Patent Publication Number: US-9901219-B2

Title: Method for control of an electronic liquid dispenser and associated dispenser system

Description:
RELATED APPLICATION 
     The present application is a Divisional Application of U.S. application Ser. No. 14/265,700, filed Apr. 30, 2014. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of electronic dispensers, such as soap dispensers, and more particularly to a dispenser system and associated control method wherein the actuating motor in the dispenser is stopped and reversed under certain abnormal operating conditions. 
     BACKGROUND 
     Electronic dispensers for dispensing any manner of metered doses of a liquid are well known in the art. Such dispensers are commonly used to dispense soap, lotions, disinfectants, and the like in public facilities, especially restaurants, hospitals, businesses, and so forth. These dispensers are typically “hands-free” systems wherein a sensor detects the presence of person&#39;s hands adjacent the dispenser and, in response, a controller causes a motor to automatically start and engage a pump actuating mechanism to dispense a metered dose of the liquid into the person&#39;s hands. In normal operations, the motor and pump actuating mechanism operate over a cycle wherein the motor is de-energized when the pump actuating mechanism (or an associated linkage or other member that moves with the pump actuator) returns to a “home” position that is detected by a sensor in communication with the controller. The “home” position is the closed position of the pump actuating mechanism wherein the liquid is prevented from draining or leaking from the reservoir. 
     An undesirable condition results, however, when any one or combination of malfunctions result in a motor jam or overrun condition, or a jam of the pump actuating mechanism in mid-cycle. When this happens, liquid may leak or even drain completely from the reservoir. For example, if the sensor that detects the home position of the pump actuating mechanism fails, the motor will continue to run and cycle the pump actuating mechanism. In another malfunction, the motor or moving members of the pump actuating mechanism may become jammed by debris or other obstruction during a dispense cycle, wherein the liquid is then free to flow from the reservoir through the open pump mechanism. 
     Proposals have been suggested to address (at least in part) the problem discussed above. For example, U.S. Pat. No. 8,646,655 describes a control method for a liquid soap dispenser wherein a stalled pump mechanism is reset to the “loading” position by reversing the pump motor upon detection that the pump actuator is still dispensing after a defined time period as measured by a run timer. A sensor is used to determine when the pump mechanism has returned to the loading position. Thus, this control method is premised on a maximum run time function of the motor, which times the actuation of the pump, to detect whether a stall of the pump mechanism has occurred. 
     U.S. Pat. No. 8,651,329 describes another control method for a liquid soap dispenser by wherein a stalled pump mechanism is reset to the loading position by reversing the pump motor. With this method, motor current is monitored during the dispense cycle and the motor is reversed if the current exceeds a predetermined level. Reversal of the motor is stopped when a sensor detects that the pump actuator has returned to the loading position. 
     The present invention provides an alternative solution whereby the control method considers multiple variables to determine a stall or jam of the pump mechanism before reversing the motor pump to return the pump mechanism to its home position. 
     SUMMARY OF THE INVENTION 
     Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     In certain aspects, the present invention provides a control method for an electronic liquid dispenser, wherein the liquid dispenser utilizes a motor powered by a voltage source to drive a pump mechanism from a home position in a dispense cycle for dispensing a metered dose of liquid from a reservoir. It should be appreciated that the control methodology is not limited to any particular type or configuration of electronic dispenser. Conventional electronic dispensers that detect the presence of a user with a sensor (e.g., an IR or capacitive sensor) and dispense a metered dose of liquid (e.g., soap, disinfectant, and the like) are well known in the art. The present invention has utility and is applicable to these various conventional dispensers, as well as to any new types of electronic dispensers that may be developed in the future. 
     The method includes starting the motor to operate the pump mechanism upon initiation of the dispense cycle. In operation, the motor performs “motor work” as a function of motor current/motor voltage, or motor voltage/motor resistance, and run time of the motor. Motor work is monitored as a more accurate and dynamic indication of a failed, stalled, or jammed motor. At one or more times during the dispense cycle, the motor work is calculated by a controller and, upon the calculated motor work exceeding a set point value during the dispense cycle, the controller stops and reverses the motor to return the pump mechanism to the home position. 
