Refillable Dispenser Dose Calibration Using Level Sensor Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing refillable dispensers inaccurately indicate when they are empty due to variance in the number of doses per refill unit, caused by factors like priming issues, clogs, and environmental factors, leading to premature replacement and waste of product.
Innovation Solution
A dispenser system equipped with a processor, memory, dose count, and sensors that recalibrate the number of doses remaining based on dispense count and product level, providing a more accurate display of remaining doses through a methodology involving a housing, actuator, and level detection, allowing for remote monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a predetermined number of dispenses is set for each refill unit, then the dispenser can track remaining doses, but the indication becomes inaccurate due to variance in actual dispenses per refill unit
Solution Approach 1:
The system uses feedback from level sensors to continuously monitor the actual product level in the refill unit. When the product reaches a predetermined low level, the system adjusts the remaining dose count to match the actual physical state, correcting for variances caused by priming issues, clogs, or partial actuations. This feedback mechanism ensures accurate indication without requiring complex manual calibration.
Solution Approach 2:
The dispenser automatically recalibrates the remaining dose count based on sensor detection of product level, without requiring manual intervention. The system self-corrects by comparing the predetermined dose count against actual product consumption and adjusting accordingly, making the dose tracking system maintain accuracy autonomously.
2Loss of substance
If the predetermined number of dispenses is set high to ensure product remains in the refill unit, then product waste is reduced, but the indicator shows empty prematurely
Solution Approach 1:
The level sensor provides continuous feedback on the actual product level in the refill unit. When the product reaches the predetermined low level, the system uses this feedback to recalculate and update the remaining dose indication, ensuring it reflects the true physical state rather than a fixed predetermined value. This prevents both premature empty indications and product waste.
3Productivity
If manual monitoring of fluid level is used, then device complexity is low, but productivity decreases due to frequent custodian intervention
Solution Approach 1:
The dispenser equipped with level sensors and automated dose tracking performs self-monitoring of product levels and automatically updates remaining dose counts. This eliminates the need for custodians to manually check fluid levels or replace refill units based on estimates, significantly reducing intervention frequency and improving operational efficiency while maintaining manageable system complexity.
4Reliability
If variance in dispenses per refill unit is not accounted for, then device complexity remains low, but reliability of dose indication deteriorates
Solution Approach 1:
The system incorporates feedback from level sensors that detect when product reaches predetermined levels. This feedback triggers automated recalibration of the remaining dose count, accounting for variances in actual dispenses caused by priming issues, clogs, or environmental factors. The recalibration ensures reliable dose indication without requiring complex manual calibration procedures.
Data Source
AI summary
An exemplary dispenser includes a housing and a refill unit. The refill unit being removable and replaceable. The dispenser also includes a processor, memory, a dose count stored in memory that is indicative of the number of doses in a full refill unit, a level sensor for detecting a predetermined level the refill unit and a dispense count indicative of the number doses of product dispensed from the refill unit. In addition, the dispenser includes memory and has logic stored in the memory for recalibrating the number of doses remaining in the refill unit as a function of the dose count, the number of doses of product dispensed and the predetermined level of product. The number of doses of product remaining in the refill unit may be displayed on the dispenser, on a remote station, or on both the dispenser and a remote station.