to the converter to enable delivery of heated cleaning fluid to the converter; and e. Providing a controllable cleaning fluid valve for delivery of a heated cleaning fluid, and providing a controllable rinsing fluid valve for delivery of a rinsing fluid; f. Providing a controller for controlled delivery of a sequence of the rinsing fluid and the heated cleaning fluid to the converter upon recognition of a rinsing fluid delivery condition and a heated cleaning fluid delivery condition, respectively; wherein the ring main is positioned proximate to the converter such that the heated cleaning fluid is able to be delivered to the converter within a predetermined time after the controller recognises the heated cleaning fluid delivery condition.

55. The method of claim 54, wherein the rinsing fluid is deliverable to a cleanable part of the converter within a predetermined time after the controller recognises the rinsing fluid delivery condition, and the controller is configured to deliver heated cleaning fluid from the ring main to the cleanable part of the converter within a range of about 1 second to about 60 seconds after occurrence of the cleaning fluid delivery condition.

56. The method of claim 54, wherein one or more of the ring main, the controllable cleaning fluid valve and the controllable rinsing fluid valve is positioned to be proximate to a boundary of the converter, and the controller is configured to deliver heated cleaning fluid from the ring main to the boundary of the converter within a range of about 1 second to about 30 seconds after occurrence of the cleaning fluid delivery condition.

57. The method of claim 55, wherein after occurrence of an initial rinsing fluid delivery condition, the controller is able to operate the controllable rinsing fluid valve to provide an initial delivery of rinsing fluid to the cleanable part of the converter for about 2 seconds to about 4 seconds.

58. The method of claim 54, wherein the controllable heated cleaning fluid valve and the controllable rinsing fluid valve comprise a single controllable valve.

59. The method of claim 54, wherein delivery of cleaning and rinsing fluid includes delivery to a fluid inlet of the converter, the fluid inlet being in fluid connection to the cleanable part of the converter; and the fluid inlet is a rinsing fluid and cleaning fluid inlet that is able to receive both heated cleaning fluid from the ring main and rinsing fluid from a rinsing fluid source.

60. The method of claim 56, wherein the converter is connected to a rinsing fluid line for supplying the rinsing fluid to the converter and the method includes the step of providing a manifold including one or both of the controllable cleaning fluid valve and the controllable rinsing fluid valve for fluid connection of both of the ring main and the rinsing fluid line to a fluid inlet of the converter; and the manifold is located proximate to the boundary of the converter or inside the converter.

61. The method of claim 54, wherein the method includes the step of heating cleaning fluid in the heating unit to a temperature in a range of about 35° C. to about 40° C.

62. The method of claim 54, wherein: the heating unit includes an outlet for introducing heated cleaning fluid into the ring main and an inlet for receiving cleaning fluid that has circulated around the ring main; the heating unit inlet is connectable to a cleaning fluid source; the method includes providing a diluter and the cleaning fluid source comprises a container of concentrated cleaning solution, the container being in fluid connection to the diluter for diluting the concentrated cleaning solution with a diluting fluid; and the diluting fluid is supplied from a diluting fluid source, and the diluting fluid source is the same source as a rinsing fluid source.

63. A system of cleaning ink from components of a converter configured for the manufacture of printed material, the system including: a. A ring main for fluid connection to the converter, the ring main positioned proximate to the converter; b. A heating unit for heating a cleaning fluid, the heating unit being connectable to the ring main to enable continuous circulation of heated cleaning fluid around the ring main, and delivery of the heated cleaning fluid to the converter; c. A controller adapted to provide controlled delivery of the heated cleaning fluid.

64. The system of cleaning ink according to claim 63, wherein the controller is configured to deliver heated cleaning fluid from the ring main to a cleanable part of the converter within a range of about 1 second to about 60 seconds after occurrence of a cleaning fluid delivery condition.

65. The system of claim 64, wherein: the system includes a controllable cleaning fluid valve for delivery of the heated cleaning fluid, and a controllable rinsing fluid valve for delivery of a rinsing fluid; the controller is configured for controlled delivery of the rinsing fluid to the converter; and after occurrence of an initial rinsing fluid delivery condition, the controller is able to operate the controllable rinsing fluid valve to provide an initial delivery of rinsing fluid to the cleanable part of the converter for about 2 seconds to about 4 seconds.

66. The system according to claim 65, wherein the controllable heated cleaning fluid valve and the controllable rinsing fluid valve comprise a single controllable valve.

67. The system according to claim 65, wherein delivery of cleaning and rinsing fluid includes delivery to a fluid inlet of the converter, the fluid inlet being in fluid connection to the cleanable part of the converter; and the fluid inlet is a rinsing fluid and cleaning fluid inlet that is able to receive both heated cleaning fluid from the ring main and rinsing fluid from a rinsing fluid source.

68. The system according to claim 65, wherein the system includes a manifold including one or both of the controllable cleaning fluid valve and the controllable rinsing fluid valve for fluid connection of both of the ring main and the rinsing fluid line to a fluid inlet of the converter, and the manifold is located proximate to a boundary of the converter or inside the converter.

