Patent Description:
Dispensers for sheet materials, such as for dispensing towels, tissue or other paper products, are commonly used in hospitals, restrooms and other facilities. When the supply of sheet material in such dispensers is running low or has been fully dispensed, it generally is not apparent until the dispenser is out of and no longer dispenses sheet material. Paper, measuring or metering systems have been used, but generally do not provide precise and/or continuous monitoring of the remaining supply of sheet material. For example, available sheet material metering systems or gauges can include a mechanical lever arm that engages the supply of sheet material and is moved as the sheet material is dispensed and reduces in diameter. After the lever arm has moved a specific distance/amount, i.e., due to a reduction in the diameter of the sheet material, the lever arm will activate a switch that in turn can activate a light or other notification mechanism to indicate a low paper condition. Accordingly, typical paper metering systems often simply provide an indication as to whether the sheet material supply is out or is about to run out, and generally do not provide substantially precise, real-time monitoring of the amount of remaining sheet material. Moreover, after the notification mechanism is activated and the sheet material is continued to be dispensed, the specific amount of sheet material remaining cannot be discerned, e.g., whether the dispenser is completely out of paper or if it still has some amount of sheet material remaining; which may result in replacement of the sheet material before complete dispensing thereof, leading to waste of the sheet material and increasing costs, or the dispenser being rendered inoperable until an empty supply roll is discovered and replaced.

<CIT> discloses a dispenser with a quantity measuring device and method of determining quantity of sheet material remaining.

The present disclosure addresses these issues and other related and unrelated issues in the art.

Briefly described, the present invention is directed to a dispenser according to claim <NUM> for dispensing sheet materials, such as towels, tissues or other paper products. The dispenser includes a housing, with a roll support mounted within the housing and rotatably supporting at least one supply of sheet material at least partially within the dispenser housing. In one embodiment, the dispenser can include, a plurality of supplies of sheet material including, for example, at least one initially full/new roll or primary supply and at least one secondary or "stub roll". The dispenser housing further includes a driven feed roller rotatably mounted therein for feeding the sheet material from each supply roll along a feed or discharge path toward and through a discharge throat arranged along the dispenser housing. The feed roller is automatically driven by a drive system including a motor. The dispenser housing also may include one or more pressing rollers and/or guide rollers arranged along the feed path and adjacent the feed roller to guide the sheet material therebetween and toward the discharge throat.

In addition, the dispenser includes a material supply monitoring and measurement system operable to continuously monitor and substantially dynamically determine a remaining amount of the supply of sheet material in the dispenser. The monitoring system includes a plurality of magnets disposed about the supply which can include a primary supply roll and a secondary or "stub" roll of sheet material, for example, along, or substantially adjacent one end of a core or supporting roll thereof, with the plurality of magnets being rotatable therewith during dispensing thereof.

The monitoring system includes a plurality of magnets arranged along, or substantially adjacent to, at least one end of the supply (or supplies) of sheet material (e.g., on a hub or along a portion of the core or support roll for the supply or supplies), defining a magnetic ring. The magnets are also arranged such that adjacent magnets have opposite polarities, such that the polarities of the magnets alternate north, south, north, south.

At least one sensor will be arranged substantially proximal or adjacent the series of magnets, and can include a reed switch, a hall element, proximity sensor, or other suitable sensor operable to measure or otherwise detect variations, fluctuations or other changes in a magnetic field generated as the magnet, or series of magnets, is rotated with the supply of sheet material during dispensing thereof and passes by the sensor. The detected variations, fluctuations or changes of the magnetic field can be correlated to number of rotations of the supply of sheet material and/or a rotation angle of the supply of sheet material for dispensing a desired length of the sheet material during each dispensing operation.

By substantially continuously monitoring the number of rotations of the core of the supply or of sheet material, and the number of rotation of the feed roller or the motor driving the rotation of the feed roller per rotation of the supply of sheet material during a dispensing operation to feed the required or desired length of sheet material as the sheet material is dispensed, a diameter of the supply of sheet material can be substantially dynamically determined during or following each dispensing operation and, based on this determined/monitored diameter, an amount of sheet material remaining in the dispenser can be dynamically determined by the monitoring system with substantial accuracy.

Additionally, other sensing devices or mechanisms, such as encoders or other detectors that can monitor and provide a measurement of the number of rotations of the motor/feed roller and/or extent of rotation of the supply of sheet material can be used, without departing from the scope of the present disclosure.

The dispenser further includes controller in communication with the at least one sensor of the monitoring system so as to require signals corresponding to the dynamic measurements or readings obtained by the at least one sensor of the monitoring system will be communicated to the controller of the material supply and the feed roller/drive motor, which signals can be indicative of or can be used to determine the number rotations of the supply of sheet material (or the core or support roll thereof) as well as a number of rotations of the feed roller and/or motor driving the feed roller for each rotation of the supply of sheet material, as the sheet material is dispensed. The determined number of rotations of the supply of sheet material and the feed roller/motor further can be used by the controller to calculate or otherwise determine a diameter of the supply of sheet material based, at least in part, on a selected length of sheet material being dispensed by each operation of the dispenser.

As the supply of sheet material is rotated to dispense the selected length of sheet material toward and through the discharge chute by the driving of the feed roller, the number of rotations of the supply of sheet material, or the angular distance of the supply during such rotation needed to dispense the selected length of sheet material during each dispensing operation can be counted and/or updated after each operation to dynamically determine the remaining diameter of the supply of sheet material. This determined remaining diameter of the supply of sheet material can be compared to an initial and/or a final diameter of the sheet material (i.e., a "full" and/or an "empty" supply roll of the sheet material) to determine and update a substantially precise amount of percentage of the sheet material remaining in the dispenser, and/or to a threshold valve to determine a potential need for replacement of the supply of sheet material. Thus, the monitoring system can provide for a substantially continuous, accurate, and precise monitoring of the amount of sheet material remaining in the dispenser, which dynamic or updated measurement further can be reported or communicated to an attendant or to provide notifications of, not only a low paper detection, but also an indication of the amount of paper remaining and/or a projection of when such remaining paper supply might run out.