     It should be appreciated that the motor work will vary between different types of pump mechanisms, and that the present methodology is not limited to any particular type of pump mechanism. For example, a cam driven pump mechanism may generate a different work profile during a normal dispense cycle as compared to a piston-driven (or other type) of pump mechanism. 
     The set point motor work value may remain the same throughout the dispense cycle or, in certain embodiments, the set point value may change during the dispense cycle depending on whether or not the particular type of pump mechanism generates a varying motor work profile during a normal dispense cycle. 
     In one embodiment, the motor work is calculated immediately after start of the motor in order to detect an initial jam of the motor and reverse the motor. The set point motor work value immediately after start of the motor is set to detect such an initial jam of the motor. 
     As mentioned, motor work may be calculated essentially continuously or at various times throughout the dispense cycle. In a particular embodiment, the pump mechanism generates a normal, repeatable motor current profile during a normal dispense cycle, the method further comprising monitoring and detecting one or more deviations of motor current from the normal current profile. When such deviations occur, motor work is calculated and the motor is reversed if the calculated motor work exceeds the set point value. 
     For example, the normal motor current profile may include an increase in motor current at the home position of the pump mechanism (e.g., as an indication that the pump mechanism has been driven against a hard stop). The method may include detecting the increase in motor current at the end of the dispense cycle before stopping the motor. If the increase is not detected, calculated work will eventually exceed the set point value and the motor will be reversed. 
     Similarly, the normal motor current profile may include an initial increase and subsequent decrease in motor current during the dispense cycle, particularly for a cam-driven pump mechanism, with the method further detecting the decrease in motor current before the calculated motor work exceeds the set point value. 
     Likewise, the normal motor voltage profile may include a decrease in motor voltage at the home position of the pump mechanism (e.g., as an indication that the pump mechanism has been driven against a hard stop). The method may include detecting the decrease in motor voltage at the end of the dispense cycle before stopping the motor. If the decrease is not detected, calculated work will eventually exceed the set point value and the motor will be reversed. 
     Similarly, the normal motor voltage profile may include an initial decrease and subsequent increase in motor voltage during the dispense cycle, particularly for a cam-driven pump mechanism, with the method further detecting the increase in motor voltage before the calculated motor work exceeds the set point value. 
     The method may further include monitoring motor characteristics after the reversal command. For example, after the motor is reversed, motor current may be monitored for an increase in motor current before stopping the motor, the increase in motor current being an indication that the pump mechanism has returned to the home position. Before the increase in motor current is detected, motor current may be monitored for steady or decreasing current for a defined time period. Likewise, after the motor is reversed, motor voltage may be monitored for a decrease before stopping the motor, the decrease in motor voltage being an indication that the pump mechanism has returned to the home position. Before the decrease in motor voltage is detected, motor voltage may be monitored for steady or increasing voltage for a defined time period. 
     The present invention also encompasses any manner of electronic liquid dispenser incorporating the control aspects discussed above. For example, an electronic liquid dispenser according to the invention includes a reservoir for storing a liquid to be dispensed in metered doses from the dispenser, and a pump mechanism operably configured with the reservoir. A motor drives the pump mechanism from a home position in a dispense cycle for dispensing the metered doses of liquid from the reservoir, the motor powered by a voltage source. A sensor (e.g., an IR or capacitive sensor) is configured to detect the presence of a user and initiate the dispense cycle. A controller is connected to the sensor and motor, as well as to a current sensor and a voltage sensor. The controller is configured to calculate motor work being performed by the motor during the dispense cycle as a function of motor current and motor voltage, or motor voltage and motor resistance, and run time of the motor. Upon the calculated motor work exceeding a set point value during the dispense cycle, the controller stops and reverses the motor to return the pump mechanism to the home position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a conventional electronic liquid soap dispenser that may incorporate aspects of the present invention; 
         FIG. 2  is a perspective component view of the conventional dispenser of  FIG. 1 ; 
         FIG. 3  is a block diagram of a dispenser in accordance with aspects of the invention; 
         FIG. 4A  is a current and voltage over time graph of an exemplary electronic dispenser over the course of a dispense cycle without a reservoir bottle inserted in the dispenser; 
         FIG. 4B  is a current and voltage over time graph of an exemplary electronic dispenser over the course of a normal dispense cycle with a reservoir bottle inserted in the dispenser; 
         FIG. 4C  is a current and voltage over time graph of an exemplary electronic dispenser over the course of a jammed dispense cycle; 
         FIG. 5  is flow chart of a dispense cycle in an electronic dispenser in accordance with aspects of the invention; and 
         FIG. 6  is a flow chart of a dispense cycle after a motor reverse command is given to the motor. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made in detail to one or more embodiments of the invention, examples of the invention, examples of which are illustrated in the drawings. Each example and embodiment is provided by way of explanation of the invention, and is not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the invention include these and other modifications and variations as coming within the scope and spirit of the invention. 
