Dispenser Power Rectification and Storage to Minimize Electrode Corrosion
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Solution Overview
Problem
Existing power management systems in dispensers face issues such as electrode corrosion, inefficient power transfer, and the need for frequent battery replacement, especially in humid environments, leading to system inefficiency and frustration for users and manufacturers.
Innovation Solution
A power management system utilizing a controller connected to a lower power zero net voltage (ZNV) power source, with a power rectification circuit converting ZNV power to higher voltage direct current (HVDC) for efficient energy storage and distribution, minimizing corrosion through pulsed DC signals and incorporating an auxiliary power cell for optimized power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a single or multiple batteries are used to provide energy to complete a dispensing cycle, then the dispenser can operate automatically, but the batteries require frequent replacement due to random expiration across different washrooms
Solution Approach 1:
The battery system is segmented into multiple individual batteries, each with its own expiration tracking. This allows independent monitoring and replacement of each battery rather than replacing all batteries as a group, improving reliability by addressing expired batteries on-demand rather than following a fixed schedule.
Solution Approach 2:
The system incorporates feedback mechanisms to monitor battery status and expiration dates. This enables the dispenser to detect when batteries need replacement and communicate this information to maintenance personnel, allowing timely intervention before automatic operation fails.
2Device complexity
If traditional battery connections are used in humid environments, then power transfer is simple, but electrode corrosion occurs at the electrical interface
Solution Approach 1:
A corrosion-resistant intermediary material or coating is introduced at the electrical interface between batteries and dispenser. This intermediary layer prevents direct contact between dissimilar metals in the humid environment, eliminating galvanic corrosion while maintaining electrical conductivity and connection simplicity.
Solution Approach 2:
The electrical connection system uses composite materials that combine corrosion resistance with electrical conductivity. This allows the connection to remain simple in structure while the composite material properties prevent electrode corrosion in humid washroom environments.
3Productivity
If consumable product is replaced frequently, then product availability is maintained, but battery replacement timing becomes unpredictable and difficult to manage
Solution Approach 1:
The system provides feedback on both consumable levels and battery status independently. This allows maintenance personnel to distinguish between consumable replacement needs and battery replacement needs, enabling timely battery replacement before expiration even when consumable replacement frequency varies across different locations.
Solution Approach 2:
The system monitors battery expiration dates in advance and provides early warning before batteries actually expire. This preliminary action allows scheduled battery replacement to be coordinated independently of consumable replacement schedules, preventing unexpected failures.
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 effectively reduces corrosion, ensures efficient power transfer, and eliminates the need for frequent battery replacements, enhancing dispenser reliability and user experience while minimizing environmental impact.
Implementation Method 1
A power rectification circuit (PRC) converts ZNV power to higher voltage direct current (HVDC) power
Implementation Method 2
An energy storage system connected to the HVDC power source receives and stores HVDC power within the energy storage system
Data Source
AI summary
A power management system for dispensers is described. The system includes a controller connected to a lower power zero net voltage (ZNV) power source. A power rectification circuit (PRC) converts ZNV power to higher voltage direct current (HVDC) power. An energy storage system connected to the HVDC power source receives and stores HVDC power within the energy storage system which is selectively provided to a dispenser motor load connected to the energy storage system. The system provides an effective solution to the problem of transferring power from a low power battery source on a disposable product to a dispenser as well as providing a system that minimizes corrosion at the electrical interface between the disposable product and the dispenser particularly in higher humidity environments.