Patent Application
20110215188
This application includes a computer program listing Appendix in the form of a compact disc (two identical copies). The files of the compact disc are specified in an Attachment located at the end of the specification and before the claims hereof.
This invention relates to a paper towel dispensing system, and more particularly to an apparatus and method wherein capacitive sensing technology senses positioning of a toweling support roller and rotation of the toweling support roller is controlled based on capacitance sensing.
Many dispenser systems are known in the prior art for dispensing paper toweling from rolls thereof. In some cases, the paper toweling is comprised of individual paper towel segments separated by perforated tear lines, and in others the toweling has no perforated tear lines formed therein, severing or cutting individual sheets from the toweling accomplished by some suitable severing structure incorporated in the dispenser.
Many paper towel dispensing cabinets employ motor driven toweling support rollers or drums to transport toweling during the dispensing operation. Rotation of the rollers is accomplished in a variety of ways, including mechanical switching associated with the roller or by employing electronic methods to control motor “on” time and control roller rotation. Such arrangements include both dispensers which are manually actuated, as by means of a push button, and those employing a sensor, such as a sensor sensing proximity of a user's hand, to initiate operation.
U.S. Pat. No. 6,820,785, issued Nov. 23, 2004, discloses an electro-mechanical roll towel dispenser including a housing with a roll carrier disposed therein to rotatably support a roll of towel material. An electro-mechanical feed mechanism is disposed in the housing to dispense measured sheets of the towel material. The feed mechanism operates in a first mechanical operational mode wherein the towel sheets are dispensed by a user grasping and pulling on a tail of the towel material extending from the housing and a second electrical operational mode wherein a measured length of a next sheet is automatically fed from the housing to define the tail for the next user.
The dispenser of U.S. Pat. No. 6,820,785 includes a sensor for detecting a parameter that is changed by an initial pull exerted on a tail of a web of material extending from the opening of the dispenser. The sensor also generates a signal sent from the sensor to a control circuit or circuitry causing the motor employed in the apparatus to drive the feed mechanism until a measured length of web material that includes the tail of web material has been fed from the dispenser in the form of a measured sheet for subsequent removal by the user.
Similar devices are disclosed in U.S. Pat. No. 3,730,409 and Patent Publication Document WO 00/63100. The devices of these latter two documents have sensors for detecting movement of a tail end of web material such that the feed mechanism is activated in response to detecting the movement.
It is known to use magnets and a sensor (Hall effect sensors or reed switches) to control rotation of a roller or drum to control the amount of dispensed toweling. By placing a magnet in a specific location on the roller, and a magnet sensor nearby, it is possible to count the revolutions of the roller. The drawbacks of this method include relatively high manufacturing expense, since magnets and sensors are expensive. Also, multiple magnets are required when one revolution of the roller does not provide sufficient control of the dispensed material.
Another traditional method is to use timers to control the length of time the motor driving the roller is energized. The primary drawback of this approach is that it requires significant and ongoing calibration due to variability of power source to the motor and variability in the mechanical structure (“friction” is variable).
