Dispenser Controller Dynamic Power Management
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Solution Overview
Problem
Soap dispensers with onboard power supplies face challenges in maintaining and replacing batteries, as it is difficult to determine the remaining power, leading to inefficient battery usage and potential downtime due to rapid discharge from high usage or energy dissipation in low-traffic environments.
Innovation Solution
A dispensing system with a controller that dynamically adjusts the power draw from batteries based on usage frequency and remaining product levels, incorporating both onboard and refill reservoir batteries, and an intermediate energy storage device like a supercapacitor to manage energy distribution efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coin cell batteries are used to power the dispenser motor, then the battery size and cost are reduced, but the battery cannot rapidly discharge energy which limits motor activation frequency
Solution Approach 1:
The power supply system is segmented into two distinct components: coin cell batteries for baseline power supply and a supercapacitor for rapid energy discharge during motor activation. This segmentation allows each component to perform its specialized function optimally - the small coin cells provide sustained low-power operation while the supercapacitor delivers high-power bursts, resolving the contradiction between small battery size and high activation frequency capability
Solution Approach 2:
The supercapacitor acts as an intermediary energy storage device between the coin cell batteries and the motor. It receives gradual charging from the low-power-density batteries and provides rapid discharging to the motor during activation cycles. This intermediary component enables the small coin cells to indirectly support high-frequency motor activation without being directly responsible for the rapid power delivery
2Productivity
If the battery discharges energy rapidly to power motor activation, then the motor can be activated frequently, but the useful life of the battery is greatly reduced
Solution Approach 1:
The power delivery function is segmented between two energy storage technologies: the supercapacitor handles rapid high-power discharge during motor activation (preserving battery life), while the coin cell batteries provide sustained low-power charging over extended periods (maximizing useful life). This functional segmentation resolves the contradiction by assigning each component to its optimal operating regime
Solution Approach 2:
The system dynamically adjusts power flow based on operational demands. The controller monitors motor activation frequency and energy levels, directing the supercapacitor to provide rapid discharge during activation events while allowing gradual charging from the coin cells during idle periods. This dynamic power management ensures high productivity during use while extending overall system lifespan
3Power
If the capacitor stores energy for multiple dispensing cycles, then rapid power delivery is achieved, but the capacitor drains quickly with repeated use and has limited storage capacity
Solution Approach 1:
The system merges two energy storage technologies with complementary characteristics: a supercapacitor for rapid power delivery and coin cell batteries for extended energy storage. The supercapacitor provides high-power bursts for motor activation while the coin cells provide sustained energy supply over longer durations. This combination resolves the contradiction by integrating the strengths of both technologies - the supercapacitor's rapid discharge capability and the batteries' extended operational duration
Solution Approach 2:
The system operates in periodic cycles of charging and discharging. During idle periods, the coin cell batteries gradually charge the supercapacitor. During dispensing cycles, the supercapacitor rapidly discharges to power the motor. This periodic charge-discharge pattern allows the capacitor to maintain high power delivery capability while the batteries replenish its energy reserves, extending the overall operational duration
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
This solution optimizes battery life by adjusting discharge rates based on usage patterns and product levels, ensuring consistent operation and reducing waste by providing a fresh energy source with each refill.
Implementation Method 1
an intermediate energy storage device or supercapacitor electrically positioned between the batteries and the motor and capable of storing a predetermined level of energy that is sufficient to activate the motor through multiple activation cycles
Implementation Method 2
a low power-density battery for recharging the intermediate energy storage device wherein the low power-density battery is integrated into the readily replaceable product reservoir
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A product dispenser and a method of operating a product dispenser, comprising the steps of: providing a product dispenser having a dispenser housing, a readily replaceable product reservoir for storing associated product, a pump having an inlet fluidly connected to the product reservoir, the pump having outlet for dispensing associated product, a low-voltage motor operatively coupled to actuate the pump, an intermediate energy storage device operatively communicated to provide operating power to the motor, wherein the intermediate energy storage device is configured to store a sufficient amount of energy to activate the motor multiple times, a low power-density battery for recharging the intermediate energy storage device wherein the low power-density battery is integrated into the readily replaceable product reservoir, a controller having a charging circuit operatively connected to the low power-density battery and the intermediate energy storage device, wherein the controller includes an activation circuit operatively connected to activate the motor, and wherein the controller includes a counter circuit configured to count the number of times the activation circuit activates the motor; incrementing the counter circuit in response to activating the motor; recharging the intermediate energy storage device at a first recharge rate in response to activating the motor when the count in the counter circuit is below predetermine counter value; and, recharging the intermediate energy storage device at a substantially different second recharge rate in response to activating the motor when the count in the counter circuit has exceeded the predetermine counter value.