Load Cell Bracket for Wide Range Weight Detection
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Solution Overview
Problem
Existing systems for monitoring the remaining amount of products in containers, especially in industrial or commercial settings, face challenges in accurately detecting when a product is empty or nearly empty due to limitations in load cell precision and accessibility issues, particularly when containers hold large volumes of liquids.
Innovation Solution
A system utilizing a load cell with a load cell bracket that allows for weight measurements over a wide range by deflecting at different rates based on load levels, generating notifications when the product is low or out, and incorporating a controller to determine product status and dispense amounts, ensuring accurate detection and notification of product exhaustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a load cell is used to detect product weight, then product exhaustion detection is enabled, but the load cell may be damaged by excessive weight from large containers
Solution Approach 1:
The system dynamically changes the load cell's operational state by introducing a contact mechanism. When the container weight exceeds a threshold, the load cell contacts the bracket which provides additional support, effectively changing the system's mechanical configuration to protect the load cell from overload while still enabling weight detection across a wide range.
Solution Approach 2:
The load cell bracket acts as an intermediary element between the load cell and the container. It provides conditional support to the load cell, engaging only when needed to prevent overload, thus mediating the interaction between the sensitive detection device and the heavy load it needs to measure.
2Measurement precision
If traditional monitoring systems are used, then product levels can be detected, but accessibility issues arise when dispensers are located away from employees
Solution Approach 1:
The system implements automatic feedback by continuously monitoring product weight through the load cell and generating notifications when product exhaustion is detected. This eliminates the need for manual checking and provides real-time information, making the system accessible regardless of its location away from employees.
Solution Approach 2:
The monitoring system performs self-service by automatically detecting product levels and generating notifications without requiring employee intervention. The load cell continuously measures weight and the system autonomously determines when product replenishment is needed, freeing employees from manual monitoring tasks.
3Strength
If a load cell bracket is introduced to prevent overload, then load cell protection is improved, but device complexity increases
Solution Approach 1:
The load cell bracket is integrated with the existing dispenser structure, merging the protection function into the overall system design. Rather than adding a completely separate protection mechanism, the bracket is incorporated as part of the mounting structure, thus minimizing additional complexity while providing essential overload protection.
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 provides precise and accurate detection of product exhaustion, preventing damage to the load cell and enabling reliable low-product and out-of-product notifications, even for large containers, ensuring compliance with health and safety regulations.
Implementation Method 1
a load cell having a fixed end and a free end, wherein the free end of the load cell deflects at a first rate of distance per unit load when a load less than a critical load is positioned to be weighed by the load cell
Data Source
AI summary
A system and method detect when a product container from which a product is dispensed is empty or nearly empty, and provides a notification of the product status. The system includes a load cell that deflects at a first rate of distance per unit load when a load less than a critical load is positioned to be weighed by the load cell, and a load cell bracket positioned such that the free end of the load cell contacts the load cell bracket when a load substantially equal to or greater than the critical load is positioned to be weighed by the load cell. The load cell bracket may prevent the load cell from further deflection, or it may permit deflection of the load cell at a second rate of distance per unit load when the load cell is in contact with the load cell bracket. The system may generate an out-of-product notification when the amount of product dispensed is substantially equal to zero, a low product notification when the amount of the product remaining is less than a threshold weight or a proof-of-delivery notification.