The following documents are also believed to be representative of the current state of the prior art in this field: U.S. Pat. No. 3,715,085, issued Feb. 6, 1973, U.S. Pat. No. 3,730,409, issued May 1, 1973, U.S. Pat. No. 3,737,087, issued Jun. 5, 1973, U.S. Pat. No. 3,949,918, issued Apr. 13, 1976, U.S. Pat. No. 3,998,308, issued Dec. 21, 1976, U.S. Pat. No. 4,666,099, issued May 19, 1987, U.S. Pat. No. 4,676,131, issued Jun. 30, 1987, U.S. Pat. No. 4,721,265, issued Jan. 26, 1988, U.S. Pat. No. 4,738,176, issued Apr. 19, 1988, U.S. Pat. No. 4,790,490, issued Dec. 13, 1988, U.S. Pat. No. 4,796,825, issued January 1989, U.S. Pat. No. 4,960,248, issued Oct. 2, 1990, U.S. Pat. No. 5,131,302, issued Jul. 21, 1992, U.S. Pat. No. 5,452,832, issued Sep. 26, 1995, U.S. Pat. No. 5,772,291, issued Jun. 30, 1998, U.S. Pat. No. 6,079,305, issued Jun. 27, 2000, U.S. Pat. No. 6,105,898, issued Aug. 22, 2000, U.S. Pat. No. 6,412,655, issued Jul. 2, 2002, U.S. Pat. No. 6,412,679, issued Jul. 2, 2002, Patent Document No. WO 9959457, dated November 1999, Patent Document No. WO 0063100, dated October 2000, U.S. Pat. No. 7,398,944, issued Jul. 15, 2008, U.S. Pat. No. 6,892,620, issued May 17, 2005, U.S. Pat. No. 7,044,421, issued May 16, 2006, U.S. Pat. No. 4,573,750, issued Mar. 4, 1986, U.S. Pat. No. 4,826,262, issued May 2, 1989, U.S. Pat. No. 6,446,901, issued Sept. 10, 2002, U.S. Pat. No. 4,270,818, issued Jun. 2, 1981, U.S. Pat. No. 6,112,631, issued Sep. 5, 2000, U.S. Pat. No. 5,375,920, issued Dec. 27, 1994, U.S. Pat. No. 7,354,015, issued Apr. 8, 2008, U.S. Pat. No. 4,738,176, issued Apr. 19, 1988, U.S. Pat. No. 790,490, issued Dec. 13, 1988, U.S. Pat. No. 6,079,305, issued Jun. 27, 2000, U.S. Pat. No. 6,419,136, issued Jul. 16, 2002, U.S. Pat. No. 6,412,679, issued Jul. 2, 2002, U.S. Pat. No. 5,441,189, issued Aug. 15, 1995, U.S. Pat. No. 5,878,381, issued Mar. 2, 1999, U.S. Pat. No. 5,691,919, issued Nov. 25, 1997, U.S. Pat. No. 5,452,832, issued Sep. 26, 1995, U.S. Pat. No. 5,340,045, issued Aug. 23, 1994, U.S. Pat. No. 5,335,811, issued Aug. 9, 1994, U.S. Pat. No. 5,244,263, issued Sep. 14, 1993, U.S. Pat. No. 4,848,854, issued Jul. 18, 1989, U.S. Pat. No. 4,738,176, issued Apr. 19, 1988, U.S. Pat. No. 4,270,818, issued Jun. 2, 1981, U.S. Pat. No. 4,170,390, issued Oct. 9, 1979, U.S. Pat. No. 5,657,945, issued Aug. 19, 1997, U.S. Pat. No. 4,122,738, issued Oct. 31, 1978, U.S. Pat. No. 6,012,664, issued Jan. 11, 2000, U.S. Pat. No. 5,816,514, issued Oct. 6, 1998, U.S. Pat. No. 5,417,783, issued May 23, 1995, U.S. Pat. No. 4,717,043, issued Jan. 5, 1988, U.S. Pat. No. 5,630,526, issued May 20, 1997, U.S. Pat. No. 6,363,824, issued Apr. 2, 2002, U.S. Pat. No. 6,293,486, issued Sep. 25, 2001, U.S. Pat. No. 6,695,246, issued Feb. 24, 2004, U.S. Pat. No. 6,854,684, issued Feb. 15, 2005, U.S. Pat. No. 6,988,689, issued Jan. 24, 2006, U.S. Pat. No. 7,325,767, issued Feb. 5, 2008, U.S. Pat. No. 7,325,768, issued Feb. 5, 2008, U.S. Pat. No. 7,168,602, issued Jan. 30, 2007, U.S. Pat. No. 6,592,067, issued Jul. 15, 2003, U.S. Pat. No. 7,341,170, issued Mar. 11, 2008, U.S. Pat. No. 7,182,288, issued Feb. 27, 2007, U.S. Pat. No. 7,296,765, issued Nov. 20, 2007, U.S. Pat. No. 6,977,588 issued Dec. 20, 2005 and U.S. Pat. No. 6,820,785, issued Nov. 23, 2004.
