Systems and methods for product level tracking of sheet product rolls
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Solution Overview
Problem
Conventional sheet product dispensers require frequent manual inspections to determine when rolls are depleted, leading to unnecessary replacements and inaccurate inventory management, especially in large commercial settings, and existing smart systems are often costly, battery-intensive, or require significant upgrades.
Innovation Solution
A system that retrofits conventional dispensers with a processor, product level sensor, and wireless communications module to track sheet product levels without replacement, using mechanical or proximity sensors that conserve energy by limiting transmissions to specific events or intervals, allowing for automatic notifications when refills are needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional sheet product dispensers are used without smart tracking systems, then device complexity and cost are reduced, but manual inspection frequency increases and inventory accuracy deteriorates
Solution Approach 1:
The dispenser system performs self-monitoring of sheet product levels through integrated sensors and processors, eliminating the need for manual inspections by maintenance personnel. The system automatically detects when sheet product is depleted and can communicate this information remotely.
Solution Approach 2:
Manual mechanical inspection processes are replaced with electronic sensing systems that automatically detect sheet product levels. Optical sensors or other detection mechanisms substitute for human visual inspection, providing continuous monitoring without physical intervention.
2Measurement precision
If full smart dispenser replacement is implemented, then product level tracking accuracy is improved, but implementation cost increases
Solution Approach 1:
The smart tracking functionality is segmented into separate modular components (sensors, processors, communication modules) that can be independently selected and installed. This allows facilities to implement tracking accuracy improvements without replacing entire dispenser assemblies, reducing overall implementation cost.
Solution Approach 2:
The sensor and processing components are designed to be universally compatible with multiple dispenser types and configurations. A single tracking module can be adapted to work with various sheet product dispensers, eliminating the need for expensive custom-built solutions and reducing implementation costs through standardization.
3Loss of information
If continuous wireless transmissions are enabled for real-time monitoring, then inventory information availability is improved, but battery consumption increases
Solution Approach 1:
Instead of continuous transmission, the system employs periodic monitoring and transmission cycles. The processor activates the sensor and communication module at scheduled intervals to check product levels and transmit information only when necessary, significantly reducing battery consumption while maintaining adequate inventory information availability.
Solution Approach 2:
The system uses feedback mechanisms to intelligently control transmission frequency. When product levels are stable and above thresholds, transmissions are minimized or suspended. When product levels approach depletion or change states, the system automatically increases monitoring frequency and transmits alerts, optimizing the balance between information availability 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
Enables efficient and accurate tracking of sheet product levels, reducing maintenance costs and battery consumption, while allowing for timely refills without disrupting dispenser operation.
Implementation Method 1
The product level sensor is configured to emit a signal toward an outer circumference of the sheet product roll and to detect a parameter of the reflected signal corresponding to a distance between the product level sensor and the sheet product roll
Data Source
AI summary
Systems, devices, and methods for providing a sheet product dispenser with automated product level tracking functionality are provided herein. Various product level sensors are disclosed herein including a product level sensor configured to emit a signal toward an outer circumference of a sheet product roll on a spindle extending along a longitudinal axis and to receive a reflected signal. The product level sensor is positioned a radial distance away from the spindle and aimed to emit the signal in a direction that is not parallel and not perpendicular to the longitudinal axis. The product level sensor detects a parameter of the reflected signal corresponding to the distance between the product level sensor and the sheet product roll. Other example embodiments include mechanical product level sensors. Various communication protocols may be employed to limit transmission of data to conserve battery life while still maintaining desired communication functionality.