69. The system according to claim 68, wherein the manifold includes a dual inlet valve having an output that is in fluid connection to the fluid inlet of the converter, wherein a first inlet of the dual inlet valve is in fluid connection to the ring main and a second inlet of the dual inlet valve is in fluid connection to the rinsing fluid line.

70. The system according to claim 63, wherein the heating unit comprises a heat exchanger configured for heating cleaning fluid in the heating unit to a temperature in a range of about 35° C. to about 40° C.

71. The system according to claim 63, wherein: the heating unit includes an outlet for introducing heated cleaning fluid into the ring main and an inlet for receiving cleaning fluid that has circulated around the ring main; the heating unit inlet is connectable to a cleaning fluid source; the method includes providing a diluter and the cleaning fluid source comprises a container of concentrated cleaning solution, the container being in fluid connection to the diluter for diluting the concentrated cleaning solution with a diluting fluid; the diluting fluid is supplied from a diluting fluid source, and the diluting fluid source is the same source as a rinsing fluid source.

72. The method of claim 54, wherein the method is a retrofit method, using one or more of, or a combination of the following existing components: a valve, a manifold, a fluid line and a controller, connected to or part of an existing converter.

73. The system of claim 63, wherein the system is a retrofit system, using one or more of, or a combination of the following existing components: a valve, a manifold, a fluid line and a controller, connected to or part of an existing converter.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0173] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0174] FIG. 1 is a schematic illustration of a system for cleaning a converter in accordance with a preferred embodiment of the present invention;

[0175] FIG. 2 is a schematic illustration of a system for cleaning a converter in accordance with another preferred embodiment of the present invention;

[0176] FIG. 3 is a flow diagram of the steps of a method for cleaning a converter, in accordance with a first illustrative method of the invention;

[0177] FIG. 4 is a schematic illustration of a manifold adapted for use with the present invention;

[0178] FIG. 5A is a schematic illustration of systems including first manifold and a second manifold for delivering heated cleaning fluid and rinsing fluid to a converter including cleanable components, in accordance with further preferred embodiments of the present invention;

[0179] FIG. 5B is a schematic illustration of systems including first manifold and a second manifold for delivering heated cleaning fluid a converter including cleanable components, in accordance with further preferred embodiments of the present invention;

[0180] FIG. 6 is a schematic illustration of systems including plurality of manifolds connected to a converter including cleanable components, in accordance with further preferred embodiments of the present invention;

[0181] FIG. 7 is a schematic illustration of the heat exchanger unit and associated components as part of a system for cleaning a converter in accordance with a preferred embodiment of the invention;

[0182] FIG. 8 is a flow diagram of the steps of a method for cleaning a converter, in accordance with a second illustrative method of the invention; and

[0183] FIG. 9 is a schematic illustration of a system for cleaning a converter in accordance with a further preferred embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0184] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[0185] FIG. 1 depicts a system 5 for cleaning two converters, 10A and 10B. The system 5 includes a heating unit 20, comprising a heat exchanger including a coiled tube though which the cleaning fluid is able to flow, and, in this way, controlled heating may be effected. In particular, the coiled tube in the heat exchanger is surrounded by a fluid (water) having an elevated temperature (approximately 100° C.). The cleaning fluid is run through the coiled tube and in this way is indirectly heated. It will be appreciated by the skilled addressee that such heat exchange unis keep the cleaning fluid separate to the surrounding heat exchange liquid (i.e. the shell side fluid), and this arrangement is used in preference to a heating element type heating unit as the cleaning fluid can deposit on the heating element and that in turn reduces the effect of the cleaning fluid, as well as causing the heating element to burn out. In particular, where the cleaning fluid includes components that are particularly sensitive to temperature, such as enzymes, the heat exchanger set up as depicted in FIG. 1 is configured to minimise the damage to such components (e.g., denaturing the enzymes) as they are not in direct contact with any high temperature heating component (e.g., a heating element). The proposed heat exchange unit arrangement also minimises fire hazards or related risks that may occur in the context of a printed material or box manufacturing plant where a naked flame or exposed high temperature heating elements can be a substantial risk due to surrounding combustible or flammable materials.

[0186] The ring main 30, is connected to the heating unit 20 via an outlet at a first end 21 such that heated cleaning fluid enters into the ring main 30, and can circulate around the length of the ring main 30, to re-enter at an inlet near a second end 22 of the heating unit 20, where it can be re-heated. The circulation of heated cleaning fluid is maintained using the circulation pump 70.

[0187] The ring main 30 is connected to each of the converters, 10A and 10B, via an isolation valve 50A, and 50B, respectively. It is noted that only one isolation valve for each converter is depicted in FIG. 1, however, in practice the ring main would be isolated from each of the printdowns 60A, 60B, 60C and 60D by separate isolation valves, so that each printdown could be separately cleaned (i.e., permitting continuous running of one or more printdowns while one or more other printdowns were being cleaned).

[0188] The ring main 30 is also connected to a t-valve which connects a cleaning fluid source 80 to the heating unit 20. The fluid line connecting the fluid source 80 to the heating unit 20 includes a chemically resistant non-return valve 85 to maintain the volume of cleaning fluid flowing around the ring main 30. In this way, the total volume of the cleaning fluid in the ring main 30 and heating unit 20 remains reasonably constant, as it is topped up from the cleaning fluid source 80 when cleaning fluid is delivered to the converters 10A, 10B.