As will be seen below, the system of the present invention utilizes the unique approach of employing targets on a paper toweling support roller sensed by capacitance sensor structure during rotation of the roller, the capacitance sensor structure sensing capacitance changes caused by the rotating targets. Use of the approach of this invention allows control of paper length, prevents of motor jams and turns the motor control on and off based on capacitance sensing.
A search of the prior art relating to employment of capacitance sensing techniques, including in systems utilizing rotating drums located the following patent documents: U.S. Pat. No. 6,036,137, issued Mar. 14, 2000, U.S. Pat. No. 5,692,313, issued Dec. 2, 1997, U.S. Patent Application Pub. No. US 2007/0099189, pub. May 3, 2007, U.S. Patent Application Pub. No. US 2007/0079526, pub. Apr. 12, 2007, Foreign Patent documents: JP 2003-187410, KR 10-2005-021832, DE 101 31 019, EP 096 178, U.S. Pat. No. 6,047,894, issued Apr. 11, 2000, U.S. Pat. No. 4,448,196, issued May 15, 1984, U.S. Pat. No. 7,256,957, issued Aug. 14, 2007, U.S. Pat. No. 6,439,068, issued Aug. 27, 2002, U.S. Patent Pub. No. US 2008/0309380, pub. Dec. 18, 2008, U.S. Pat. No. 6,119,523, issued Sep. 19, 2000, U.S. Pat. No. 5,351,685, issued Oct. 4, 1994, U.S. Pat. No. 7,301,350, issued Nov. 27, 2007.
The systems disclosed in the located prior art do not remotely relate to paper towel dispensers. There is no teaching or suggestion of the unique combinations of structural components or method steps disclosed and claimed herein.
The present invention encompasses a paper towel dispenser apparatus for dispensing paper toweling from a roll of paper toweling.
The apparatus includes a housing and a roll support within the housing for supporting a roll of paper toweling.
A rotatable toweling support roller is located within the housing for receiving paper toweling from the roll of paper toweling and transporting the paper toweling.
An electric motor is operatively associated with the toweling support roller for rotating the toweling support roller.
At least one target is operatively associated with the rotatable toweling support roller and movable responsive to rotation of the rotatable toweling support roller by the electric motor.
Capacitance sensor structure is operatively associated with the electric motor. A controller is employed for receiving signals from the capacitance sensor structure for controlling rotation of the rotatable toweling support roller by the electric motor responsive to capacitance changes caused by movement of the at least one target sensed by the capacitance sensor structure.
The invention also encompasses a method of dispensing paper toweling from a roll of paper toweling from dispenser apparatus including a housing, a roll support within the housing, a rotatable toweling support roller within the housing and an electric motor for rotating the toweling support roller.
The method includes the step of operatively connecting at least one target to the rotatable toweling support roller. While toweling from the roll is located on the rotatable toweling support roller, the electric motor is employed to rotate the toweling support roller and the at least one target to transport the paper toweling.
Sensor structure is employed in operative association with the electric motor to sense capacitance changes caused by movement of the at least one target.
Signals from the sensor structure representative of the capacitance changes sensed by the sensor structure and representative of target movement are directed to a controller.
The controller is employed to control rotational movement of the rotatable toweling support roller responsive to the signals received by the controller from the sensor structure.
Other features, advantages and objects of the present invention will become apparent with reference to the following description and accompanying drawings.
Referring now to the drawings, paper toweling dispenser apparatus constructed in accordance with the teachings of the present invention is illustrated. The apparatus is for dispensing paper toweling from a roll of paper toweling.
The dispenser includes a housing 10 defining an interior. A roll support 12 of any suitable construction is located within the housing.
Rotatably mounted within the housing 10 is a rotatable toweling support roller 16 which is positioned below roll of paper toweling 14 and receives and supports unwound toweling, as shown. Dispensed toweling exits opening 18 formed in the front of the housing or cabinet. Any suitable means may be utilized to sever individual sheets from the toweling during dispensing, for example a cutter blade located at or near the opening 18 or elsewhere in the path of the dispensed toweling. In the interest of simplicity and due to the fact that such expedients are well known, a cutter blade has not been illustrated.
