Sheet Product Dispenser Roll Switching Using Optical Stub Detection
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Solution Overview
Problem
Existing sheet product dispensers face challenges in accurately detecting when a stub roll is depleted, leading to waste and increased costs, and they often require manual refilling or generate false signals with non-perforated sheets, while also consuming battery power and producing noise.
Innovation Solution
A sheet product dispenser with an electromechanical actuator and sensor system that moves a transfer bar to switch from a stub roll to a main roll based on detection of remaining sheet product, using a cam mechanism and proximity sensor to optimize dispensing and minimize waste, noise, and battery consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical lever is used to detect stub roll depletion, then the transfer mechanism is activated, but sheet product waste occurs due to imprecise detection
Solution Approach 1:
The patent replaces the mechanical lever detection system with an optical sensor system. The optical sensor emits light and detects its reflection from the stub roll, enabling precise measurement of the stub roll's presence and dimensions without mechanical contact. This substitution eliminates the imprecision of mechanical lever detection and allows accurate determination of when the stub roll is truly depleted, preventing premature transfer activation and reducing sheet product waste.
2Extent of automation
If a sensor in the dispensing chute is used to detect sheet product edge, then automatic dispensing is enabled, but false signals are generated with non-perforated sheets
Solution Approach 1:
The patent replaces the mechanical edge-detection sensor in the dispensing chute with an optical sensor system positioned adjacent to the roller assembly. The optical sensor detects the stub roll's presence and dimensions optically, without requiring physical contact or relying on sheet product features like perforations. This eliminates false signals with non-perforated sheets while maintaining automatic dispensing capability.
Solution Approach 2:
The patent introduces light as an intermediary between the detection system and the sheet product. The optical sensor emits light that reflects off the stub roll and returns to the sensor, allowing indirect detection of the stub roll's presence and dimensions without mechanical contact. This intermediary approach enables reliable detection regardless of sheet product characteristics such as perforations.
3Reliability
If the transfer bar is activated early to ensure sheet product availability, then no gap in dispensing occurs, but sheet product from both rolls is dispensed causing waste
Solution Approach 1:
The patent employs feedback through the optical sensor system that continuously monitors the stub roll's presence and dimensions. The sensor provides real-time information to the control system, which activates the transfer mechanism only when the optical detection confirms the stub roll is truly depleted. This feedback-based approach ensures continuous dispensing reliability while avoiding premature transfer activation that would cause sheet product waste from both rolls being dispensed simultaneously.
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 ensures efficient switching between rolls, reducing waste and noise, while maintaining consistent dispensing and conserving battery power by accurately detecting stub roll depletion and activating the transfer mechanism only when necessary.
Implementation Method 1
An optical sensor, such as a reflective type sensor, may be used to sense the presence or absence of sheet product
Implementation Method 2
An electromechanical actuator may be used to move the transfer bar between a first and second position
Implementation Method 3
A cam may be rotatably coupled to the roller assembly shaft
Data Source
AI summary
A sheet product dispenser is provided for sheet product from a roller. The sheet product dispenser includes a first roll of sheet product, called a stub roll, a main roll of sheet product, and a dispensing arrangement. A sensor is provided for detecting when sheet product on a stub roll is depleted. The sensor generates a signal in response to the depletion of the stub roll and a controller activates an electromechanical actuator. The actuator acts to operate a transfer bar that moves an end portion of the main roll sheet product adjacent a roller assembly that engages the main roller sheet product.