The monitoring system also can include a means for automatically determining the length of sheet material dispensed during each distribution of sheet material by an operator. In one example, the length of the sheet material dispensed can be determined based, at least in part, on the number of rotations and/or angle of the driven feed roller or its motor. For a feed roller with a specific diameter, a fixed length of sheet material (i.e., <NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), etc.. ) generally may be dispensed or pulled from the supply with the rotation of the feed roller during a dispensing operation. By monitoring the number and/or the amount of rotations of the feed roller, the controller of the dispenser can determine about how much sheet material is dispensed during a dispensing operation or cycle, as well as when a selected or pre-determined length of sheet material is dispensed during each dispensing operation. The monitoring system also can include one or more sensors that continuously monitor rotation of the motor or the drive shaft driving the feed roller, which sensors can be in communication with and send a signal indicative of the number of rotations of the motor and/or feed roller to the controller. The number of rotations of the motor for feeding a specific length of sheet material thus can be determined and recorded, and further correlated to a substantially precise length of sheet material dispensed which information further can be used for substantially continuously monitoring and updating of the remaining amount of sheet material in the dispenser.

The present disclosure, in another aspect, is directed to a method for substantially continuously monitoring the amount of sheet material remaining in a dispenser. The method may include monitoring rotations, angles, and/or an angular distance of the supply of sheet material as it is dispensed, at intervals or substantially continuously; for example, by measuring or otherwise detecting the presence, fluctuations or variations of a magnetic field due to the plurality of magnets rotating with the supply of sheet material during dispensing and passing by one or more sensors arranged substantially adjacent the supply in a position(s) or location to detect/sense the plurality of magnets as the supply is rotated. In addition, the rotation of the motor and/or feed roller also will be monitored for determining a number of rotations of the motor or feed roller per rotation of the supply of sheet material. The detected number of rotations of the feed roller and/or the motor driving the feed roller per rotation of the supply of sheet material during each dispensing cycle or operation can be correlated with a changing diameter of the supply of sheet material from the dispensing the specific or prescribed length of sheet material. The method further can include continuously monitoring when the selected or specified length of sheet material is dispensed, for example, by monitoring the number of rotations of the feed roller or the motor of the feed roll mechanism during each operation for a length of sheet material dispensed, to substantially continuously determine when the specific length of sheet material dispensed and/or how much material is dispensed.

The diameter of the supply of sheet material thus can be substantially dynamically determined upon each dispensing operation by monitoring and detecting the number of rotations of the supply of sheet material required to dispense the determined or selected length of sheet material and the feed roller and/or motor driving the feed roller per rotation of the supply of sheet material during such a dispensing operation, and the changes in this detected number of rotations after each dispensing operation, or after a selected series of dispensing operations. This information farther can be compared to an initial and/or a final diameter of the sheet material to provide a running count or monitored amount of sheet material remaining in the supply of sheet material in the dispenser. The controller additionally can provide updates of this remaining diameter to notify personnel of a low supply condition and/or the remaining supply amount in the dispenser.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the below listed drawing figures.

<FIG>, <FIG>, and <FIG> show a dispenser <NUM> for a sheet material having a material supply monitoring and/or measurement system <NUM> for continuously, accurately, and precisely monitoring a remaining amount of sheet material in the dispenser <NUM>. As shown in <FIG>, an example dispenser <NUM> for sheet material <NUM>, such as tissue, paper products and/or other suitable materials, will inchide a dispenser housing <NUM> having a cover <NUM>, a from <NUM>, rear <NUM>, side <NUM>/<NUM>, and bottom <NUM> sides or portions. The dispenser <NUM> further includes at least one supply <NUM> of sheet material, such as a roll of paper at least partially supported along the dispenser housing <NUM>. The dispenser <NUM> includes one or more supports <NUM> that can engage a core or center support roll <NUM> of the supply so as to rotatably support the supply <NUM> of sheet material along, or at least partially within, the dispenser housing <NUM>. The dispenser <NUM> further can include at least one additional supply <NUM> (<FIG>, <FIG>, <FIG>) of sheet material having a core or center support roll <NUM> that is rotatably mounted to one or more additional supports <NUM>. In one embodiment, the first supply of sheet material <NUM> can be a full or new roll of sheet material and the second supply <NUM> can be a "stub roll" that includes a roll and sheet material that has been at least partially dispensed, and can serve as a backup supply if the primary supply <NUM> runs out. For example, a full/new roll could be loaded into supports <NUM> and when the full roll has been substantially dispensed, e.g., more than <NUM>% of the supply has been dispensed, the partially dispensed roll (e.g., a "stub roll") can be moved to another position within the dispenser and can be supported by the additional supports <NUM> from which the "stub roll" can be fully dispensed.

In one example embodiment, as shown in <FIG> and <FIG>, the supports <NUM> can include one or more arms <NUM> that are connected to the dispenser housing <NUM>, such as at sides <NUM>/<NUM>, and that can be biased into engagement with and/or rotatably coupled to the ends 26A/B of the supply <NUM> of sheet material or the core <NUM> thereof, so that the supply <NUM> of sheet material is enabled to substantially freely rotate with respect to the arms <NUM> as the sheet material is pulled from the supply during dispensing of the sheet material. The supply <NUM> of sheet material may be otherwise rotatably mounted to, or along, the dispenser housing <NUM>, without departing from the present disclosure. For example, the ends 26A/B of the supply <NUM> of sheet material may be at least partially received within grooves defined in a portion of the dispenser housing <NUM>, e.g., sides <NUM>/<NUM>, or can be directly connected to at least a portion of the dispenser housing <NUM>, such as by one or more bearings or other suitable connection mechanisms for rotatably mounting the supply <NUM> of sheet material.

