Usage-Based Refill Prediction for Random-Use Dispensing Systems
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Solution Overview
Problem
Existing dispensing systems fail to accurately predict and indicate when products in dispensers, such as paper towel and soap dispensers, will be depleted before the next scheduled maintenance, leading to unnecessary replacements and increased costs due to their inability to account for varying usage patterns.
Innovation Solution
A method and device that sets an activation count for the dispenser, calculates a running average of material usage, and compares it with a service interval to indicate when refilling is needed, preventing complete depletion by triggering a warning before the next scheduled service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fixed recording indicators (counters or sensors) are used to trigger warnings, then the dispenser can indicate low product, but the warning may only trigger after complete consumption of product and cannot predict future depletion due to varying usage
Solution Approach 1:
The system performs preliminary action by calculating and displaying the remaining service interval before product depletion occurs. The controller computes how many additional service intervals the current product supply will last and displays this information in advance, allowing service scheduling ahead of time rather than reacting after depletion. This resolves the contradiction by providing accurate prediction (improving measurement precision) while enabling advance planning (reducing service time loss).
Solution Approach 2:
The system applies dynamics by making the warning indicator adaptive rather than fixed. The remaining service interval display dynamically updates based on actual usage patterns, adjusting the prediction as product is consumed and usage varies. This dynamic approach improves detection accuracy by reflecting real-time conditions while maintaining efficient service scheduling.
2Reliability
If frequent checks of refill containers are performed, then accurate monitoring of product depletion is achieved, but time and resources are wasted checking non-depleted containers
Solution Approach 1:
The dispenser performs self-service by automatically calculating and displaying the remaining service interval based on its own usage data. The controller continuously monitors dispensing activity and computes how much longer the current product supply will last, presenting this information without requiring external inspection. This eliminates the need for frequent manual checks while maintaining reliable monitoring, resolving the contradiction between accuracy and time investment.
Solution Approach 2:
The system implements feedback by continuously monitoring usage and updating the remaining service interval display in real-time. This closed-loop feedback mechanism provides ongoing accurate information about product depletion status without requiring external verification, achieving reliable monitoring while minimizing the time and resources needed for checks.
3Ease of operation
If product replacement is performed based on fixed schedules, then service planning is simplified, but unnecessary replacements occur increasing service time and product cost
Solution Approach 1:
The system enables preliminary action by providing advance notice of remaining service intervals, allowing service providers to plan replacements ahead of time based on actual product consumption rather than fixed schedules. The display shows exactly how many service intervals remain, enabling optimization of service timing to match actual need, thus reducing unnecessary replacements and product waste while maintaining operational simplicity.
Solution Approach 2:
The system applies parameter changes by transitioning from fixed-time scheduling to usage-based scheduling. The remaining service interval display provides dynamic information based on actual dispensing patterns, allowing the service schedule parameter to adapt to real-world usage variations. This reduces product waste by aligning replacements with actual depletion while keeping service planning straightforward through clear numerical indication.
Data Source
AI summary
A method and device for indicating whether a dispensable product will require refilling prior to the next scheduled service interval includes tracking the amount of use over a first interval, and calculating a frequency based from the use over the first interval. The quantity remaining is compared with the required amount, which is the product of the number of weeks in the service interval and the calculated frequency. Thus, when the quantity remaining is less that the required amount, a warning will be provided to indicate that the dispensing product should be replaced, as it will be empty before the next service interval.