Sheet Product Dispenser Roller Assembly for Jam-Free Dispensing
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Solution Overview
Problem
Conventional automated sheet product dispensers experience paper jamming and excessive wear due to abrupt motor speed changes and failure to disengage the sheet from the tear bar, leading to inefficient and unreliable operation.
Innovation Solution
The use of a DC stepper motor with controlled acceleration and deceleration during the dispense cycle, combined with a roller assembly featuring flexible rubber portions and a baffle to prevent overspin, along with a modular design that includes a pair of support arms and shaft plugs with springs for improved stability and assembly, addresses the issues of paper jamming and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric drive motors are used with abrupt activation and deactivation during dispense cycles, then dispensing speed and productivity are improved, but paper jamming and excessive parts wear occur
Solution Approach 1:
The patent applies dynamics by implementing gradual acceleration and deceleration phases in the motor control cycle. The motor speed is progressively increased from zero to operating speed and then gradually decreased, rather than abrupt changes. This dynamic speed control eliminates impulses that cause paper jamming and reduces mechanical stress on parts, thereby improving reliability while maintaining productivity.
2Stability of the object's composition
If the sheet product remains engaged with the tear bar after dispensing, then the tear bar maintains its position, but jamming occurs during subsequent dispense cycles
Solution Approach 1:
The patent implements periodic action by introducing a reverse motion phase in the dispense cycle. After the forward dispense motion, the mechanism periodically reverses to disengage the sheet product from the tear bar before the next dispense cycle begins. This periodic reverse action prevents accumulated engagement that would otherwise cause jamming in subsequent cycles, while the tear bar returns to its stable position ready for the next operation.
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 minimizes product damage and jamming by controlling the acceleration and deceleration of the sheet product, reduces impulse loads, and enhances the assembly and stability of the dispenser, resulting in improved reliability and efficiency.
Implementation Method 1
a control unit controlling the DC stepper motor to move the sheet product with a gradually increasing acceleration during a portion of the dispense cycle
Implementation Method 2
a plurality of flexible rubber portions spaced along a length of the roller frame, the rubber portions being overmolded onto the roller frame
Implementation Method 3
the shaft plug including an aperture for receiving a portion of a roller shaft and an aperture sized to receive a spring, the chassis defining a pair of plug retainers for holding the plugs and roller, the springs tending to bias the roller away from the spring retainers
Implementation Method 4
insertion of the sheet product roll support shaft into hub ends causes the support arm connected to the rear wall to deflect to a substantially greater degree than the other support arm
Data Source
AI summary
A dispensing mechanism for a sheet product dispenser includes a chassis, a roller positioned within and coupled to the chassis, and a spring configured to bias the roller into contact with a sheet product. Another dispensing mechanism for a sheet product dispenser includes a chassis, a roller positioned within the chassis, a pair of plugs, and a pair of springs. The roller is coupled to the chassis via the plugs, and the springs are configured to bias the roller into contact with a sheet product. Still another dispensing mechanism for a sheet product dispenser includes a chassis, a first roller positioned within and coupled to the chassis, a second roller positioned within and coupled to the chassis, and a spring configured to bias the first roller toward the second roller and into contact with a sheet product.