The additional supports <NUM> (<FIG>, <FIG>) can include one or more arms <NUM> that are connected to the dispenser housing <NUM>, such as at sides <NUM>/<NUM>, and that can be biased into engagement with and/or rotatably coupled to the ends 27A/B of the supply <NUM> of sheet material or the core <NUM> thereof, so that the supply <NUM> of sheet material is enabled to substantially freely rotate with respect to the arms <NUM> as the sheet material is pulled from the supply during dispensing of the sheet material. The supply <NUM> of sheet material may be otherwise rotatably mounted to, or along, the dispenser housing <NUM>, without departing from the present disclosure. For example, the ends 27A/B of the supply <NUM> of sheet material can be directly connected to at least a portion of the dispenser housing <NUM>, such as by one or more bearings, bushings, etc., or other suitable connection mechanisms for rotatably mounting the supply <NUM> of sheet material.

Additionally, as shown in <FIG> and <FIG>, the dispenser <NUM> further will include a feed roller <NUM> rotatably mounted therein. The feed roller <NUM> will be operable to rotate/pull and guide/feed the sheet material <NUM> along a feed or discharge path <NUM> towards a discharge chute <NUM> of the dispenser for dispensing or distribution of a length of the sheet material to a user. The discharge chute <NUM> can comprise an opening or slot <NUM> arranged along the bottom portion <NUM> of the dispenser housing <NUM>. A portion of the sheet material <NUM> will be at least partially disposed about and in engagement or contact with the feed roller <NUM>, such that, upon rotation of the feed roller the sheet material will be pulled, causing the supply <NUM> of sheet material to be rotated and an amount or length of sheet material <NUM> to thus be fed to and through the discharge chute <NUM>. The feed roller <NUM> can have a diameter selected for feeding a prescribed or predetermined or known length or amount of sheet material. For example, the feed roll <NUM> can have a diameter or size selected to feed an <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>") or other predetermined length of sheet material for each revolution or pre-set series of revolution per dispensing operation.

The feed roller <NUM> is automatically driven by a drive mechanism <NUM> (shown in <FIG>) that activates when one or more sensors detect a predetermined condition, for example, when a proximity sensor <NUM>, such as an infrared sensor, detects the presence of a user's hand adjacent or below the dispenser housing <NUM>, or detects the absence of sheet material extending from the discharge chute <NUM>. The one or more sensors also can include a switch or lever, e.g., flapper or pawl member <NUM>, arranged along a tear bar <NUM> or other cutting mechanism that is activated when a user tears away a select amount of sheet material. Additionally, the feed roller <NUM> can be manually driven, e.g., when an operator actuates a knob or lever or pulls or tensions a portion of sheet material <NUM> extending from the discharge chute <NUM> (not shown).

The drive mechanism <NUM> of the feed roller comprises a motor <NUM>, such as a DC motor (e.g., brush or brushless DC motor), an AC motor, stepper motor, servo motor or other similar motor or actuator. The motor <NUM> can be powered by a battery pack <NUM> or other power source arranged at least partially within or along the dispenser housing <NUM>, As indicated in <FIG>, the drive mechanism <NUM> also can be integrated with the feed roller <NUM>, or can be arranged separately from the feed roller <NUM> and can be in communication therewith and/or drive the feed roller through one or more gear assemblies <NUM>, though other transmissions mechanisms, devices, assemblies, etc., such as one or more pulley assemblies, can be used without departing from the scope of the present disclosure. Any suitable arrangement or configuration for the drive mechanism can be employed, however, without departing from the scope of the present disclosure.

<FIG>, <FIG> and <FIG> further show that the dispenser <NUM> can include one or more guide or pressing rollers <NUM>/<NUM> rotatably mounted along the feed path <NUM> of the sheet material, adjacent the feed roller <NUM>, in positions so as to contact and/or functionally engage and guide the sheet material <NUM> therebetween as the sheet material is fed along the discharge path <NUM> for dispensing thereof. The guide rollers <NUM>/<NUM> can be biased toward the feed roller <NUM>, such as by one or more springs or other suitable biasing members to contact and engage the sheet material between each guide roller and the feed roller, however, one or more of the guide rollers can be fixed, i.e., unbiased, without departing from the present disclosure. Additionally, although a pair of pressing rollers <NUM>/<NUM> can be used as indicated in <FIG>, any number, arrangement, and/or configuration of biased or unbiased guide rollers, such as one, three, or four guide rollers also can be employed without departing from the present disclosure, e.g. as indicated in <FIG> and <FIG> the dispenser <NUM> further can include one or more cutting mechanisms as such as a blade or tear bar <NUM> (<FIG>), configured to cut, perforate, tear or otherwise sever the sheet material. In one example, a cutting mechanism can be disposed along the feed roller <NUM> and can be movable therewith to cut or perforate the sheet material <NUM> as it is dispensed.

Additionally, or in the alternative, the cutting mechanism can include a tear bar <NUM>, with a jagged or serrated edge, that is arranged along or adjacent the discharge chute <NUM> of the dispenser to allow a user to tear off a desired amount or length of sheet material <NUM> after it is dispensed.