An electric motor 20 having a motor shaft is positioned in the housing, the motor shaft having a gear 22 which meshes with a set of gears 24 to drive a gear 26 affixed to roller 16 for rotation therewith. A pinch roll 28 maintains the tail end of the toweling in firm engagement with the surface of the roller, 16.
The toweling support roller 16 has a pair of targets operatively associated therewith and movable responsive to rotation of the rotatable toweling support roller by the electric motor. More particularly, in the arrangement illustrated, roller 16 has a pair of strips 30 extending along the complete (or partial) length thereof and in diametric opposition to one another. The strips are formed of any suitable metallic material and may be solid metal or adhesive foil for example, the material preferably being strongly dielectric. Any suitable sensor material may be utilized without departing from the spirit or scope of this invention as long as it allows capacitance sensing during rotation of the roller.
The strips 30 may suitably be covered, as shown in
Located within housing 10 and positioned closely adjacent to the peripheral surface of roller 16 is a processor printed circuit board 32 which includes a capacitance sensor 34 of any suitable type. It will be appreciated that the processor can be located virtually anywhere, potentially even including outside the housing. Also, the processor and sensor do not have to be incorporated on the same printed circuit board. In addition, the sensor itself does not have to be on a printed circuit board either. It can, in principle, be fashioned exclusively from wire or e.g. flex cable, which is another potential advantage.
The arrangement disclosed allows complete software control. There are no mechanical switches or other components that can wear or fail. Two CD copies of such software is attached to this application as an Appendix.
By inserting metal sensor targets into the drum assembly of the dispenser, one is able to “see” the sensor targets and the spaces between them as a rotational count, providing a window of four counts (two targets and two spaces). The sensor may suitably be statically located at the paper guide just below the rotating paper toweling support roller within range of sensing the capacitance changes as the drum rotates.
It is possible to use one sensor board for'both proximity detection and drum roller control. There can be real cost savings with such an approach. The general principle is that the micro controller has an algorithmic means of deciding when to treat the one sensor as a proximity detector and when to treat it as a drum roller controller, and applies different delta math in each case.
As will be described in greater detail below, software allows one to count the on/off patterns of the rotating drum, producing the logical control for the processor to know where the drum was and how far it had rotated. By controlling the amount of rotation, one can calculate paper lengths with a predetermined formula embedded into the firmware. One can also detect the performance of the motor and disconnect power if the PCB does not see the drum within specified time frames during rotation.
In the illustrated embodiment, a proximity sensor printed circuit board 40 is located at the front of housing 10 and connected via a flat flexible cable 42 to processor printed circuit board 32, the circuitry of which is shown in
A flat flexible cable 44 connects processor printed circuit board 32 to power supply printed circuit board 46.
Using capacitance sensing for tracking a rotating or otherwise periodically moving object poses challenges. The traditional approach to dealing with capacitance sensed signals is to smooth out or average them as shown in the capacitance/time graph or diagram of
For a rotating device of circular shape, the signal generated should generally be expressed as sine wave or other essentially periodic waveform of relatively stable frequency. To detect a specific point on the rotating cylinder (roller) passing near the sensor, then it is only necessary to search for a peak value.
However, with noise it is possible that the peak value with negative noise won't meet the value necessary to trigger a detection event. Or, a value with positive noise far from a peak event may be sufficient to trigger a false detection.
For this reason, the preferred approach for capacitance sensing of the targets and spaces therebetween on rotatable paper toweling support roller 16 is the capacitance sensing method disclosed in co-pending U.S. patent application Ser. No. ______, filed ______. This approach, sometimes referred to herein as the “delta method” or “delta detection method”, now will be described.
With reference to
Each box depicted by dash lines in
The capacitance sensor forms what is essentially an antenna, and the oscillations from the sensor will not produce a single, stable frequency, but rather a noisy series of readings.
One method for reducing the effect of the noise is to smooth out the signal (e.g. low-pass filter or average). This may be done with RC-type circuits in the analog domain or through signal processing in the digital domain. The smoothed out signal is depicted in
Multiple averages or different time-lengths may also be used. This is typically done by looking at times when an average of shorter time length crosses over or under an average of longer time length. This is shown in
These methods have drawbacks for detecting short-duration events such as a hand wave. The
The delta method is presented in block diagram form in
Utilizing the delta detection method, the starting point for processing data is the counting window.
