Sheet product dispenser with product level gauge system
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Solution Overview
Problem
Sheet product dispensers lack effective monitoring systems to track the remaining product level, leading to potential empty conditions and inefficient inventory management, especially in multi-roll dispensers where roll reassignment and double sheeting can occur.
Innovation Solution
Incorporating sensors within the dispenser to measure data associated with the rolls, including rotation and diameter, to determine the remaining product level, detect roll reassignment, and prevent double sheeting, with the ability to transmit data for remote monitoring and alert users.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are added to monitor roll diameter and rotation, then product level tracking accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical sensors that use light reflection principles. The sensor detects roll diameter changes by measuring the angle of incidence and reflection of light beams, eliminating the need for mechanical gauges while achieving high measurement precision.
Solution Approach 2:
The patent introduces an optical beam as an intermediary between the sensor and the roll. The light beam reflects off the roll surface at angles that correspond to the roll diameter, allowing indirect measurement without physical contact with the roll, thus simplifying the device while maintaining accuracy.
2Reliability
If multiple sensors are used to detect roll rotation and diameter, then reliability of dispensing monitoring is improved, but device complexity increases
Solution Approach 1:
The patent designs a multi-functional sensor system where a single optical sensor assembly performs multiple functions: detecting roll diameter through light angle measurement, detecting roll rotation through sequential beam interruption, and providing presence detection. This consolidates multiple monitoring functions into one device, improving reliability without proportionally increasing complexity.
Solution Approach 2:
The patent combines diameter detection and rotation detection capabilities into a single sensor assembly. The optical beam serves dual purposes: its reflection angle indicates diameter while its interruption pattern indicates rotation, merging two measurement functions into one integrated system that enhances reliability without adding separate sensor components.
3Productivity
If real-time sensor data is transmitted for remote monitoring, then inventory management efficiency is improved, but use of energy increases
Solution Approach 1:
The patent implements periodic data transmission instead of continuous transmission. The sensor system transmits inventory status data at predetermined intervals or when threshold changes are detected, allowing remote monitoring and inventory management efficiency while minimizing energy consumption by keeping the transmission system dormant between measurement cycles.
4Measurement precision
If sensors contact the roll surface to measure diameter, then measurement precision is improved, but the roll surface may be damaged
Solution Approach 1:
The patent uses an optical beam as an intermediary to measure roll diameter without physical contact. The light beam reflects off the roll surface, and the angle of reflection provides precise diameter information while the non-contact nature of optical measurement prevents any damage to the roll surface.
Solution Approach 2:
The patent replaces mechanical contact-based diameter measurement with optical reflection-based measurement. Instead of using physical gauges that touch and potentially damage the roll, the system uses light beams that reflect off the surface, providing the same measurement precision without the harmful mechanical contact.
Data Source
AI summary
An example sheet product dispenser includes a housing, a first roll holder, and a second roll holder. A first roll of sheet product is positioned on the first roll holder and assigned as a primary roll and a second roll of sheet product is positioned on the second roll holder and assigned as a secondary roll. A dispensing mechanism is configured to dispense sheet product from at least one of the first roll and the second roll. A sensor is configured to sense measurement data associated with the primary roll, including sensing when the primary roll rotates to dispense and measuring the diameter of the primary roll. A data communication device is in communication with the sensor and configured to transmit the measurement data. A controller is configured to determine situational information regarding the sheet product dispenser and provide corresponding alerts to users regarding the situational information and measured data.