As shown in <FIG> and <FIG>, the supply/supplies <NUM> and <NUM> of sheet material will be rotatably coupled to the supports <NUM> and additional supports <NUM>, respectively. For example, as shown in <FIG> and <FIG>, the supports <NUM>/<NUM> generally include or are coupled to connecting members or to hubs <NUM>/<NUM> at each end of the supply or other suitable attachment mechanism operable and/or configured to be connected to the ends 26A/B or 27A/B of the supplies <NUM>/<NUM> of sheet material, such that the supplies <NUM>/<NUM> of sheet material are rotatable therewith. For example, hubs <NUM> can include a hub body <NUM> that is rotatably engaged with or coupled to a corresponding support arm <NUM>. <FIG> shows that each hub body <NUM> can have a substantially circular or disk-like shape, though any suitable shape, such as a semi-spherical or polygonal shape, can be employed without departing from the present disclosure. Each hub body <NUM> also can have a hole or opening <NUM> defined therethrough and configured to receive a pin <NUM> or other suitable mechanism that further can be received through a corresponding hole or opening <NUM> in an associated or adjacent arm <NUM> to rotatably couple each hub body <NUM> to its arm <NUM>, as shown in <FIG>. The pin <NUM> can be secured in place by a clip or locking ring <NUM> or other suitable attachment mechanism (<FIG>). The secondary supply or stub roll <NUM> can be similarly rotatably supported from its support <NUM>.

Additionally, each of the supplies <NUM>/<NUM> of sheet material can include a rigid supply roller or core <NUM> around which the sheet material <NUM> is rolled or otherwise disposed. Each supply roller <NUM> generally can include a cylindrical body <NUM> with a cavity <NUM> defined therein and an opening <NUM> at each of its ends 60A/B (<FIG>, <FIG>, and <FIG>). shaped, sized, dimensioned or otherwise configured such that at least a portion of the hub body <NUM> of each hub is at least partially received within a corresponding opening <NUM> at each end 60A/B of the supply roller body <NUM>. For example, as shown in <FIG> and <FIG>. the hub body <NUM> can include a frustoconical, conical, or otherwise angled portion <NUM> that fits into an opening 60A/B and projects at least partially into the internal cavity <NUM> of the supply roller body <NUM>. e.g., in frictional engagement therewith, such that the core <NUM> of the sheet material supply and thus the supply of sheet material are rotatable. Each hub body <NUM> further can include one or more stoppers, tabs or other suitable projecting portions <NUM> that are sized, dimensioned, or configured to engage at least a portion of the supply roller body <NUM> to prevent slippage between the hub bodies <NUM> and supply roller or core <NUM> during dispensing of the sheet material.

As further shown in <FIG>, the proximity sensor <NUM> for detecting the presence of a user's hand or other suitable portion of a user's body or object can be disposed along the dispenser housing <NUM>. The sensor <NUM> will be positioned so as to detect the presence of a user's hand or other portion within an area or proximity below the dispenser housing <NUM>, and will send a signal to a controller <NUM>, in response to which operation of the dispenser can be activated to dispense a measured/select amount of sheet material.

<FIG> additionally shows that the dispenser <NUM> can include a pivotally mounted lever, flapper or pawl member <NUM> generally located proximate to the tear bar <NUM>. in one embodiment, the flapper member <NUM> is positioned such that movement of sheet material into the tear bar <NUM> for severance thereof causes the sheet material to at least partially engage and pivot or otherwise move the flapper member <NUM> from a first position <NUM> to a second position <NUM>. In addition, a signal means <NUM> can be in communication with the flapper member <NUM> such that movement of the flapper member <NUM> to its second position <NUM> can cause the signal means <NUM> to transmit or otherwise send a signal, e.g., to notify or indicate to the controller <NUM> of the dispenser, that the sheet material <NUM> has been removed or at least pulled or otherwise engaged against the tear bar <NUM>.

In addition, that the dispenser <NUM> can include a sheet material detection sensor <NUM> operable to detect sheet material <NUM> in and along the discharge chute <NUM>. In one embodiment, the sheet material detection sensor <NUM> can include at least one signal emitter and at least one signal detector <NUM>/<NUM> (e.g., at least one IR signal emitter and at least one IR detector) disposed along opposing portions of the discharge chute <NUM>. The emitter and detector will be focused or directed across at least a portion of the discharge path, such that when sheet material is present in the discharge chute/path, the detector will not receive a signal from the emitter, i.e., the signal will be blocked, indicating the presence of the sheet material in the discharge chute, while the location of the sensor <NUM> also substantially avoids inadvertent detection of a user's hand.

The proximity sensor <NUM>, the flapper or pawl member <NUM>. and the sheet material detection sensor <NUM> can include any suitable components, have any suitable construction, and/or perform any suitable functions or operations, without departing from the scope of the present disclosure, for example, as detailed in <CIT>and <CIT>.

The dispenser <NUM> additionally includes a sheet material monitoring and/or monitoring system <NUM> generally shown in <FIG>, and operable to substantially continuously measure the feeding of lengths of the sheet material during each operation of the dispenser for dynamically determining and tracking the amount of remaining sheet material <NUM> of the supplies <NUM>/<NUM> of sheet material with enhanced precision and accuracy as the sheet material continues to be dispensed from the dispenser. The monitoring system <NUM> includes a plurality of magnets (<NUM>, <NUM>) disposed along the supply <NUM> and/or the supply <NUM>. for example, attached along at least one end, e.g., ends 26A or 26B, thereof, such that the plurality of magnets (<NUM>, <NUM>) is rotatable with the supply <NUM> and/or <NUM> during a dispensing operation.

The monitoring system <NUM> includes a plurality of magnets <NUM>, e.g.. arranged about one of the ends of the supply <NUM> and/or the supply <NUM>, and rotatable therewith, which plurality of magnets <NUM> is arranged to form a magnetic ring <NUM> with adjacent magnets having opposite and alternating polarities, the magnets arranged with alternating polarities, north, south, north, south and so on (<FIG>). The plurality of magnets <NUM> can include rare-earth magnets, electro magnets, and/or otherwise magnetized materials.

