Sheet Roll Dispenser Transfer Bar for Stub Roll Switching
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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 noise, battery conservation, and inconsistent dispensing.
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 remaining sheet product, using a cam mechanism and proximity sensing to optimize dispensing and minimize waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a mechanical lever is used to detect stub roll diameter, then the transfer mechanism can be activated, but sheet product waste occurs due to premature secondary roll dispensing
Solution Approach 1:
The patent replaces the mechanical lever-based diameter detection system with an optical sensing system. The optical sensor detects the presence or absence of sheet product at the dispensing chute, providing more precise control over when the transfer mechanism activates, thereby preventing premature secondary roll dispensing and reducing sheet product waste.
2Extent of automation
If a sensor in the dispensing chute is used to detect sheet product edge, then automated dispensing control is achieved, but false signals are generated for non-perforated sheet product
Solution Approach 1:
The patent introduces an intermediary optical sensing system that detects the presence of sheet product at the dispensing chute without requiring physical contact or interaction with the sheet product's perforations. This optical intermediary provides reliable detection for both perforated and non-perforated sheet product, eliminating false signals while maintaining automated dispensing control.
3Extent of automation
If a transfer bar with linkages is used to move secondary roll sheet product, then automatic transfer is achieved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex linkage system from the transfer bar mechanism. By using a simplified transfer bar that can be directly actuated by an electromechanical actuator, the patent maintains automatic sheet product transfer functionality while significantly reducing device complexity and the number of moving parts.
4Ease of operation
If continuous operation is maintained to ensure sheet product availability, then user needs are met, but battery power is consumed and noise increases
Solution Approach 1:
The patent implements periodic action by placing the optical sensor in the dispensing chute that continuously monitors sheet product presence without requiring continuous motor operation. The system only activates the dispensing motor when sheet product is actually needed, thereby ensuring sheet product availability while minimizing battery power consumption and reducing noise from continuous motor 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 system ensures efficient switching between rolls, reducing waste, conserving battery power, and minimizing noise while maintaining consistent dispensing of sheet product.
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.