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 difficulties in maintaining accurate inventory, 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 replacing the dispenser, using mechanical or proximity sensors to determine remaining product quantity and transmit refill notifications only when necessary, thereby conserving battery life and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional sheet product dispensers are used without automation, then device complexity and cost are low, but manual inspection time and labor requirements increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection with an optical sensing system. A light source emits light through the dispenser housing, and a photodetector detects the light intensity to determine sheet product levels automatically, eliminating the need for manual visual inspection while adding minimal system complexity
Solution Approach 2:
The dispenser system performs self-monitoring of sheet product levels through the optical sensor system. The processor automatically analyzes light intensity readings and determines when product replacement is needed, enabling the system to service itself without human intervention for inventory checks
2Measurement precision
If smart dispenser systems with continuous monitoring are implemented, then product level tracking accuracy improves, but battery consumption increases significantly
Solution Approach 1:
Instead of continuous monitoring, the system uses periodic sensing triggered by dispensing events. The processor activates the light source and photodetector only when a sheet is dispensed or when product level checks are warranted, maintaining measurement precision while dramatically reducing battery consumption compared to continuous operation
Solution Approach 2:
The system applies sensing action selectively rather than continuously. The optical sensor system performs measurements only when necessary (upon dispensing events or threshold triggers), providing sufficient product level tracking accuracy while using far less energy than would be required for constant monitoring
3Extent of automation
If existing smart systems replace conventional dispensers entirely, then automation and tracking capability improve, but installation cost and complexity increase
Solution Approach 1:
The patent merges the optical sensing components (light source, photodetector, processor) with an existing conventional dispenser housing. The system integrates automation capability into the existing structure rather than replacing it, reducing installation cost and complexity while maintaining full automation functionality
Solution Approach 2:
The optical sensor system is designed to work with standard dispenser housings and sheet product rolls. The light source can be positioned to illuminate through various housing types, and the processor can adapt to different product levels, making the automation system universally applicable to existing dispensers without custom manufacturing
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 automatic and accurate tracking of sheet product levels, reducing unnecessary replacements and maintenance costs while extending battery life through controlled sensor usage and wireless transmissions.
Implementation Method 1
The product level sensor is configured to emit light toward an outer circumference of a sheet product roll on a spindle extending along a longitudinal axis and to detect reflected light therefrom
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.