As further shown in <FIG>, <FIG>, and <FIG>, the magnetic ring <NUM><NUM> of magnets <NUM> can be mounted to or arranged about a hub <NUM> or <NUM> of at least one of the support arms <NUM> or <NUM> and to which an end of the core of the supply <NUM> or <NUM> of sheet material is mounted so as to be rotatably supported by the support arms.

The present disclosure is not limited to a specific configuration and/or arrangement of magnet(s), however, and the plurality of magnets can be mounted along or connected to the supply/supplies of sheet material, such as by being directly connected to or formed with the supply roller or core <NUM> for the supply/supplies of sheet material or otherwise connected thereto, such that the magnets rotate with the rotation of the supply of sheet material during a dispensing operation, as generally shown in <FIG>.

The monitoring system <NUM> also will include at least one sensor <NUM>, for example, a reed switch, a hall element, proximity sensor, or other suitable sensing mechanism or device operable to measure or detect the presence of a magnet and/or fluctuations or variations in a magnetic field. The at least one sensor <NUM> can be arranged or positioned within or along the dispenser housing typically being located substantially adjacent the plurality of magnets <NUM>, in a position to detect the presence of the magnet(s) and/or measure or otherwise detect fluctuations or variations in the magnetic field created as the plurality of magnets is rotated or otherwise moves past the sensor with the rotation of the supply <NUM> of sheet material during a dispensing operation. For example, the sensor <NUM> can be arranged along an arm <NUM> substantially adjacent or proximal to the rotating hub <NUM> to which the magnet or ring of magnets is mounted, such as shown in <FIG>. The sensor <NUM> further can be received within a cavity or chamber <NUM> defined in the arm <NUM> and can be secured, such as by a snap fitting, fastener or other suitable connection mechanism. The chamber <NUM> may be at least partially enclosed by a cover <NUM> or other portion that can be removably attached to the arm <NUM>. Other sensors, detecting mechanisms, etc., such as an encoder or other detector capable of monitoring and determining the rotation of the sheet material supply also can be used.

As indicated in <FIG>, a similar sensor <NUM> further can be arranged along the dispenser housing substantially proximate or adjacent to the supports <NUM> for the second ("stub") roll <NUM>. This sensor <NUM> can be located and configured to function in a substantially similar manner as the sensor <NUM> monitoring rotation of the main or primary supply <NUM>. However, it will also be understood that the magnet <NUM> and sensor <NUM> for the second (stub) roll <NUM> do not have to be used as it is not necessary or required that the dispenser include a second or stub roll; that the monitoring system monitor the second (stub) roll or to do so in the same manner as the supply <NUM>. Moreover, it will be understood that the sheet material of the second supply roll <NUM> generally can be maintained out of engagement with the feed roller until the main or primary supply <NUM> has been substantially exhausted, or the supply is detected as having a selected minimum amount remaining sufficient to trigger feeding of sheet material from the second supply roll.

The detection of the magnet passing by, or fluctuations, variations and/or changes in the magnetic field being detected by the sensor <NUM> can be correlated with an angle, an annular distance and/or a number of rotations (including partial rotations) of the supply <NUM> of sheet material as the sheet material is dispensed. The changes in polarities detected as the ring of magnets is rotated can be counted and empirically correlated to a specific number of rotations or an amount or distance of rotation of a supply <NUM>/<NUM> of the sheet material, e.g., during one dispensing operation, <NUM> rotations may be detected for feeding <NUM>" of sheet material, while <NUM>, <NUM> or <NUM> rotations may be detected during subsequent dispensing operations for feeding a <NUM>" length of the sheet material. Furthermore, based at least in part on a known, predetermined length of the sheet material being dispensed by the revolution of the feed roller during a dispensing cycle or operation, radian measurements can be used to determine a substantially precise diameter of the sheet material remaining on the supply roll based on the number of rotations of the supply roll detected/measured by the sensor <NUM>.

In one example, the monitoring system <NUM> may communicate signals indicative of the number of rotations of the supplies <NUM>/<NUM> of sheet material operating and being measured by the sensor <NUM> during a dispenser operation or cycle to a controller <NUM> (<FIG>) of the dispenser <NUM> such as by a wired or wireless connection. <FIG> generally illustrates an example controller or control system <NUM><NUM> for the dispenser, which can comprise a processor 110A, programing or control software 110B, including programing, instructions, workflows, etc. for facilitating operation of the monitoring system. The controller <NUM> further can communicate with a signal means <NUM>, including the hand or proximity detector <NUM>, the pawl or flapper bar member <NUM>, and the sheet material detection sensor <NUM>; and in response to signals therefrom, control operation of the feed roller motor and/or provide output signals a display <NUM>. A power supply <NUM>, which can include a battery <NUM> or AC power connection <NUM> also generally will be connected to the controller for powering the operation of the dispenser. Further examples of control systems are shown in <CIT> and <CIT>.

The controller receives inputs from the supply roll sensor <NUM> as to the number of rotations thereof, and from a motor sensor or detector assembly <NUM> that monitors and detects rotations of the motor and/or the feed roller; and in response, the dispenser controller <NUM> can use this measured information to calculate a remaining diameter of the supply of the sheet material following completion of each dispensing operation or cycle, or at least selected ones of the dispensing cycles. This calculated/updated remaining diameter or amount further can be compared to an initial and/or a final diameter of the sheet material to determine a substantially precise percentage of sheet material remaining in the dispenser. Thus, the monitoring system <NUM> can provide for substantially precise, continuous, and updated monitoring of the amount of sheet material remaining in the dispenser.

