Sensor device and method for detecting a filling status of dispenser for a consumable
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Solution Overview
Problem
Current sensor technologies for monitoring dispenser filling status, particularly for web materials, face challenges in accurately measuring the level of consumables in large dispensers and across various types, often requiring multiple sensors, which increases costs and complexity, and struggle with high granularity measurements needed during frequent usage events.
Innovation Solution
A capacitive sensor device with an elongated and planar sensor area, featuring a first and second channel, is used to measure changes in capacitance, allowing for precise detection of the filling status of web material-based consumables in dispensers, enabling accurate and efficient refilling management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to accurately measure the level of consumables in large dispensers, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The capacitive sensor is divided into multiple independent measurement channels (first channel, second channel, etc.), each capable of independently detecting capacitance changes in different regions of the dispenser. This segmentation allows a single sensor device to cover the entire dispenser volume, replacing the need for multiple separate sensors while maintaining high measurement precision.
Solution Approach 2:
The capacitive sensor device is designed with multi-channel capability that enables it to detect filling status across the entire dispenser simultaneously. Each channel can be independently configured to monitor different consumable levels or types, making the device universally applicable to various dispenser sizes and configurations without requiring additional sensors.
2Adaptability or versatility
If multiple sensors are deployed to monitor filling status across various dispenser types, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The capacitive sensor device incorporates multiple measurement channels that can be configured to adapt to different dispenser types and consumable materials. The sensor can detect various materials (paper towels, toilet paper, diapers, etc.) using the same hardware platform, eliminating the need to manufacture different sensor models for different dispenser types and thereby reducing production costs.
Solution Approach 2:
The sensor system allows for adjustable measurement parameters such as capacitance thresholds, measurement ranges, and detection sensitivity through software configuration rather than hardware changes. This enables the same sensor device to adapt to different dispenser sizes, shapes, and consumable types by simply changing measurement parameters, significantly reducing manufacturing complexity and cost.
3Measurement precision
If high granularity measurements are implemented during frequent usage events, then measurement precision is improved, but use of energy increases
Solution Approach 1:
The capacitive sensor system employs periodic measurement cycles where high-granularity measurements are taken at intervals rather than continuously. During frequent usage events, the sensor can increase measurement frequency temporarily, then return to lower frequency operation, maintaining measurement precision when needed while reducing overall energy consumption during stable periods.
Solution Approach 2:
The measurement system dynamically adjusts its operation mode based on detected usage patterns. When rapid consumption is detected (indicating frequent usage events), the sensor automatically increases measurement granularity and frequency. When usage is stable or slow, it reduces measurement intensity, thereby optimizing the balance between measurement precision and energy consumption in real-time.
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 capacitive sensor system provides accurate and granular data on the filling status of dispensers, supporting efficient refilling processes and reducing the need for multiple sensors, thus lowering costs and enhancing management capabilities.
Implementation Method 1
a capacitive sensor (210) comprising an elongated and planar sensor area
Data Source
AI summary
A sensor device is provided to detect a filling status of a consumable in a dispenser, the consumable being web material, and the filling status relating to a spatial extension of the consumable in the dispenser. The sensor device includes a capacitive sensor having an elongated and planar sensor area; and a first measurement section configured to measure the filling status of the dispenser. The capacitive sensor includes a first channel and a second channel. The first measurement section is configured to measure the filling status of the dispenser based on changes in capacitance detected by the first channel and the second channel.