[0189] The ring main 30 is positioned proximate to a boundary of the converter to reduce the ‘dead time’ prior to heated cleaning fluid delivery (i.e., the time before which the controller can deliver heated cleaning fluid into the converter).

[0190] The heating unit 20 is adapted to heat the cleaning fluid to a temperature of approximately 40° C., so that it can be circulated around the ring main 30 at or around this temperature. The ring main 30 comprises a plurality of connected flanged copper pieces, and is insulated to minimise loss of heat of the heated cleaning fluid as it travels around the ring main 30.

[0191] The system 5 further includes a controller (not shown) that controls delivery of heated cleaning fluid into converter 10A using solenoid valve 40 for controlling flow of the heating cleaning fluid through the manifold 47 and into the converter (and in particular to the anilox roll 65 of the converter 10A, though the cleaning fluid will travel to other cleanable parts of the converter such as the ink lines, and ink chamber, as part of this process).

[0192] The ring main 30 is connected to the manifold 47 located at the boundary of the converter 10A, via a downpipe that extends from the ring main 30 to a manifold 47. The manifold 47 may alternatively be located inside the converter 10A.

[0193] The manifold 47 includes a dual inlet valve including a cleaning fluid solenoid valve 40 and, a rinsing fluid solenoid valve 45 and an output 48 that is in fluid connection to the fluid inlet 49 of the first printdown 60A of converter 10A, wherein a first inlet of the dual inlet valve (located adjacent to the cleaning fluid solenoid valve 40) is in fluid connection to the ring main 30, via isolation valve 50A and a second inlet of the dual inlet valve (located adjacent to the rinsing fluid solenoid valve 45) is in fluid connection to the rinsing fluid line 95.

[0194] The controller controls delivery of rinsing fluid via rinsing fluid line 95 from rinsing fluid source 90 (i.e., mains water supply), by selectively activating solenoid valve 40 that is connected to the rinsing fluid line 95.

[0195] Further, the controller controls delivery of rinsing fluid and cleaning fluid into the second converter 10B, in a manner analogous to the control of delivery of rinsing fluid and cleaning fluid to the first converter 10A.

[0196] In operation, the controller is able to activate the cleaning fluid solenoid valve 40 to deliver heated cleaning fluid from the ring main 30 to the anilox roll 65 of the converter 10A within about 5 to 15 seconds of occurrence of a cleaning initiation condition at the controller.

[0197] In these about 5 to 15 seconds, the following takes place: [0198] a first timed rinse of about 3 to 5 seconds of rinsing fluid is delivered to the anilox roll 65 by the controller activating rinsing fluid solenoid valve 45 in manifold 47 to connect the fluid line 95 to the fluid inlet 49 of the first printdown 60A; [0199] a sequence comprising timed delivery of heated cleaning fluid to the anilox roll 65 commences. This sequence comprises activation by the controller of cleaning fluid solenoid 40 so that heated cleaning fluid travels from ring main 30 through the manifold 47 and along the piping external and internal to the converter, and to the anilox roll 65 of first printdown 60A. The sequence of heated cleaning fluid delivery may last for about 60 seconds, about 90 seconds, about 180 seconds or about 240 seconds, depending on whether the cleaning initiation condition recognised by the controller comprises a two-minute, four-minute, six-minute, or eight-minute controlled alternating timed delivery cycle. A four-minute cycle is described in more detailed below.

[0200] It is noted that heated cleaning fluid circulates around the ring main 30, as far as the manifold 47. Heated cleaning fluid likewise circulates as far as further manifolds, not shown, each respective further manifold being located adjacent to the boundary of the respective printdowns 60B, 60C and 60D.

[0201] The ring main 30 is located proximate to the converter 10A, to provide a short piping path having a length of about 1 to 2 meters for the heated cleaning fluid to travel between the manifold 47 and the fluid inlet 49 of the first printdown 60A of the converter 10A, the fluid inlet 49 comprising an existing rinsing fluid pipe in fluid connection to a cleanable part of the converter (i.e., the anilox roll 65), via internal piping in the converter 10A.

[0202] It will be understood that the short piping path for the converter 10A includes the length of piping past the heated cleaning fluid isolation valve 40, through the manifold 47 and to the fluid inlet 49.

[0203] The controller is configured to provide alternating timed delivery of the heated cleaning fluid and the rinsing fluid to the converters 10A, and 10B. In particular, the controller is configured to deliver about 3 to 5 seconds of rinsing fluid, then about 90 seconds of heated cleaning fluid, then a second rinse of about 90 to 120 seconds of rinsing fluid.

