Sheet product dispenser
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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, with issues related to perforated vs. non-perforated sheets and noise generation.
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 secondary roll based on detection of sheet product availability, using a cam mechanism and optical sensors to minimize waste and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical lever is used to detect stub roll diameter, then the system can detect when the stub roll is depleted, but the detection is imprecise causing the secondary roll to dispense before complete depletion, resulting in wasted sheet product
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, allowing precise measurement of the stub roll's presence or characteristics without mechanical contact. This substitution enables accurate detection of when the stub roll is truly depleted, preventing premature activation of the secondary roll and eliminating sheet product waste.
2Productivity
If a sensor in the dispensing chute is used to detect sheet product edge, then the system can control dispensing timing, but the sensor generates false signals with non-perforated sheets and creates a gap in dispensing
Solution Approach 1:
The patent replaces the mechanical/optical sensor in the dispensing chute with a different optical detection approach positioned elsewhere in the system. The new sensor configuration detects sheet product characteristics without being subject to the same interference from non-perforated sheets, eliminating false signals and ensuring reliable detection for consistent dispensing control.
Solution Approach 2:
The patent introduces an intermediary detection mechanism that indirectly measures sheet product availability rather than directly sensing the sheet edge in the chute. This intermediary approach uses optical properties or other characteristics that are reliably detectable regardless of perforation status, providing accurate timing signals for dispensing control without false positives.
3Extent of automation
If a transfer motor and linkages are used to activate the transfer bar, then the secondary roll can be automatically transferred, but the system generates noise and consumes additional energy
Solution Approach 1:
The patent replaces the transfer motor and linkage mechanism with an electromechanical actuator that directly moves the transfer bar. This actuator uses electromagnetic fields to produce linear or rotational motion without the need for mechanical linkages, gears, or belts that generate noise. The direct electromagnetic actuation maintains full automation of the secondary roll transfer while dramatically reducing noise generation and energy consumption.
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 accurate detection of stub roll depletion, reduces waste, and provides consistent dispensing while conserving battery power and minimizing noise.
Implementation Method 1
A sensor is arranged in operable communication with the roller assembly, the sensor being electrically coupled to the electromechanical actuator
Implementation Method 2
An electromechanical actuator is arranged having a movable portion coupled to the transfer bar, wherein the movable portion is arranged to move the transfer bar between the first position and the second position
Implementation Method 3
Sheet product is generally dispensed using a roller system where the sheet product is passed between two rollers and the resulting friction pulls the sheet product from the dispensing roll
Data Source
AI summary
A sheet product dispenser includes a transfer bar, a roller assembly, a motor, a sensor, and a controller. The transfer bar is movable between first and second positions. The roller assembly, disposed proximate the transfer bar second position, has a drive roller and a pinch roller that define a nip. The motor is in operable communication with the transfer bar to move the transfer bar between the first and second positions. The sensor is in operable communication with the dispenser cover. The controller is in operable communication with the sensor and the motor, and is responsive to executable instructions to facilitate actuation of the motor in response to a signal from the sensor to cause the transfer bar to move between the first position and second positions. The transfer bar includes at least one finger that drives an end of a roll of sheet product towards the nip upon actuation of the transfer bar from the first position to the second position.