The sequence of readings is stored, usually in memory attached to a microcontroller or other programmable device. No averages need be computed, although the method will also work with both averaged and filtered readings. For example, well known techniques such as pre-filtering signals to eliminate 60 Hz noise are compatible with the proposed method. The method looks at the difference between readings taken at different points in time. These points in time may in fact be consecutive readings, or they may be separated by a set or arbitrary length of time, as depicted in
Using this collected raw data, the processing then proceeds as follows. The difference or the delta between counting windows is calculated and this is stored in an array of delta values. The length of the array is a function of the type of event detected, and the noise signal.
If the raw frequency were to be plotted, this array of delta values could be considered a proxy for the second derivative of the raw frequency curve. A detection event now becomes a specific pattern in this second derivative.
One example of what the algorithm will search for, while maintaining an array of delta values of suitable length, or an array of readings upon which delta computations are performed at each time interval, is a pattern similar to a square wave pulse, such as depicted in
In a linear representation, this pattern match will look similar to that shown in
The comparison values may be stored as an explicit sequence of values, or stored implicitly as a part of the mathematical function that performs event detection.
In some applications, one delta calculation may be insufficient to establish a detection event. The delta method can be extended to use multiple samples, across arbitrary lengths of time, as illustrated in
In this case, the reading at time (Y+1) is compared to the reading at time (X+1), and the reading at time (X) is compared to the reading at time (Y). The two comparisons may look for the same threshold, or they may be independent tests.
For example, for a very sharp change in the signal, the comparison between X and Y may look for a small change and a large change between (X+1) or (Y+1). Alternatively, a small change in a noisy environment may look for a moderate, identical change in both comparisons.
Multiple windows can also be used when storage space is limited, as more windows allow storage of smaller amounts of data.
The delta method technology can be effectively used to track roller 16 movement. A capacitance sensor 34 is mounted near the roller and metallic targets 30 are attached to the roller in a way that the sensor can read the target material and, as the target passes by the sensor, a detection event is recorded. The sensor may for example be a copper pad within printed circuit board 32.
The delta method for this particular application is the general delta method described above. The look-back distance between samples is a function of the sampling rate and the rotational speed of the roller. The counting window is small, to allow for multiple counts across the general maximum and minimum parts of the expected curve. See
For random noise, this significantly increases the probability of detecting a peak while reducing the chance of a false positive. This is because a threshold value closer to the theoretical maximum distance between peaks and minimums can be used.
Two further variations or embodiments are proposed to deal with particularly challenging sensing environments as shown in
The first variation uses multiple simultaneous deltas. This can be achieved in several ways, the simplest being to perform multiple comparisons at each point in time. With multiple comparisons, a detection event can be treated as a more complex “voting” scheme—e.g., two out of three delta compares meet a threshold.
The second variation is to detect both maximum and minimum values in the signal generated by the rotating object. This is shown in
This is advantageous as it doubles the resolution at which the roller can be controlled, which allows for finer control of the quantity being dispensed by the roller or drum. The cost implications are obvious.
There may be implementations wherein the rotating roller spun by an electric motor, cannot maintain a constant rotational speed or cadence.
An example of how this can occur is in the case of a battery-powered motor, the batteries having been significantly depleted, cause a slowing rotation of the roller. In the case of a paper dispenser where the paper is stored on a large roll, the rotational speed may be different between a full roll (heavy) and a nearly depleted roll (light). A further example is the possible effect of friction of the mechanical structure changing as the dispenser is used over time.
The delta method allows an approach for dealing with these variations in rotational speed. As shown in
The variation of this look-back method distance is a function of the particular embodiment; for example, the look-back distance can be a function of the measured voltage at the battery terminals. Or the mechanical changes over time can be characterized, and the look-back distance can be calculated using an algorithm that understands the “aging” of the frictional resistance of the mechanical system.