The controller further can receive inputs from the sensor <NUM> (or sensors) to verify that sheet material was actually dispensed from one of the supplies <NUM>/<NUM>, For example, operators often may just dispose of (i.e., throw away) partially dispensed ("stub") rolls as opposed to moving the roils to the additional support <NUM> for fully dispensing the sheet material/paper therefrom, which can waste a considerable amount of sheet material. Accordingly, the sensor <NUM> dispensed adjacent to the support <NUM> can send a signal to verify that the second ("stub") roll has been loaded for dispensing, as well as the number of rotations thereof for determining an amount of sheet material remaining on this roll.

The monitoring system <NUM> additionally can include a means for automatically determining the length of sheet material dispensed during each distribution of sheet material by an operator. In one example, the length of the sheet material dispensed can be determined, based at least in part, on a programmed or known number of rotations of the motor <NUM> and/or the feed roller <NUM>. Specifically, the feed roller <NUM> can have a specific diameter selected for feeding a substantially fixed or known length of sheet material with each rotation thereof. Thus, monitoring the number of rotations of the feed roller <NUM> and/or its motor enables the controller to determine completion of each dispensing cycle and also can allow for a substantially more precise determination of the length of sheet material dispensed during each cycle including cycles or operations that may have been prematurely halted, such as by a user pulling/tearing the paper before the motor has fed a full sheet length. Additionally, or in the alternative, the number of rotations of the motor <NUM> or a drive shaft <NUM> thereof for each rotation of the feed roller <NUM> can be determined, for example, based on a specific pulley or gear ratio between the or a drive shaft <NUM> thereof for each rotation of the feed roller <NUM> can be determined, for example, based on a specific pulley or gear ratio between the motor <NUM> and the feed roller <NUM>, and a unit length of sheet material dispensed can be determined based upon the number of rotations of the motor <NUM> or its drive shaft.

The correlation of the number of rotations of the motor <NUM> and/or feed roller for each unit length of sheet material will be communicated to the controller <NUM> and be used to determine a specific length of sheet material that has been dispensed, and/or when a specified length of the sheet material (e.g., <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), etc.. ,) has been dispensed, and a dispensing operation completed, by monitoring the operation of the motor <NUM> and/or rotation of the feed roller <NUM>.

To determine the number of rotations of the motor <NUM>, i.e., in arrangements where the motor can rotate with the feed roller, or to monitor and detect the number of rotations of the drive shaft <NUM> of the motor, as generally indicated in <FIG>, the monitoring system <NUM> further can include at least one sensor assembly <NUM> that is located/positioned to continuously monitor rotations of the motor. The sensor assembly <NUM> can be in communication with, e.g., wired or wirelessly, and send a signal indicative of the number of motor rotations to the dispenser controller <NUM>. For example, the sensing assembly <NUM> can include at least one sensor <NUM>, for example, a reed switch, a hall element, or other suitable sensing mechanism operable to measure or detect variations in magnetic field. As indicated in <FIG>, the sensor assembly <NUM> can be located adjacent the drive shaft <NUM> and further can include at least one magnet <NUM> arranged along the drive shaft <NUM> of the motor, with the sensor <NUM> being arranged or positioned on or adjacent the motor <NUM> substantially adjacent the drive shaft <NUM>, such that the at least one sensor <NUM> can detect the presence of and/or fluctuations or variations in magnetic field as the at least one magnet <NUM> rotates or moves past the sensor <NUM> with the rotation of the drive shaft <NUM>. A similar sensor assembly can be additionally arranged about the feed roller <NUM>, to determine the movement, number of rotations, or rotation angle thereof. Based on the number of rotations of the motor or the feed roller, as detected-'determined by the sensor assembly, a substantially precise length of sheet material dispensed can be monitored and detected/determined.

The dispenser controller <NUM> receives the information from the monitoring system <NUM> as to both the number of rotations of a supply of sheet material and the number of rotations of the feed roller <NUM>, and/or its drive motor <NUM>, detected during each dispensing cycle of operation. Typically, the feed roller <NUM> and its motor <NUM> can be operated for a predetermined number of rotations to feed the desired, predetermined or pre-selected length/amount of the sheet material (e.g., <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"), <NUM>,<NUM> (<NUM>"),. When the feed roller <NUM> or motor <NUM> has completed such a predetermined number of rotations, the controller <NUM> can then use the reported/monitored rotations of the supply of sheet material, compared with prior measurements of the supply, to determine a current or updated diameter of the supply of sheet material. This calculated, substantially dynamically updated diameter further will be compared to a base value (e.g., the diameter of a full roll or an empty/near empty roll) to determine a remaining amount of sheet material. If this calculated remaining amount of sheet material is below a threshold amount, a notification can be provided to signal a need for a replacement change of the supply.

By way of illustration, depending upon the predetermined or preset length of sheet material that is desired or generally selected to be fed during a dispensing operation, a number of motor rotations and/or rotations of the feed roller can be generally correlated or known. For example, based upon size of the feed roller and gearing of the motor with respect to the feed roller, and/or historical operation data, an amount of paper dispensed per motor rotation can be known or otherwise determined. Based upon such a known or calculated value of paper dispensed per motor rotation, and the detected or measured number of motor rotations required to complete one paper roll rotation, the diameter of the paper or sheet material supply roll can determined following a dispensing operation. For example, for a known length of sheet material dispensed per motor rotation (mr) of approximately. <NUM>, the diameter (D) of the supply roll can be determined based upon the following formula:
<MAT>
Simplified: D = mr / <NUM>.

Alternatively, where the feed roller rotation is being measured or monitored, and a number of motor rotations (mr) per rotation of the feed roller is known, such as based upon gearing, etc., the diameter (D) of the sheet material supply roll can be calculated as follows:
<MAT>
Simplified: D = <NUM> x mr.

