Adaptive Dispenser Drive Control for Roll Transition Resistance
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Solution Overview
Problem
Existing product dispensers face inefficiencies due to increased dispensing resistance when switching from a stub roll to a full roll, leading to wasted energy and reduced operational efficiency, as they are often designed to handle the highest resistance levels consistently, rather than adapting to varying conditions.
Innovation Solution
A dispenser system with a drive system that adjusts its output drive condition based on dispensing resistance, using a primary and secondary motive power device and a controller to operate in a first output drive condition for low resistance and a second output drive condition for elevated resistance, ensuring efficient energy use and consistent product availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive system is designed to overcome the highest dispensing resistance, then sheet product availability is ensured during roll transitions, but energy consumption increases and operational efficiency decreases
Solution Approach 1:
The drive system dynamically adjusts its output between two drive conditions based on real-time dispensing resistance levels. The controller monitors resistance and switches between a first output drive condition for normal operation and a second output drive condition for elevated resistance, allowing the system to adapt to varying operational needs rather than maintaining constant high-power output
Solution Approach 2:
The system changes the operational parameters of the drive system by defining two distinct output drive conditions with different power levels. The controller selects the appropriate drive condition based on the measured dispensing resistance, thereby optimizing the balance between reliability and energy consumption across different operational scenarios
2Reliability
If the drive system operates at high power to overcome elevated resistance, then product dispensing reliability is maintained, but energy waste increases during normal operation
Solution Approach 1:
The drive system transitions from static high-power operation to dynamic power adjustment, switching between two drive conditions based on actual resistance levels. During normal operation with low resistance, the system operates in the first output drive condition with lower power consumption, while switching to the second output drive condition only when elevated resistance is detected
Solution Approach 2:
The system applies partial action by using only the necessary power level for current operational conditions. Instead of continuously applying maximum power, the controller selectively engages the second output drive condition only when dispensing resistance exceeds normal thresholds, thereby avoiding energy waste during routine operation
3Use of energy by moving object
If the drive system is optimized for low resistance operation, then energy efficiency is improved, but the system cannot overcome elevated dispensing resistance during roll transitions
Solution Approach 1:
The drive system incorporates dynamic adaptability by monitoring dispensing resistance and switching between two output drive conditions. The controller detects when resistance elevates during roll transitions and automatically transitions to the second output drive condition, ensuring the system maintains the ability to overcome elevated resistance while preserving energy efficiency during normal operation
Solution Approach 2:
The system prepares for elevated resistance conditions by having the second output drive condition readily available and switchable. The controller continuously monitors resistance levels and can quickly transition to the higher-power drive condition when needed, ensuring the system is prepared to overcome resistance spikes without continuously operating at high power
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces overall energy consumption by adapting to varying dispensing resistances, maintaining efficient operation across normal and elevated resistance conditions, thereby minimizing waste and extending maintenance intervals.
Implementation Method 1
Sheet product is generally dispensed using a roller system where the sheet product is passed between a drive roller and a pinch roller and the resulting friction pulls the sheet product from the dispensing roll
Data Source
AI summary
A product dispenser includes a product housing including a drive system and a dispensing apparatus. The drive system includes a motive power device and a controller and is configured to receive energy from an energy supply. The dispensing apparatus is configured to dispense the product. During a condition when the product is being dispensed, the dispensing apparatus is subject to a dispensing resistance and the drive system provides an output to the dispensing apparatus to overcome the dispensing resistance, the output being characterized by a dispensing parameter. The controller receives the dispensing parameter and responsively operates the motive power device, such that the controller operates the motive power device in a first output drive condition in response to the dispensing parameter being below a threshold value, and operates the motive power device in a second output drive condition in response to the dispensing parameter being above a threshold value.