Dispenser Refill Prediction Using Usage-Based Depletion Indicators
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Solution Overview
Problem
Existing dispensing systems fail to accurately predict and indicate when products in dispensers, such as paper towel and soap dispensers, will be depleted before the next scheduled maintenance, leading to unnecessary replacements and increased costs.
Innovation Solution
A method and device that sets an activation count for the number of dispenses remaining, calculates a running average of material usage, and compares it with the service interval to indicate when refilling is needed, preventing complete emptying of the product before the next scheduled service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed recording indicators are used to trigger warnings, then the device complexity is reduced, but the measurement precision of product depletion prediction deteriorates
Solution Approach 1:
The system transitions from static fixed-threshold indicators to dynamic indicators that adapt to actual usage patterns. The indicator threshold is no longer constant but changes based on the running average of material usage, allowing the system to maintain precision while managing complexity through adaptive behavior rather than complex hardware.
Solution Approach 2:
The system implements feedback by continuously monitoring material usage and adjusting the indicator threshold based on the running average. This feedback loop allows the system to learn from actual usage patterns and improve prediction accuracy over time, resolving the contradiction between simple device design and precise prediction.
2Reliability
If frequent checks are performed to ensure product availability, then the reliability of product supply is improved, but the loss of time for checking dispensers increases
Solution Approach 1:
The system performs preliminary action by predicting product depletion before it actually occurs. By calculating the running average of usage and projecting future depletion based on this trend, the system provides advance warning, allowing service providers to plan replenishment in advance rather than performing frequent reactive checks.
Solution Approach 2:
The indicator system essentially monitors itself by using its own historical data to predict future states. The running average calculation and depletion prediction are self-contained operations that require no external intervention, allowing the system to autonomously provide reliable depletion warnings without requiring frequent manual checks.
3Reliability
If product replacement is performed frequently to prevent emptying, then the reliability of dispensing is improved, but the loss of substance through unnecessary replacement increases
Solution Approach 1:
The system replaces mechanical replacement schedules with a predictive model based on actual usage trends. Instead of following fixed replacement intervals or simple threshold-based indicators, the system uses running average calculations to predict actual depletion points, substituting data-driven predictions for mechanical replacement routines and thereby eliminating unnecessary replacements.
Solution Approach 2:
The system dynamically changes the replacement decision parameter from fixed thresholds or time intervals to a dynamic prediction based on running average usage. This parameter change allows the system to optimize replacement timing based on actual consumption patterns, maintaining reliability while minimizing waste from premature replacement.
Data Source
AI summary
A method and device for indicating whether a dispensable product will require refilling prior to the next scheduled service interval includes tracking the amount of use over a first interval, and calculating a frequency based from the use over the first interval. The quantity remaining is compared with the required amount, which is the product of the number of weeks in the service interval and the calculated frequency. Thus, when the quantity remaining is less that the required amount, a warning will be provided to indicate that the dispensing product should be replaced, as it will be empty before the next service interval.