[0204] The controller, comprising a programmable logic controller is configured to recognise and respond to a cleaning initiation condition, and automatically execute activation of the two solenoid valves 40 and 45, and in particular, starting from a condition in which both solenoid valves 40 and 45 are closed, first opening the rinsing fluid solenoid valve 45 for about 5 to about 15 seconds to deliver rinsing fluid into the converter; then closing rinsing fluid solenoid valve 45 and opening the cleaning fluid solenoid valve 40 for about 90 seconds to deliver heated cleaning from the ring main 30 into the converter; and then closing cleaning fluid solenoid valve 40 and opening the rinsing fluid solenoid valve 45 for about 90 to 120 seconds to deliver a second rinse of rinsing fluid into the converter, after which time the rinsing fluid solenoid valve 45 is closed (i.e., both cleaning fluid and rinsing fluid valves 45, 40 are closed), completing the approximately four minute cleaning cycle.

[0205] In FIG. 1, the cleaning fluid is sourced from cleaning fluid container 80 which has a fluid connection to the heating unit 20, via the chemically resistant non-return valve 85 (i.e., the non-return valve is chosen to be resistant to degradation by the chemicals used in the cleaning fluid). In this embodiment, the cleaning fluid container contains a pre-diluted mixture of cleaning fluid and water.

[0206] The system 5 depicted in FIG. 1 includes an automatically controllable circulation pump 70 for circulating the heated cleaning fluid around the ring main. The circulation pump 70 is controllable by the controller to be inactive for at least 4 hours per 24-hour period. This provides for less degradation of the cleaning system 5, and in particular the circulation pump itself which is susceptible to degradation, as the system 5 is not continuously used over long periods of time. Providing a regular period where the cleaning system 5 is not in use also provides the benefit of downtime to perform any modifications or repairs to the cleaning system.

[0207] FIG. 1 depicts two converters, 10A and 10B, however it will be understood that the system may be adapted for cleaning more than two converters, including by extending the ring main 30, and adding any further manifolds.

[0208] FIG. 2 shows a second illustrative embodiment of a system in accordance with the invention. The cleaning system 6 of FIG. 2 is substantially the same as the cleaning system 5 depicted in FIG. 1, but includes additional components which are described in detail below. It is noted that additional converters may be connected in line with converters 10A, 10B in accordance with the invention as described in this specification.

[0209] In FIG. 2, mains water supply 90 provides rinsing fluid source, a diluting fluid source via diluting fluid line 97, and a heat exchange fluid source via heat exchange fluid line 99. The pressure from the mains water supply assists in moving the fluid (including water acting as rinsing fluid, and the cleaning fluid later diluted with the water) along the lines of the system 6, including moving the fluids through the heat exchange unit 20, the ring main 30 (together with circulation pump 70) and into the converters 10A, 10B, as well as to produce foaming at the sprayers 75, 76 located around the ring main 30.

[0210] Water travels along rinsing fluid line 95, past isolation valve 91, and filter 92 then via water lines 95A, 95B onto each of the converters 10A, 10B, respectively, for delivery of rinsing fluid. The filter 92 is a 200 mesh Y strainer filter designed to prevent and capture foreign material entering past the strainer (for example, rust particles, excess pipe joining material, swarf from pipe cutting).

[0211] Diluting fluid line 97 includes isolation valve 93, filter 94, and pressure regulator 96 (set to 55 psi or less) for controlling pressure in the diluting fluid line 97 which is important to manage pressure peaks in the mains water supply which, if unregulated, may damage the diluter 83. Downstream of the pressure regulator 96 is a testable non-return valve 98 for ensuring that cleaning fluid is prevented from entering the mains water supply 90.

[0212] Downstream of the non-return valve 98 is a diluter 83, the diluter comprising a proportional dosing injector (e.g., MixRite) for proportional mixing of cleaning fluid (delivered to the diluter 83 via measuring unit 82) with the water (delivered to the diluter 83 from mains water supply source 90 along rinsing fluid line 97).

[0213] Measuring unit 82 is in fluid connection with the diluter 83 and cleaning fluid source 80 (described in relation to FIG. 1).

[0214] Diluting of cleaning fluid is performed at a ratio of approximately 1:50 or 1:65 with water.

[0215] Measuring unit 82 comprises an electronic volumetric flow meter connected to the container 80 and measures usage of the concentrated cleaning fluid in the container, and it is able to wirelessly communicate flow related data to a personal electronic computer (not shown) of a person/entity monitoring cleaning fluid usage. The flow measuring unit 82 includes data/event logging such that events comprising flow rates or refilling of the container will be time stamped and recorded in the unit. Measuring unit 82 also operates to identify leaks in the cleaning fluid lines or where cleaning fluid is separately removed from the cleaning fluid source 80 (e.g., via a tap at the bottom of the container). The data generated by the measuring unit is communicated by WiFi to the personal electronic computer by a microcontroller and a dedicated WiFi controller/module in the unit 82.

[0216] Additionally, FIG. 2 depicts sprayers 75, 76 for manual application of foamed diluted cleaning fluid to parts of the converters 10A, 10B or equipment used therewith. Each sprayer 75, 76 is connected to its own hose reel (e.g., a retractable garden hose type system) and further isolation valves for isolating those components (e.g., for cleaning, repairing or replacement).

[0217] Ring main 30 in FIG. 2 further includes isolation valves 71 and 72 to isolate circulation pump 70 (e.g., for cleaning, repair or replacement). Downstream of the isolation valve 72 is a further chemically resistant non-return valve to prevent unheated cleaning solution from the container 80 flowing into heated cleaning fluid circulating around the ring main 30.

