Method and device for indicating future need for product replacement of random-use dispensing
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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 due to their inability to account for varying usage patterns.
Innovation Solution
A method and device that set an activation count for the number of dispenses remaining, calculate a running average of material usage over a service interval, and compare this with the product of the service interval and average usage to indicate when refilling is needed, preventing complete depletion before the next scheduled service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fixed recording indicators (counters or sensors) are used to trigger warnings, then the dispenser can indicate low product, but the warning may only trigger after complete consumption of the product
Solution Approach 1:
The system performs preliminary action by calculating and displaying the service interval (weeks remaining) before the product is actually depleted. The controller computes how many weeks of service remain based on usage patterns and displays this information in advance, allowing proactive scheduling of maintenance before complete consumption occurs.
Solution Approach 2:
The system applies dynamics by using a running average of usage patterns that continuously adapts to varying dispensing rates. Instead of fixed thresholds, the service interval calculation dynamically adjusts based on actual usage behavior, enabling accurate prediction of depletion timing under different usage conditions.
2Reliability
If service providers check each dispenser frequently to determine if refill containers need replacement, then they can ensure timely replacement, but it is time-consuming
Solution Approach 1:
The dispenser performs self-service by automatically monitoring its own usage and calculating when service is needed. The controller continuously tracks dispensing events, computes the service interval based on running averages, and displays the weeks remaining without human intervention, eliminating the need for frequent manual checks.
Solution Approach 2:
The system implements feedback by displaying real-time service interval information to service providers. The indicator shows how many weeks of service remain, providing immediate feedback that enables efficient route planning and scheduling, allowing providers to consolidate visits and reduce travel time between dispensers.
3Reliability
If service providers replace product in advance to ensure dispenser availability, then the dispenser will not empty, but unnecessary replacement increases cost in service time and product
Solution Approach 1:
The system enables preliminary action by providing advance notice of when service is actually needed through the service interval display. Service providers can plan maintenance activities in advance based on accurate predictions rather than replacing product too early, ensuring dispenser availability while avoiding unnecessary replacements.
Solution Approach 2:
The system applies parameter changes by using a running average of usage patterns to dynamically adjust the service interval prediction. This allows the system to adapt to changing usage conditions and provide accurate replacement timing, preventing both premature and delayed replacement by continuously updating the depletion forecast based on actual dispensing behavior.
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.