Sheet Product Dispenser Calibration for Color-Independent Level Sensing

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Solution Overview

Problem

Existing sheet product dispensers face challenges in accurately determining the remaining product level independently of the sheet product's color, as traditional sensors rely on light reflection, which can be affected by the color of the product, leading to inaccurate measurements.

Innovation Solution

The use of time-of-flight sensors, such as infrared or ultrasonic sensors, to measure the time it takes for a signal to be reflected back, allowing for the determination of the remaining product level without color dependency, combined with an automatic calibration method to adjust the product depletion curve based on measured time-of-flight or distance, ensuring accurate estimations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional light reflection sensors are used to determine product level, then the sensor can detect the amount of sheet product remaining, but the measurement accuracy deteriorates when the sheet product color varies (white/light vs. brown/dark)

Engineering Contradiction:

Improveproduct level measurement accuracyVSAvoidcolor independence

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent changes the measurement parameter from light reflection intensity to time-of-flight of a signal. The sensor emits a signal (light or sound) and measures the time it takes for the signal to travel to the product roll surface and back. This time measurement is independent of the product color, resolving the contradiction between measurement accuracy and color independence.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the optical reflection-based measurement system with a time-of-flight measurement system. Instead of measuring how much light is reflected (which depends on color), the system measures the time for a signal to travel to and from the product, substituting a color-independent physical measurement method.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If a predetermined product depletion curve is used for all dispensers, then manufacturing is simplified, but measurement accuracy deteriorates due to manufacturing tolerances and environmental variations

Engineering Contradiction:

Improveproduct depletion curve standardizationVSAvoidproduct level determination accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent performs preliminary calibration action during the product roll installation process. When a new product roll is installed, the system automatically measures the actual time-of-flight to the roll surface and uses this measurement to generate or adjust the product depletion curve specific to that dispenser unit. This preliminary calibration ensures accurate measurements while maintaining ease of manufacture through automated processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements a feedback mechanism where the actual measured time-of-flight values are fed back into the system to adjust and refine the product depletion curve. The controller compares expected time-of-flight values (based on a standard curve) with actual measurements and automatically adjusts the curve to match real-world conditions, improving accuracy while maintaining manufacturing simplicity.

Inventive Principle:

Principle #23Feedback

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 enables accurate determination of the remaining sheet product level independently of the product's color and adjusts for manufacturing tolerances and environmental variations, providing reliable and precise product level indicators and alerts.

Implementation Method 1

the sensor is configured to emit a signal toward the product roll and receive the signal. The signal is reflected off a surface of the product roll. The controller is configured to determine a time-of-flight of the signal that correlates to the time period from when the signal was emitted by the sensor to when the signal was received by the sensor

Methodology Applied

Scientific EffectTime-of-flight: Time of Flight

Implementation Method 2

The signal is reflected off a surface of the product roll

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS10506901B2Sheet product dispenser with product level indicator calibration

Publication Date: 2019.12.17 GPCP IP HOLDINGS LLC

AI summary

A sheet product dispenser is provided including a housing including a roll holder configured to receive a product roll, a dispensing mechanism configured to dispense a portion of the sheet product from the product roll, a sensor configured to emit a signal toward the product roll and receive a reflection of the signal from a surface of the product roll, and a controller. The controller is configured to receive an indication of replacement of the product roll, determine a time-of-flight of the signal, and determine an expected time-of-flight (or corresponding distance of travel) of a theoretical signal to a theoretical full product roll. The controller is further configured to compare the time-of-flight (or a corresponding distance of travel) of the signal to the product roll to the expected time-of-flight or distance, and adjust a product depletion curve based on the comparison.