[0218] An isolation valve 99A and non-return valve (not shown) is also provided near to the heat exchange fluid inlet of the heating unit 20 to provide for isolation of the that part of the heating unit 20 and to prevent heated heat exchange fluid (i.e., boiling water) existing the heating unit 20, respectively.

[0219] With regard to FIGS. 1 and 2., non-return valves and isolation valves (not shown) are also included in systems 5 and 6 along each water line 95A, 95B connecting the rinsing fluid line 95 to each of the converters to prevent backflow of water along each water line, and for isolating those elements of each system 5, 6.

[0220] FIG. 3 is a flow chart of steps in an illustrative cleaning method of the invention. The method comprises four necessary steps, and four preferential steps (indicated by dashed lines). The necessary and preferential steps comprise: [0221] First step 100 comprising providing a heating unit for heating a cleaning fluid; preferential step 150 comprises heating cleaning fluid in the heating unit to about 40 to about 55° C.; [0222] Second step 200 comprising providing a ring main for fluid connection to the converter; preferential step 250 comprises positioning the ring main proximate to a boundary of the converter; [0223] Third step 300 comprising connecting the heating unit to the ring main; preferential step 350 comprises providing a manifold for fluid connection of the ring main and a rinsing fluid source to the converter; and [0224] Fourth step 400 comprising providing a controller for controlled delivery of the heated cleaning fluid and a rinsing fluid to the converter; where the preferential step 450 comprises connecting one or more hose reels and sprayers to the ring main for manual application of heated cleaning fluid to components of the converter.

[0225] FIG. 4 is a schematic representation of manifold 147 that is located proximate to the boundary of converter 110, and that controls the delivery of rinsing fluid from rinsing fluid line 195 and the delivery of heated cleaning fluid from the ring main 130 to the converter 110. The outlet 148 of the manifold 147 is connected to a fluid inlet 149 of the converter 110.

[0226] The manifold 147 includes a first non-return check valve 144A to prevent flow of heated cleaning fluid into the rinsing fluid line 195. The manifold further includes a second non-return check valve 144B to prevent flow of rinsing fluid into the ring main 130.

[0227] The manifold 147 further includes two isolation valves 150A, 150B, one on each of the rinsing fluid line 195 and ring main 130, respectively. Isolation valves 150A, 150B are designed to allow isolation of the manifold from both the rinsing line and the ring main, to allow cleaning, repair, replacement etc. The outlet 148 of the manifold is disconnectable from the converter.

[0228] The manifold 147 includes two controllable solenoid valves 145, 140, one on each of the rinsing fluid line 195 and ring main 130, respectively. Controllable solenoid valves are responsive to a PLC controller 141 to control the delivery of rinsing fluid and heated cleaning fluid to the converter 110 in a timed alternating sequence. The heated/cleaning fluid therefore travels through the piping of the manifold 147 including tee section 143 and then into the converter 110, when the solenoid valves 140, 145 are activated.

[0229] Between solenoid valve 140 and isolation valve 150B there is provided a cleaning fluid filter 142, comprising a 200 mesh Y strainer.

[0230] PLC controller 141 is pre-programmed to send signals to each of the solenoid valves 145, 140 along PLC lines 146A and 146B. The controller 141 is located separate from the manifold, in a switch box for the converter 110, and may control multiple manifolds for multiple printdowns on the converter 110 (not shown on FIG. 4).

[0231] FIG. 5A illustrates different two different manifold configurations on a single converter 210A. Manifold configurations would not usually vary between printdowns on the one machine, however, for convenience FIG. 5A shows both a first manifold 247A that is located partially within the boundary of the converter 210A, and a second manifold 247B that is effectively located completely within or at the boundary of the converter 210A. Both manifolds are located proximate to the boundary of the converter 210A, however in other configurations one or more of the existing converter controllable valves 245A, 245B, 240B may be located deeper within the converter 210A (e.g., further along the ink line 268A, 268B).

[0232] First and second manifolds 247A, 247B each have a rinsing fluid inlet 265A, 265B and a heated cleaning fluid inlet 266A, 266B, respectively connecting to the rinsing fluid line 295 and ring main 230 via rinsing fluid lines 295A, 295B and ring main lines 230A, 230B.

[0233] First manifold 247A includes a controllable heating fluid valve 240A that is located external to the converter 210A, and a rinsing fluid valve 245A that is located internal to the converter.

[0234] Second manifold 247B includes a controllable heating fluid valve 240B that is internal external to the converter 210A, and a rinsing fluid valve 245B that is located internal to the converter.

[0235] The set-ups of manifolds 247A and 248B contemplate scenarios where there is rinsing fluid line 295 is an existing line and rinsing fluid valves 245A, 245B are each existing rinsing valve reconfigured for use with the invention.

[0236] The cleaning system of the invention, in the case of manifold 247A, applies a retrofit single controllable valve - the heated cleaning fluid valve 240A. It also repurposes existing rinsing fluid inlet 265A, and adds the controllable valve 240A in line with the existing ink line inlet 249A (existing ink line inlet 249A remains able to receive ink).

