Soap Dispenser Float-Accelerometer Sensor for Fill Level Monitoring
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Solution Overview
Problem
Conventional liquid soap dispensers in commercial lavatories face challenges in accurately determining the soap level, leading to inefficient maintenance, potential overfilling, and increased costs due to expensive fill level sensors, which are often costly and impractical for facilities with multiple washbasins.
Innovation Solution
A low-cost fill level sensor integrated into the liquid soap supply container using an accelerometer-linked linkage system that provides feedback on soap levels without requiring visual inspection, utilizing a float and accelerometer to measure volume changes and prevent overfilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional fill level sensors (optics, infrared devices, reed switches, or magnet arrangements) are used to measure soap level, then measurement precision is improved, but device cost increases significantly
Solution Approach 1:
The patent replaces conventional electronic fill level sensors (optical, infrared, reed switch, or magnetic sensors) with a mechanical sensing system consisting of a float, linkage mechanism, and accelerometer. The float moves with soap level changes, transmitting mechanical motion through linkages to the accelerometer, which converts mechanical displacement into an electrical signal. This mechanical substitution dramatically reduces component cost while maintaining measurement functionality.
Solution Approach 2:
The patent employs inexpensive, readily available components such as a standard float, simple linkages, and a low-cost accelerometer module. These components are significantly cheaper than specialized fill level sensors while being sufficient for the application's measurement needs, making the overall system economically viable for widespread deployment in facilities with multiple soap dispensers.
2Device complexity
If visual inspection methods are used to determine soap level, then device complexity is reduced, but measurement precision and ease of operation deteriorate
Solution Approach 1:
The system automatically monitors soap levels through the float-accelerometer mechanism and can trigger refilling alerts or shutdowns without human intervention. The float continuously tracks the soap surface, and the accelerometer automatically converts this mechanical position into measurable data, eliminating the need for manual visual inspection by maintenance personnel.
Solution Approach 2:
The accelerometer provides continuous feedback on float position, which directly correlates to soap level. This feedback mechanism enables automatic detection of low soap conditions and can trigger notifications to maintenance systems, replacing imprecise visual estimates with accurate, objective measurements while keeping the overall device relatively simple.
3Ease of manufacture
If container is mounted three feet from wash basin edge, then ease of installation is improved, but ease of operation for visual inspection deteriorates
Solution Approach 1:
The patent replaces the human visual inspection process with a mechanical sensing system (float and accelerometer) that automatically measures soap level. Since the sensing mechanism is internal and automated, the container can be optimally positioned three feet from the wash basin edge for ease of installation and aesthetics, without compromising the ability to monitor soap levels accurately.
4Device complexity
If manual refilling without level monitoring is performed, then device complexity is reduced, but loss of substance increases due to overfilling
Solution Approach 1:
The float-accelerometer system provides real-time feedback on the current soap level during the refilling process. When the soap reaches the maximum level, the float rises accordingly, and the accelerometer detects this position change, triggering an alert or automatic shutdown signal. This feedback loop prevents overfilling and soap waste while adding minimal complexity to the refilling operation.
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 solution allows for accurate and cost-effective monitoring of soap levels, reducing maintenance inefficiencies and preventing overfilling, while being suitable for facilities with multiple soap dispensers, thus enhancing operational efficiency and reducing waste.
Implementation Method 1
a float-bearing member that changes elevations in response to volume changes within a liquid soap container
Implementation Method 2
an accelerometer mounted to the float-bearing member that provides feedback regarding a fill level within the liquid soap container... Inclinometers have commonly been used to measure the tilt of a member in relation to gravity
Data Source
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AI summary
A fill level sensor assembly (72) for a liquid soap container or vessel (26) has a float-bearing arm (71) and an accelerometer (88) that is attached to a surface of the arm (71) to detect changes in the volume of liquid soap in the container (26). A feedback system (93) then conveys fill status information based on the output of the accelerometer (88), such as to service personnel who may be responsible for replenishing the supply of liquid soap in the container (26).