     As discussed, the present invention relates to control methods for electronic liquid dispensers, and dispensers that incorporate such control methods. Although having particular usefulness as a liquid soap dispenser, the dispenser according to the invention is not limited to a liquid soap dispenser and may be utilized in any application wherein it is desired to dispense metered doses of a viscous liquid, such as disinfectant, moisturizer, sanitizer, and so forth. The liquid dispenser will be described herein with reference to a soap dispenser for ease of explanation. The present invention is not limited to any particular type or configuration of dispenser, so long as the dispenser has the structural and control functionalities to incorporate the aspects of the invention. For sake of illustration only,  FIGS. 1 and 2  are provided to illustrate a type of conventional dispenser that may utilize aspects of the present invention. 
     A liquid dispenser  10  is illustrated in  FIGS. 1 and 2  as a liquid soap dispenser, which is a particularly useful embodiment of the present invention. The dispenser  10  includes any suitable housing structure  14 . The housing  14  may contain a back side, side walls or members  16 , and a front side  20 . The housing  14  can take on any desired configuration and be formed from any number of components. In the illustrated embodiment, the housing  14  includes a front component  24  and a back component  22 . The front and back components may be separately manufactured and permanently joined. The components may be manufactured from any desired material. 
     The housing  14  defines an internal liquid reservoir within the internal volume thereof that is filled with a liquid, such as soap, through port  130 , which may also act as a vent. In the illustrated embodiment, the liquid reservoir includes essentially the entire volume defined by the front component  24  and back component  22 . Although not illustrated, it should be understood that any number of internal structural members, such as baffles or the like, may be included within the reservoir. In this particular embodiment, the housing  14  thus also serves as a closed or sealed reservoir that cannot be opened by the maintenance technician. A desired amount of viscous liquid, for example soap, is preloaded into the housing  14  prior to the housing being delivered to its point of use. In alternate embodiments of soap dispensers, the reservoir may be defined by soap-filled bags, bottles, or other containers that are inserted into the dispenser housing. 
     In the illustrated dispenser  10 , the pump mechanism is contained wholly within the housing  14 , and may include a cylinder  92  that is slidable within a chamber, wherein the volume of the chamber determines the metered dose of liquid dispensed upon each actuation of the pump. The chamber may be formed by any internal structure of the housing  14 . The cylinder  92  includes a delivery channel that terminates at a dispensing orifice defined in the front end face  93  of the cylinder  92 . 
     In other embodiments, the pump mechanism may be separately contained within the dispenser housing, wherein the reservoir mates with the pump mechanism upon insertion of the reservoir into the pump housing. 
     Any manner of suitable mounting assembly  200  is provided for mounting the dispenser (particularly the housing  14 ) to a supporting wall structure  12 . In the illustrated embodiment, the mounting assembly  200  includes an enclosed back unit  202  that is mountable against the supporting wall structure  12  by any conventional means, such as screws, adhesives, and the like. Various components of the electronic actuating mechanism may be housed in the back unit  202 . As seen in  FIG. 2 , the back unit  202  may include a wall  210  to which is attached the bracket  58 . The housing  14  is attachable to the bracket  58 , as described above, such that the back  18  of the housing  14  is flush against the wall  210 , as in the configuration of  FIG. 1 . The bracket  58  may be mounted to the wall  210 , or formed integrally therewith. 