[0237] The cleaning system of the invention, in the case of manifold 247B, also reconfigures existing valve 240B (i.e., an ink line valve) for connection to the ring main 230 (existing valve 240B is connected to an existing ink line, into which the ring main is teed - not shown on FIG. 5A).

[0238] In the case of manifold 247B, heated cleaning fluid inlet 266B is a repurposed existing ink line inlet to the converter, and inlet 265B is a repurposed existing rinsing fluid inlet.

[0239] It can therefore be understood that manifold 247B may comprise a component as little as a tee (or Y) section to connect the ring line 230 to the existing converter ink line inlet 266B. In set-ups such as that depicted in FIG. 5A, where the cleaning system or method of the invention comprises a retrofit system or retrofitting to an existing converter already including connection to a rinsing fluid line, then existing lines and valves controlling flow of rinsing fluid and/or ink may be retained and controlled by the controller.

[0240] Manifolds 247A, 247B therefore respectively connect to existing ink lines 268A, 268B, that are in fluid connection to other respective cleanable parts of each printdown 260A, 260B, namely the ink tray 261A, 261B, ink applicator 262A, 262B (which may be comprise an ink chamber and doctor blade, or an ink tray and fountain roll, for example), and anilox roll 263A, 263B.

[0241] FIG. 5B depicts a similar cleaning system to that presented in FIG. 5A, except the rinsing fluid line and components associated with delivery of rinsing fluid in FIG. 5A are not present in FIG. 5B.

[0242] FIG. 5B depicts two manifolds 247C, 247D, each connected to ring main 230 via first line 230C and second line 230D, respectively.

[0243] Manifold 247C includes heated fluid solenoid valve 240C, where manifold outlet 248C is connected to the ink line inlet 266C of the printdown 260C on the converter 210B, for delivering heated cleaning solution along the ink line 268C and to cleanable converter components 261C, 262C and 263C. The manifold 247C is external to the converter 210B and attached nearby the boundary of the converter 210B.

[0244] Manifold 247D includes heated fluid solenoid valve 240D, which is a reconfigured existing ink valve of the printdown 260C, for delivering heated cleaning solution along the ink line 268D and to cleanable converter components 261D, 262D and 263D. The manifold 247D is internal to the converter 210B.

[0245] Both valves 240C and 240D in manifolds 247C, and 247D respectively, are controlled by a programmable controller (not shown in FIGS. 5A and 5B), for delivering heated cleaning fluid from the ring main 230 to each printdown 260C, 260D to the boundary of the converter 210B (and to the cleanable components) within a predetermined period of time. The programmable controller (not shown) is also configured to deliver heated cleaning fluid to the cleanable components for a predetermined amount of time.

[0246] It will be understood that features such as a rinsing fluid line, rinsing fluid valves internal to the converter, or other components associated with rinsing fluid delivery, while not depicted in FIG. 5B and not necessarily present in all embodiments of the invention, remain compatible with embodiments of the invention that do not specifically require them. For example, the invention may comprise a retrofit system that provides delivery of heated cleaning (from a ring main) to an existing converter, to supplement existing rinsing fluid delivery provided by existing components (e.g., exiting rinsing lines, and valves operated by an existing controller).

[0247] FIG. 6 illustrates different two different internal printdown configurations on a single converter 310, such that cleaning is performed differently on each printdown 360A, 360B. Internal configurations would not usually vary between printdowns on the one machine, but do so in FIG. 6 for illustrative purposes. Both manifolds 347A, 347B are located proximate to the boundary of the converter 310, and each are connected to the rinsing fluid line 395 and the ring main 330. The internals of the manifolds 347A, 347B are not shown in FIG. 6, nor described in detail with reference to FIG. 6 as each manifold can be taken to have the same internal configuration as that depicted in FIG. 4.

[0248] The outlet 348A of manifold 347A connects to twin inlets 364A, 367A comprising, respectively, an existing ink line inlet 364A and a direct anilox roll cleaning inlet 367A for printdown 360A on the converter 310.

[0249] In the configuration on printdown 360A, therefore, manifold 347A is adapted to provide a sequence of heated cleaning fluid and rinsing fluid to ink line 368A, to clean further cleanable parts comprising ink tray 361A, applicator 362A and anilox roll 363A as the rinsing and cleaning fluid travels around the ink circuit around those cleanable parts before leaving the tray 361A via drain (not shown). Manifold 347A further provides for direct cleaning of the anilox roll 363A via existing direct anilox roll rinsing fluid inlet 367A, the latter being reconfigured to be connected to the manifold outlet 348A. In this manner, more thorough cleaning of the anilox roll 363A may be achieved.

[0250] In the configuration on second printdown 360B, manifold 347B is adapted to provide a sequence of rinsing fluid and heated cleaning fluid to ink line 368B, to clean further cleanable parts comprising ink tray 361B, applicator 362B and anilox roll 363B as the rinsing and cleaning fluid travels around the ink circuit and around those cleanable parts before leaving the tray 361B via drain (not shown).