Accordingly, the remaining diameter or supply of the sheet material can be dynamically calculated, e.g., after a selected number of dispensing cycles or operations, or after substantially each dispensing cycle or operation. This dynamically determined diameter or remaining amount of the supply of sheet material thereafter can be compared to a threshold value or a base value, such as a full or empty/near empty roll diameter, to determine a remaining amount of the supply of sheet material and/or if a low paper notification or signal should be provided such as via display or sent to maintenance personnel by the controller.

In one example embodiment or aspect of the operation of the monitoring system <NUM> for measuring and monitoring the supply of sheet material being dispensed by the dispenser <NUM>, as indicated in <FIG> and <FIG>, the dispenser can be operated for a calibration cycle or start-up operation (<FIG>). For example, after a roll or supply of paper material has been loaded into the dispenser, upon closing of the cover and/or engagement of a control switch for the dispenser (Step <NUM>), the dispenser can be operated to engage and run the feed roller for at least an initial cycle (Step <NUM>). As indicated at Step <NUM>, the motor and/or feed roller rotations will be monitored as will the rotations of the supply of sheet material during the dispensing cycle. Based on this information, as indicated at Step <NUM>, a number of motor and/or feed roller rotations for each rotation of the supply roll of the sheet material is calculated or determined; and based upon this calculated or determined value, the remaining diameter of the sheet material supply roll can be determined or calculated (Step <NUM>). As indicated at Step <NUM>, this process is repeated for a selected number of initial dispensing cycles (e.g., <NUM>-<NUM> cycles, although greater or fewer cycles also can be used).

After the desired or selected number of initial dispensing cycles has been completed, an average remaining diameter is calculated (Step <NUM>). A next cycle/operation of the dispenser is then run (Step <NUM>), and the calculated remaining diameter of the sheet material supply roll is compared to the average remaining diameter derived from the calibration cycles (Step <NUM>). If this next remaining diameter value is greater than the average remaining diameter value developed by the calibration cycles, the system can generate an error signal (Step <NUM>) and thereafter can alert maintenance staff to check the dispenser, and can reset and renin the calibration operation (at least for an abbreviated number of cycles) (Step <NUM>). If the next calculated diameter of the sheet material supply is not greater than the average remaining diameter developed by the calibration cycles, the dispenser can be signaled as ready for operation (at Step <NUM>).

Thereafter, as generally illustrated in <FIG>, the monitoring system <NUM> will be operable during at least selected dispensing operations to calculate a remaining amount or diameter of the sheet material supply within the dispenser. As indicated at Step <NUM>. the operation of the dispenser generally will start in response to the controller receiving a signal from a hand sensor or other detector <NUM> (<FIG>), which can indicate the presence of a user (e.g., their hand), or alternatively, the engagement and/or pulling of a hanging sheet of the sheet material can initiate a dispensing operation. In response, the feed motor for the feed roller is engaged and operated to feed a selected length of the sheet material (Step <NUM>). As the feed roller is operated to feed the selected length of sheet material, the supply of sheet material generally is rotated.

The rotation of the supply of sheet material is monitored to detect the number of rotations thereof for feeding the selected length of material (Step 222A), while the motor and/or feed roller also are monitored (Step 222B). Based on this information, the system will determine the number of rotations of the motor per substantially complete rotation of the supply roll (Step <NUM>). Using the determined or calculated number of motor rotations per rotation of the supply roll and number of motor/feed roller rotations detected, a remaining paper diameter of the supply roll is calculated, at Step <NUM>.

This calculated remaining paper diameter is then compared to a threshold value at Step <NUM> (and/or to values of a full and a deleted roll to calculate a remaining paper/supply percentage). If the calculated paper diameter is greater than the threshold value, the dispenser can be reset for a next dispensing operation, as indicated at Step <NUM>. If the calculated paper diameter is less than a selected or determined threshold value, as indicated at Step <NUM>, a signal or alert of a low paper supply can be generated and provided either via the display <NUM> (<FIG>) connected to the controller <NUM> of the dispenser, or can be otherwise transmitted or sent to maintenance staff, such as an antenna or wireless connection <NUM>.

In addition, while the number of rotations of the feed roller preferably can be set to feed a known amount of sheet material to be dispensed for each cycle, the rotations of the feed roller <NUM> and/or the motor <NUM> still generally can be monitored to determine the amount of sheet material fed. For example, during a manual operation, or if the operation of the dispenser is interfered with, a full length of sheet material may not be fed. Thus, the monitoring system can actively monitor the amount of sheet material fed per each cycle to provide a running total or substantially dynamically determined amount of remaining sheet material with as much precision or accuracy as possible during each operation of the dispenser <NUM>.

The controller <NUM> further may be in communication with a notification system operable to indicate the remaining amount of sheet material in the dispenser determined by the controller. For example, the notification system can include a display, such as an LED or LCD display <NUM> (<FIG>. ), arranged along an external portion of the housing operable to numerically or graphically indicate the amount of sheet material remaining. Alternatively, the notification system can include a series of lights, such as LED lights, arranged on the housing that activate or deactivate based on the remaining amount of sheet material determined by the controller. In addition, or in the alternative, the controller can be configured to communicate with a computer, server, or mobile device, e.g., a tablet, smartphone, watch or other smart device. For example, the controller <NUM> can include, or otherwise be in communication with, an antenna, such as a Bluetooth, RF, or WiFi antenna, such that signals indicative of the remaining amount of sheet material can be communicated to the computer, sensor, or mobile device, to facilitate continuous, remote monitoring of the remaining amount of sheet material.