     The mounting assembly  200  may include a base unit  206  that can be attached to, or formed integral with, the back unit  202 . The base unit  206  is disposed under the housing  14  and may support a portion of the weight of the housing. For example, the housing  14  may rest at least partially on support members  207  once attached to the back unit  202 , as seen in  FIG. 1 . Alternately, the housing  14  may be supported entirely on the wall  210  above the base unit  206 . The base unit  206  may include an upturned front member  213  that covers components of a pump actuator, and provides an overall aesthetically pleasing profile to the combined housing  14  and mounting assembly  200 , as particularly seen in  FIG. 1 . 
     An electronic actuating mechanism  215  provided to drive the pump mechanism may be housed in one of the units of the mounting assembly. This mechanism may include a motor driven actuator  226  that engages with the pump mechanism within the housing upon insertion of the housing  14  into the mounting assembly  200 . A motor  218 , such as a DC motor, and associated power supply circuitry  217  are also carried by the mounting assembly  200 . The motor  218  is in driving engagement with the actuator  216 . Power for the motor  218  and associated circuitry may be supplied by one or more replaceable batteries  234  also carried by the mounting assembly, or may be a direct hard-wire supply, for example DC current converted from a building&#39;s AC system. For sake of clarity, the wiring and circuitry components are not illustrated in the various views of the dispenser. Such connections are, however, a matter of simple design choice for those skilled in the art and need not be described in detail herein. 
     In the illustrated embodiments, the motor driven actuator  215  includes a member that is slidable in a horizontal path to engage and move the pump cylinder  92  from a resting or “home” position to a dispensing position within the pump chamber (within the housing  14 ). The cylinder  92  may be engaged by the actuator  226  so as to be driven throughout the dispense cycle, including return of the cylinder to its home position. 
     Motive force from the motor  218  may be transferred to the actuator  226  in any number of suitable embodiments. In the illustrated embodiments, the motor  218  includes an off-center drive cam  222  engaged within an elongated cam surface  224 , such as an elongated slot, defined in the motor driven actuator  226 . This eccentric or off-center cam arrangement converts rotational movement of the motor shaft to linear movement of the motor driven actuator  226 , which in turn engages and moves the pump cylinder  92  in a linear path from its rest position to a dispensing position wherein a metered dose of the viscous liquid is expelled from the pump chamber. Operation of the actuator  226  is hidden from view by the upturned wall  213  of the base unit  206 . An opening  232  (i.e., an elongated slot) may be defined in the actuator  226  proximate to the front end that is aligned with the delivery end of the pump cylinder  92  such that the metered dose of liquid is dispensed through the opening  232 . 
     Operation of the electronic dispenser may be initiated manually or automatically. For example, for manual actuation, a push-button  212  or similar device may be provided with the mounting assembly  200  wherein a user initiates a dispensing sequence by manually pushing the button  212  or otherwise actuating the manual device. This manual actuation in turn results in an electronic motor driven dispensing cycle as described above. In an alternate embodiment, a sensor  214  may be provided and integrated with the control circuitry for automatic initiation of the dispensing sequence. The sensor  214  may be, for example, a heat sensor, motion sensor, or any one or combination of sensors widely known and used for detecting the presence of a person in relatively close proximity to the dispenser  10 . 
       FIG. 3  is a block diagram of an exemplary electronic dispenser that may be used to practice aspects of the current invention. The dispenser  300  includes a reservoir or bottle  306  that includes a liquid (e.g., soap) to be dispensed in metered doses. A motor  302  drives a pump mechanism  304  in response to a dispense command issued from a controller  312 . The pump mechanism  304  may be variously configured within the scope and spirit of the invention. For example, any manner of gearing/linkage  320  may be configured to convert rotational movement of the motor  302  into any other type of motion needed to drive a pump  305 , which may be, for example, reciprocating linear motion. In a particular embodiment, the pump  305  may be cam driven, wherein the linkage  320  includes a suitable cam arrangement. As discussed above, the pump  305  may be an integral component of the reservoir  306  such that the pump  305  is replaced with the reservoir  306 . In an alternate embodiment, the pump  305  may be a permanent component of the dispenser housing that mates with the reservoir  306  upon installation of the reservoir in the dispenser housing. It should be appreciated that the present methodology and dispenser system is not limited to any particular type of motor and pump mechanism configuration. 