[0251] FIG. 7 depicts a set-up of a heat exchange unit 210 and associated system piping and plumbing. Tote 180 including the cleaning fluid concentrate is connected to measuring unit 182 (e.g., a Bintech unit), each of which are shown in dashed lines as they are located behind a wall in the represented set-up.

[0252] Measuring unit 182 is connected to diluter 183, the latter including connection to diluting fluid line 197 and the heat exchange unit 120, so that rinsing fluid is diluted prior to entry into the heat exchange unit 120.

[0253] The mains water supply 190 supplies feed line 188, which in turn supplies: [0254] the diluting fluid line 197; [0255] the rinsing fluid and the heat exchanger fluid line 195/199, which later splits into the rinsing fluid line 195 and heat exchanger fluid line 199 at duo valve 201.

[0256] Water feed line 188 further includes a pressure limiting valve 196 to regulate pressure of the fluid through the diluter 183, the heat exchanger fluid line 199 and through the rinsing line 195. An isolation valve 188A is able to isolate the mains supply 190 from the feed line 188.

[0257] An isolation valve 193 is able to isolate the diluter 183 from the water feed line 188.

[0258] Heat exchange unit 20 is connected to the diluter 183 at inlet 122A to receive a cold diluted mixture of water and cleaning fluid. Once the heating fluid reaches heat exchanger outlet 121A it is at a temperature of about 38 degrees. This may be monitored by the temperature gauge 123. The heated cleaning fluid then travels along cleaning fluid line 130 to the converters.

[0259] Twin circulation pumps 170A, 170B are located in parallel on the returning section 125 of heated cleaning fluid line 130, so that each pump runs for alternating 12 hour, or shorter, blocks of time for continuous circulation of the heated cleaning fluid around the ring main. This provides an opportunity for one of the circulation pumps 170A, 170B to cool and/or be maintained or repaired, while the other one is running.

[0260] A number of isolation and non-return valves are included, for reasons that have been described elsewhere in the specification, including: [0261] Non return valves 173A, 173B on the cleaning fluid return line 125 [0262] Non return valve 198 next to pressure regulator 198 [0263] Non return valve 185 between the diluter 183 and heat exchanger inlet 122A [0264] Isolation valves 172A and 172B to isolate the circulation pumps 170A, 170B.

[0265] FIG. 8 is a flow chart of steps in an illustrative cleaning method of the invention. The method comprises six necessary steps, and one preferential step (indicated by dashed lines). The necessary and preferential steps comprise: [0266] A first step 455: providing a heating unit for heating a cleaning fluid; [0267] A second step 500: providing a ring main for continuous circulation of heated cleaning fluid around the ring main; [0268] A third step 550: connecting the heating unit to the ring main; [0269] A fourth step 600: connecting the ring main to the converter to enable delivery of heated cleaning fluid to the converter; [0270] A fifth step 650: providing a controller for controlled delivery of a sequence of a rinsing fluid and the heated cleaning fluid to the converter upon recognition of respective rinsing fluid and heated cleaning fluid delivery conditions; [0271] A sixth step 700: providing a controllable cleaning fluid valve for delivery of the heated cleaning fluid, and providing a controllable rinsing fluid valve for delivery of the rinsing fluid; and optionally [0272] A seventh step 750: positioning the one or more controllable valves and/or a manifold proximate to the boundary of the converter.

[0273] FIG. 9 illustrates a cleaning system 406 that is substantially the same as system 6 of FIG. 2, except that it includes the following additional components: [0274] a) Circulation pumps 470A and 470B for circulating heated cleaning fluid along the ring main 430 including through the return section 425. [0275] b) Isolation valves 455 and 458 for isolating the rinsing fluid line 495 from each converter [0276] c) Isolation valves 456 and 457 for isolating the ring main 430 from each converter [0277] d) Isolation valves 451 and 452 for isolating individual printdowns [0278] e) Isolation valves 471A, 471B, 472A, 472B for isolating circulation pumps 470A and 470B [0279] f) Non return valves 453, 454 and 459, 459A for preventing cross contamination of heated cleaning fluid and rinsing fluid lines [0280] g) Water softening unit 489 [0281] h) Temperature gauges 469A and 469B for reading the temperature of heated cleaning fluid as it exits the heat exchanger, and when it starts to return back to the heat exchanger along the return section 425.

[0282] Apart from components such as mains water supply 490 and ring main 430, only the additional components that are not present FIG. 2 are identified on FIG. 9.

[0283] With reference to FIGS. 4 and 9, non-return valves 144A, 144B on the manifold, as well as non-return valves on each line coming into the converters 453, 454, 459, 459A, and isolation valves 455, 456, 457, 458 before the non-return valves operate to fully isolate the converters. There is an excess of non-return valves to ensure no cleaning fluid can leak back into the rinsing fluid lines and that diluted cleaning solution cannot find its way back into the cleaning solution supply (e.g., tote).

[0284] To further understand the role and application of the additional components in FIG. 9 and referred to above, including the twin circulation pumps, isolation valves and non-return valves, reference is made to systems of the invention described in detailed elsewhere in the specification.

