Sheet Roll Dispenser Transfer Bar Control for Stub Roll Depletion
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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 sensor accuracy and noise reduction.
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 sensor to minimize waste and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical lever is used to detect stub roll diameter, then the transfer mechanism can be activated, but sheet product is wasted because the secondary roll dispenses before complete depletion
Solution Approach 1:
The patent replaces the mechanical lever detection system with an optical sensor system. The optical sensor detects the presence or absence of sheet product directly, eliminating the imprecise mechanical diameter measurement. This substitution enables accurate detection of when the stub roll is truly depleted, preventing premature activation of the transfer mechanism and reducing sheet product waste.
2Extent of automation
If a sensor in the dispensing chute is used to detect sheet product edge, then automatic dispensing can be achieved, but a gap in dispensing occurs during transfer
Solution Approach 1:
The optical sensor is positioned to detect the presence of sheet product on the stub roll before complete depletion occurs. This preliminary detection triggers the transfer mechanism to activate in advance, ensuring continuous dispensing operation. The system prepares for transfer beforehand, eliminating the dispensing gap that occurs when detection happens after depletion.
3Extent of automation
If a transfer motor with linkages is used to move the transfer bar, then automatic transfer can be achieved, but noise is generated
Solution Approach 1:
The patent replaces the transfer motor with linkages system with an electromechanical actuator. This actuator uses electromagnetic fields to directly drive the transfer bar, eliminating the mechanical linkages that generate noise through friction, impact, and vibration. The electromagnetic actuation provides smooth, quiet operation while maintaining automatic transfer capability.
4Extent of automation
If the sensor detects the front edge of sheet product, then automatic transfer can be triggered, but considerable time elapses before rear edge passes the sensor
Solution Approach 1:
The patent positions the optical sensor in a location that detects sheet product presence in a different spatial dimension - specifically, detecting the leading edge of sheet product as it approaches the dispensing area. This strategic positioning allows the system to trigger transfer based on sheet product arrival rather than waiting for edge passage, significantly reducing the time delay before transfer activation.
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 and maintaining consistent dispensing while conserving battery power and minimizing noise.
Implementation Method 1
An optical sensor is positioned adjacent the roller assembly and arranged to detect the presence or absence of sheet product
Implementation Method 2
An electromechanical actuator is arranged having a movable portion coupled to the transfer bar, wherein the movable portion moves 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 is provided for sheet product from a roller. The sheet product dispenser includes a first roll of sheet product, called a stub roll, a main roll of sheet product, and a dispensing arrangement. A sensor is provided for detecting when sheet product on a stub roll is depleted. The sensor generates a signal in response to the depletion of the stub roll and a controller activates an electromechanical actuator. The actuator acts to operate a transfer bar that moves an end portion of the main roll sheet product adjacent a roller assembly that engages the main roller sheet product.