Dispenser Power Rectification to Prevent Electrode Corrosion
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Solution Overview
Problem
Existing dispensing systems face issues with battery management, electrode corrosion, and unauthorized consumable product usage, leading to inefficiencies and increased maintenance costs, particularly in humid environments where galvanic corrosion occurs, and there is a need for improved power management and energy efficiency to minimize delays in product dispensing.
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 to convert ZNV power to higher voltage direct current (HVDC) for energy storage, which is selectively directed to a dispenser load, incorporating an auxiliary power cell and capacitors for efficient power distribution and corrosion prevention through zero net voltage signal transfer.
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 expire at different rates across washrooms and require frequent monitoring and replacement
Solution Approach 1:
The battery system is segmented into multiple replaceable battery packs, each with its own power capacity. This allows individual battery packs to be replaced independently when depleted, rather than replacing all batteries in a multi-battery system simultaneously or monitoring each battery's charge level continuously. The segmentation transforms a complex battery management problem into a simple replaceable unit system.
2Power
If traditional battery systems are used in dispensers, then power can be provided to mechanical components, but electrode corrosion occurs particularly in humid environments
Solution Approach 1:
A rectification circuit serves as an intermediary between the battery and the motor load. This circuit converts the battery's alternating current output into direct current, which is then supplied to the motor. The intermediary conversion process eliminates the galvanic corrosion caused by alternating current while maintaining effective power delivery to mechanical components.
Solution Approach 2:
The electrical parameter of current type is changed from alternating current (AC) to direct current (DC) through rectification. This parameter change fundamentally alters the interaction between electricity and the electrical contacts, eliminating the electrochemical corrosion process that occurs with AC while preserving the power delivery capability needed for motor operation.
3Reliability
If batteries are replaced manually in large facilities with hundreds or thousands of washrooms, then power can be restored to inoperative dispensers, but substantial personnel time and costs are required
Solution Approach 1:
The system enables self-service operation where the consumable product packaging itself serves as the battery carrier. When a consumer replaces the consumable product, the new packaging automatically provides fresh battery power to the dispenser. This eliminates the need for specialized personnel to monitor and replace batteries, as the system recharges itself through normal product replacement cycles.
4Ease of manufacture
If frictional connection between electrodes is used for power transfer, then simple electrical connection can be achieved, but galvanic corrosion occurs at the electrical interface
Solution Approach 1:
The rectification circuit acts as an intermediary that transforms the electrical connection method. Instead of relying on frictional contact between electrodes that causes galvanic corrosion, the system uses a controlled rectification process that converts AC to DC. This intermediary conversion eliminates the direct galvanic interaction while maintaining reliable power transfer.
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 manages power delivery, reduces corrosion, minimizes maintenance needs, and ensures efficient energy use by prioritizing power from capacitors and auxiliary power cells, allowing for quick activation and reducing the need for frequent battery replacements, while preventing unauthorized consumable product usage through integrated security features.
Implementation Method 1
A controller is connected to a lower power zero net voltage (ZNV) power source. A power rectification circuit (PRC) converts the ZNV power source to a higher voltage direct current (HVDC) power source.
Implementation Method 2
An energy storage system connected to the HVDC power source receives and stores HVDC power within the energy storage system. In one embodiment, the energy storage system includes at least one capacitor.
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.