[0285] Water softening unit 489 is a further filter optionally included to remove calcium, magnesium, and/or other metal cations if the mains water supply 490 supplies hard water, with a result of softer water requiring less cleaning fluid for the same cleaning effort (where cleaning fluid is not wasted bonding with the metal cations). Water softening unit 489 also extends the lifetime of the piping and fittings in the system 406 by reducing or eliminating scale build-up in pipes and fittings. In alternative embodiments, where it is practical, a single water softening unit may be placed next to the mains water supply 490, before splitting of diluting fluid line 497 and rinsing fluid line 495, so that water supplied along diluting fluid line 497 and rinsing fluid line 495 is softened by that single water softening unit.

[0286] The invention thus provides an automatic heated cleaning system and method which helps maintain a converter in an optimal state without significant labour costs and preventing ink buildup. Particularly, the use of heated cleaning fluid, which is available instantaneously (while the system or method is operating) provides a substantially improved cleaning due to the heated cleaning fluid operating more effectively to clean the ink from the converter. It will be understood by the person skilled in the art that an increase in temperature of approximately 10 degrees will approximately double (or substantially improve) the effectiveness of the cleaning fluid and approximately halve (or substantially reduce) the time taken for the cleaning fluid to effectively clean. Therefore, the increased temperatures for cleaning fluid provided by the invention of up to about 40 degrees (or potentially higher, subject to internal converter piping), are able to deliver two, four or even higher efficiency multiples, depending on the temperatures under which a comparable unheated cleaning method or system operates.

[0287] It can be seen that one or more of the following benefits may be delivered by the proposed invention: gains in production time; gains in time for maintenance; improved printing quality; a reduction in water or cleaning fluid usage by significant percentages; a reduction in the cost of waste water processing and the cost of water used; reduction in the need to replace and/or manually repair or clean equipment, and in particular anilox rolls, ink chambers, and piping in a converter.

Interpretation

[0288] Persons skilled in the art will appreciate that many variations may be made to the invention without departing from the scope of the invention, which is determined from the broadest scope and claims.

[0289] The methods and/or systems of the invention may be applied in new machines used in the printing industry. In particular, the method and/or system of the invention, or a part of the method and/or system, may be applied in a new converter installation where new converters incorporating the essential features of the invention, include connection to the ring main, are installed as new.

[0290] However, the systems and/or methods of the invention are particularly suited to retrofit application to existing equipment including a converter and related components. The invention is able to clean ink residue or other ink deposits from components such as anilox rolls, ink chambers, ink lines, and other equipment referred to herein.

[0291] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0292] Similarly, it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

[0293] Furthermore, while some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0294] The terms in the claims have the broadest scope of meaning they would have been given by a person of ordinary skill in the art as of the relevant date.

[0295] Neither the title nor any abstract of the present application should be taken as limiting in any way the scope of the claimed invention

[0296] Where the preamble of a claim recites a purpose, benefit, or possible use of the claimed invention, it does not limit the claimed invention to having only that purpose, benefit or possible use.

[0297] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/- 0.1% of the stated value (or range of values), +/-1% of the stated value (or range of values), +/- 2% of the stated value (or range of values), +/- 5% of the stated value (or range of values), +/- 10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “X” is disclosed the “less than or equal to X” as well as “greater than or equal to X” (e.g., where X is a numerical value) is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

Different Instances of Objects

[0298] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details

[0299] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology

[0300] Where two or more valves performing different roles are referred to, one valve may nevertheless be used to carry out dual roles. For example, a single two way automatically controllable valve (or three way automatically controllable valve) valve can automatically controllable valve delivery of both cleaning fluid and rinsing fluid.

[0301] Where the term “sequence” is used in relation to a sequence of applications of rinsing fluid and cleaning fluid, it may mean only one application of rinsing fluid and one application of cleaning fluid, however it may also include more than one application of the rinsing fluid and/or cleaning fluid.

[0302] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “forward”, “rearward”, “radially”, “peripherally”, “upwardly”, “downwardly”, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0303] The terms “a” and “an” mean “one or more”, unless expressly specified otherwise.

[0304] In the present specification, terms such as “part”, “component”, “means”, “section”, or “segment” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items having one or more parts. It is envisaged that where a “part”, “component”, “means”, “section”, “segment”, or similar term is described as consisting of a single item, then a functionally equivalent object consisting of multiple items is considered to fall within the scope of the term; and similarly, where a “part”, “component”, “means”, “section”, “segment”, or similar term is described as consisting of multiple items, a functionally equivalent object consisting of a single item is considered to fall within the scope of the term. The intended interpretation of such terms described in this paragraph should apply unless the contrary is expressly stated, or the context requires otherwise

[0305] The term “connected” or a similar term, should not be interpreted as being limitative to direct connections only. Thus, the scope of the expression an item A connected to an item B should not be limited to items or systems wherein an output of item A is directly connected to an input of item B. It means that there exists a path between an output of A and an input of B which may be a path including other items or means. “Connected”, or a similar term, may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other yet still co-operate or interact with each other.

Comprising and Including

[0306] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0307] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

[0308] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0309] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability

[0310] It is apparent from the above, that the arrangements described are applicable to the printed material and/or box manufacturing industries.