     Still referring to  FIG. 3 , the dispenser  300  includes a sensor  310  in communication with the controller  312  for detecting the presence of a user adjacent to the dispenser  300 , wherein the controller  312  then issues a dispense command. Such sensors  310  are well known in the art, and may include any manner of suitable active or passive proximity-type of sensor typically used in electronic dispensers. The invention is not limited to any particular type of sensor. 
     A voltage source, such as a battery  308 , supplies power to the various electronic components of the dispenser  300 . In an alternate embodiment, the dispenser  300  may be hard-wired to a structure&#39;s power system. 
     Any suitable voltage sensor  316  and current sensor  314  are provided for sensing the voltage and current draw states of the motor  302  during the dispense cycle. The sensors  316  and  314  are in communication with the controller  312 . It should be appreciated that, in an embodiment wherein motor work is calculated as a function of motor voltage and known motor winding resistance, the current sensor  316  is not necessary. 
     Any manner of suitable timing device or circuit  318  is provided for timing the run time of the motor  302  throughout the dispense cycle. 
     It should be noted in  FIG. 3  that the dispenser  300  does not utilize any type of mechanical or electronic switch to determine if or when the pump mechanism  304  has returned to its “home” or start position. For example, the dispenser  300  does not utilize a magnetic contact to convey to the controller  312  that a component of the pump  305  or linkage  320  has reached a position that is indicative of the home position of the pump mechanism  304 . Thus, the control methodology and system of the present invention are not prone to failures of such switches or contacts. 
     As discussed above, the present dispenser control methodology relies in part of the fact that the motor  302  will generate a “normal” electrical profile over the course of the dispense cycle as a function of the power required by the motor to move the pump mechanism  304  through a complete cycle. This profile may be a voltage or current profile.  FIG. 4A  is a current and voltage over time graph of an exemplary motor/pump mechanism configuration without a reservoir bottle installed in the dispenser. Thus, the current graph over time illustrates the power output of the motor  302  at a given supply voltage required to cycle the pump mechanism  304  without resistance to fluid flow through the pump mechanism or other frictional forces from the reservoir  306 . Likewise, the voltage graph over time also depicts the power output of the motor  302  at a given resistance (predetermined or rated) of the motor required to cycle the pump mechanism  304  without resistance to fluid flow through the pump mechanism or other frictional forces from the reservoir  306 .  FIG. 4A  depicts an initial current spike and initial voltage drop at the start of the dispense cycle that reflects the starting characteristics of the motor. The current tapers back down and voltage increases to nominal levels throughout the dispense sequence of the pump mechanism until the end of the cycle when the pump mechanism hits a hard stop at the home position of the pump (or linkage), which is reflected by a slight increase in current and slight decrease in voltage (due to resistance of the pump mechanism at the hard stop) before the motor is stopped at the end of the dispense cycle. 
       FIG. 4B  illustrates a current and voltage over time graph for the same type of dispenser over the course of a normal dispense cycle wherein the pump mechanism  304  dispenses a metered dose of liquid from a reservoir  306 . After the initial current spike and voltage drop, the respective graphs follow a somewhat bell-curve shape that reflects the power output of the motor  302  required to move the pump mechanism and dispense the metered fluid dose. Again, at the end of the cycle, current increases slightly and voltage decreases slightly as the pump mechanism returns to the home position before the motor is stopped. 
     It should be appreciated that the “normal” current and voltage profiles in  FIG. 4B  will differ between various motor/pump configurations, and that the profiles in  FIG. 4B  are for discussion purposes only. The point of consideration is that, under normal dispensing conditions and voltage supply to the motor, a given motor/pump configuration will generate a repeatable current and voltage profile from which motor work can be calculated over the course of the dispense cycle. With a normal baseline profile, deviations in motor work that occur in abnormal (e.g., jam) conditions can be readily calculated. 