The controller <NUM> also can include a memory <NUM> that can store historical data for a predetermined time period. For example, the recorded measurements of the supply of sheet material over the past hour, two hours, day, etc. , can be stored and used by the controller (or a computer or server linked to the controller) to develop a projected end of supply based on historical uses/trends. This projected end of supply can be communicated to maintenance staff, such as wirelessly from the controller or through the display of the dispenser (e.g., displaying a remaining percentage or projected run-out of the supply), to allow them to prioritize servicing of the dispenser (i.e., immediate attention is required or replacement may not be needed for several hours or until the next day.

<FIG> shows a flow diagram illustrating an exemplary process <NUM> of operation of the dispenser in various modes, e.g., in an automatic feeding mode. As shown in <FIG>, at Step <NUM>, the motor <NUM> can start or otherwise be activated, for example, upon detection of a user's hand or an object by the proximity sensor <NUM>, or by activation of the flapper member <NUM>, such as due to a user pulling a hanging tail or paper length, etc..

Upon starting a dispensing cycle or operation the controller <NUM> can determine whether the monitoring system <NUM> has detected rotation of the motor <NUM> (at Step <NUM>). If motor rotation is signal is provided by the monitoring system, the controller <NUM> can activate the sheet material detection sensor <NUM>, to cause the emitter of the sheet material detection sensor to emit at least one pulse (Step <NUM>). Additional pulses can be sent after each motor rotation is detected by the measurement system. Thus, the operation of the sheet material detection sensor generally will be tied to the actual detected rotations of the motor (i.e., the motor driveshaft), with the number of pulses and timing thereof varying during each dispensing operation.

Thereafter, at Step <NUM>, when a pulse is sent, a determination can be made as to whether the sheet material detection sensor <NUM> is obstructed or blocked by the sheet material. If the sensor <NUM> is not blocked or obstructed, rotation of the motor <NUM> can be stopped or otherwise deactivated (Step <NUM>) because, for example, the sheet material has already been removed by a user.

If the sheet material detection sensor <NUM> is blocked or obstructed, however, a determination can be made as to whether a paper jam has been detected at Step <NUM>. If a paper jam is detected, the motor <NUM> can be stopped or otherwise deactivated. If a paper jam is not detected, the controller <NUM> can determine whether a stop signal has been received from the flapper member <NUM> (at Step <NUM>), e.g., if the flapper member <NUM> has been moved to its second position <NUM> due to engagement with the sheet material, such as for tearing or separating the sheet material.

If a stop signal has been received from the flapper member <NUM>, the motor <NUM> can be stopped or deactivated (at Step <NUM>). If a stop signal is not received from the flapper member <NUM>, a determination can be made by the controller <NUM> as to whether the number of actual rotations of the motor detected by the measurement system corresponds to the number of expected motor rotations for dispensing the desired length of sheet material (at Step <NUM>).

Accordingly, if sheet material is signaled as missing or tom, e.g., based upon activation of the flapper member <NUM> or detection of the paper being missing in the discharge chute by the sheet material sensor <NUM>, before the motor completes the corresponding number of revolutions to feed a prescribed length of sheet material, this might be indicative of an early tear by a user and the motor can be stopped, for example, to avoid sheet material extending from the discharge chute (e.g., a tail) if not wanted or to avoid or otherwise prevent a paper jam.

If, at Step <NUM>, it is determined that the motor <NUM> has completed the corresponding number of revolutions for feeding the prescribed length of sheet material, the motor <NUM> may be stopped or otherwise deactivated. However, if not, the process can return to step <NUM> to continue to detect further motor rotations. If no motor rotations are detected, the process <NUM> may continue again to Steps <NUM> through <NUM>.

Any of Steps <NUM> to <NUM> can be arranged in any suitable sequence or can be omitted entirely, without departing from the scope of the present disclosure. Also, additional steps can be included, without departing from the scope of the present disclosure. For example, upon stoppage of the motor, the sheet material, detection sensor can be activated or pulsed to verify that the discharge chute is clear of sheet material and to reset the dispenser for subsequent operations.

Claim 1:
A dispenser (<NUM>) for dispensing a sheet material, comprising:
a roll support (<NUM>) for supporting a supply (<NUM>) of the sheet material;
a feed roller (<NUM>) arranged along a feed path (<NUM>) of the sheet material downstream from the supply (<NUM>) of sheet material, the feed roller (<NUM>) engaging and pulling the sheet material from the supply (<NUM>) of sheet material for feeding along the feed path (<NUM>) upon the rotation of the feed roller (<NUM>);
a controller (<NUM>) in communication with the feed roller (<NUM>) and including programming for monitoring rotation of the feed roller (<NUM>) during a dispensing cycle for feeding a selected length of the sheet material from the supply (<NUM>) of sheet material;
a material supply monitoring system (<NUM>) in communication with the controller (<NUM>) and operable to detect a number of rotations or an angle of rotation of the supply sheet material during at least a series of dispensing cycles, the material supply monitoring system (<NUM>) including a plurality of magnets (<NUM>, <NUM>) that is rotatable with the supply (<NUM>, <NUM>) of sheet material, and at least one sensor (<NUM>) operable to measure or detect fluctuations or variations in a magnetic field created as the plurality of magnets (<NUM>, <NUM>) is rotated or otherwise moves past the at least one sensor (<NUM>) with the rotation of the supply (<NUM>) of sheet material, and based upon the fluctuations or variations in the magnetic field, a remaining diameter of the supply (<NUM>) of sheet material is substantially dynamically determined after at least each of the series of dispensing cycles; and
a drive motor (<NUM>) coupled to the feed roller (<NUM>) and in communication with the controller (<NUM>), which controls operation of the drive motor (<NUM>) to drive the rotation of the feed roller (<NUM>) for feeding the selected length of sheet material;
wherein the plurality of magnets (<NUM>) is arranged to form magnetic ring (<NUM>) with adjacent magnets of the plurality of magnets (<NUM>) having opposite and alternating polarities.