       FIG. 4C  illustrates a current and voltage over time graph during a jammed dispense cycle wherein an abnormal condition in the pump mechanism  304  results in the motor fighting against a jam of the pump or linkage. After the initial starting current spike and voltage drop, current remains high and voltage remains low as the motor generates more power against the jam condition. At a certain time, the motor work setpoint value is exceeded and the motor is commanded to stop and then to subsequently reverse. The reverse command generates another starting current spike and voltage drop followed by a tapering of current and increase in voltage. As the pump or linkage returns to the home position in the reverse direction, a slight current increase and voltage decrease are detected before the motor is stopped.  FIG. 5  is a flowchart of an exemplary methodology in accordance with aspects of the invention. The method includes starting the motor at step  400  to operate the pump mechanism upon initiation of the dispense cycle. This command is generated by the controller in response to a manual operation (e.g., pushes a dispense button) taken by a user at the dispenser, or is generated automatically by the controller in response to detection of the user by a sensor  310  ( FIG. 3 ). As discussed above, in operation, the motor performs “motor work” as a function of motor current and motor voltage, or motor voltage and motor resistance, and run time of the motor. Work may be calculated as:
 
Work=(Current)×(Voltage)×(run time);
 
or
 
Work=(Voltage/Resistance)×(run time)
 
     Motor work is monitored as a more accurate and dynamic indication of a failed, stalled, or jammed motor. At one or more times during the dispense cycle, the motor work is calculated by the controller and, upon the calculated motor work exceeding a set point value during the dispense cycle, the controller stops and reverses the motor to return the pump mechanism to the home position. The set point motor work value may remain the same throughout the dispense cycle or, in certain embodiments, the set point value may change during the dispense cycle depending on whether or not the particular type of pump mechanism generates a varying motor work profile during a normal dispense cycle. 
     At step  402 , motor work is calculated essentially immediately after start of the motor in order to detect an initial jam of the motor and reverse the motor, as would be the situation depicted in  FIG. 4C . The set point motor work value immediately after start of the motor is set to detect such an initial jam of the motor. In  FIG. 5 , this value is stated as “5.0 Joules” for illustration only. 
     At step  404 , the calculated motor work is compared to the set point value and if this value is exceeded, the motor is stopped and reversed at step  406 . 
     If the calculated motor work is less than the initial set point value, then a comparison of motor current and calculated work is done at step  408 . If current or voltage exceed a certain value and work eventually exceeds another set point value, then a condition may exist wherein a weak voltage source (e.g., weak batteries) are present and the motor cannot overcome the spring or frictional forces of the pump mechanism. If this situation exists, then the motor is stopped and reversed at step  410 . 
     If the motor is not reversed in step  408 , the control method then continues to essentially monitor for a normal work profile (as evidenced by the current or voltage profiles). For example, at step  412 , current is monitored for a decrease, or voltage is monitored for an increase, over a defined period of time, which reflects that required power has peaked and that the motor is returning the pump mechanism to the home position. If this condition is not met, the system returns to step  408  and eventually motor work will exceed the set point value defined at step  408 . 
     If the conditions at step  412  are satisfied, motor work is again calculated at step  414  and current is monitored at step  416  for an increase that is indicative of the pump mechanism reaching the home position. If the current increase or voltage decrease is detected, then the dispense cycle is over and the motor is stopped at step  422 . 
     If the current increase is not detected at step  416 , then calculated work is compared to a set point value at step  420 . If this value is exceeded before the current increase or voltage decrease is detected, the pump mechanism has failed to seat or reach the home position and the motor is stopped and reversed at step  424 . 
       FIG. 6  is a flow chart depicting monitoring steps that may take place after a motor stop and reverse command is issued by the controller at any point  424  in the process of  FIG. 5 . At step  426 , current or voltage are monitored to ensure that power is steady or decreasing for a defined period of time. If this condition is satisfied, current is monitored at step  428  for the slight increase, or voltage is monitored for a slight decrease, that is indicative of the pump mechanism reaching the home position, and the motor is stopped at step  430 . 
     While the present invention has been described in connection with certain preferred embodiments it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.