System for diagnosing the current state of a seat or a part thereof

Abstract

This invention relates to a system for diagnosing the current state of a seat, or of a part thereof, comprising the application to each seat of a plurality of sensors which are connected to a central unit having the task of collecting, storing, and sorting the data transmitted thereto from the sensors in order to process and organise the said data in order to make the data available to the end user via specific software, the said sensors comprising sensors for measuring sinking or weight, sensors for measuring vibrations, mainly in the backrest and armrests, sensors for testing the integrity of the covering materials, sensors for measuring the deformation of the padding (foam) and the integrity of the covering, sensors for measuring the reclining range, and sensors for measuring microbial alteration.

Description

[0001] SYSTEM FOR DIAGNOSING THE CURRENT STATE OF A SEAT OR A PART THEREOF

[0002] DESCRIPTION

[0003] This invention concerns a system for diagnosing the current state of a seat or a part thereof belonging to a plurality of seats used in means of land, sea, and air transport in addition to furnishings for constructions intended to seat audiences, such as theatres, stadiums, and the like.

[0004] It is mainly aimed at the provision of services concerning measuring and testing the current state of certain characteristics and properties of seats, such as the correct geometric arrangement, the correct load situation, temperature trends, the degree of wear of work surfaces, and therefore measuring for damage and likewise the functionality of the said seats, in addition to monitoring the misuse thereof in the sense of any use other than the intended use.

[0005] In particular, the general object of the invention is to offer a system capable of diagnosing the current state of the seat or one of its parts by detecting and communicating any faults or malfunctions in order, for example, to be able to forecast possible breakages and likewise to provide operators with information on misuse of seats by users in addition to providing current information on seat occupancy and the like and also on custom services requested by individual customers.

[0006] Indeed, apart from certain prior art cases in the automotive field which are, in any case, limited to presence detection (for example seat belt reminders in the automotive industry), there are no systems that achieve the object of detecting / measuring - and consequently enabling organic, general monitoring - of a plurality of characteristics of the seats concerning the current state thereof and their level of efficiency and providing, in real time during normal operation or use, all the information deemed useful for monitoring the current situation in terms of efficiency, in addition to promptly remedying any failures or out-of-control situations, when necessary, and - furthermore - in order to rationalise scheduled maintenance.

[0007] One advantage of the invention lies in the system's ability to provide a realtime snapshot of the current situation of the seats with reference to a plurality of previously identified parameters which are kept monitored.

[0008] Among the other advantages, there is undoubtedly the advantage that the system constantly and economically provides the data that is necessary to perform system maintenance and programming.

[0009] These advantages and others are achieved by means of the present invention, consisting of a system for diagnosing the current state of a seat or a part thereof belonging to a plurality of seats used in means of land, sea, and air transport in addition to furnishings for constructions intended to seat audiences, such as theatres, stadiums, and the like, in accordance with the appended claims and as described and explained in this description and in the accompanying figures, in which:

[0010] Figure 1 shows, schematically, a front view of a pair of train seats arranged side by side;

[0011] Figure 2 shows a top-down view of the pair of seats in Figure 1 wherein the said figure highlights, schematically, a system of collaborating load cells arranged to form a sensor for measuring sinking or weight;

[0012] Figure 3 shows, schematically, a cross section taken along line l-l in Figure 1 , wherein the said figure highlights, schematically, an enlargement of an arrangement of a gyroscopic sensor on the backrest, a sensor for measuring the weight on the seat, a temperature sensor, and a pressure sensor;

[0013] Figure 4 shows a top-down view of Figure 1 highlighting a mesh sensor distributed under the seat base covering of a seat in order to detect peak loads and any tears or loss of integrity of the said covering;

[0014] Figure 5 shows part of a perspective view of the armrest 6 in Figure 1 ; Figure 6 shows, on an enlarged scale, a detail of the end of the armrest 6 showing the housing of a gyroscopic sensor therein.

[0015] With reference to the accompanying figures, Figures 10 and 11 show two seats placed side by side to form an overall pair of seats joined by two structural bars which form a horizontal subframe 7 and are in turn fixed, in this case, to the system for mounting the said system onto the structure of the vehicle (train) through a connection with the wall of the said vehicle consisting of a wall attachment 12 and a cantilever 20 which is fixed to the subframe 7 by means of an attachment 9. Each one of the seats 10 and 11 respectively includes a seat base 4 in addition to a backrest 3. Two armrests 6 and a single intermediate armrest 18 are also envisaged between the two seats 10 and 11 .

[0016] In other embodiments, the seat bases may be based structurally on a plastic container / reinforcement unit fastened to the floor of the vehicle by means of a support fastened to the seat which houses the foam rubber padding and the inserts for attachment to the structure.

[0017] Various types of sensors are applied to the seats which comprise:

[0018] - sensors for measuring sinking or weight,

[0019] - sensors for measuring vibrations, mainly in the backrest and armrests,

[0020] - sensors for testing the integrity of the covering materials,

[0021] - sensors for measuring deformation of the padding (foam),

[0022] - sensors for measuring the reclining range,

[0023] - sensors for measuring microbial alteration.

[0024] Given that the seat bases 4 in the embodiment illustrated are interchangeable right with left and left with right and are made up of an external upholstery (predominantly made of eco-leather or velvet) coupled to a layer of additional fire-resistant protective covering (see standard EN45545) which covers a shaped cushion made of foam rubber or the like glued onto an anatomically shaped wooden board or onto a structure (reinforcement unit / container) made of shaped plastic, the sensors for measuring sinking or weight, in addition to the sensors for measuring vibrations occurring in the seats are applied to the individual seat bases 4 of the seats.

[0025] The "weight" parameter is certainly the most interesting for predictive statistical analysis concerning use of the seat and to estimate the deterioration thereof and loss of sitting comfort.

[0026] The determination of this parameter is carried out: by direct measurement using load cells that measure the total weight applied to the seat base; the load cells cannot be applied directly to the seat and so are applied to a support incorporated into the structure; or by measuring the force (pressure) in parts thereof, in which case the total load weighing on the seat cannot be measured (this type of sensor is particularly suited to being used as a sensor for detecting the presence of SBR (Seat Belt Reminders); or by using mesh sensors distributed over the seat base to identify peak loads, any tears, or loss of integrity of the covering (see Figure 4).

[0027] For the measurements made using any of the aforesaid sensor types, the chronological succession of the intervention times and the durations of the measurements are univocally attributed to the seat in question (tracking). This tracking is carried out by an identification system integrated into the acquisition system which allows, among other things, the acquisition of data such as the number of use sessions and the durations thereof over a given period of time which allow one to determine a “history” of the seat.

[0028] For the analysis of vibrations of the parts or components of the seats, an analysis system was adopted which takes into consideration an analysis of possible damage or malfunctions within a certain period due to impacts and stresses that exceed pre-established thresholds. This also allows the management of the monitoring of the state of the components which, in the event of damage, will produce vibrations which are different from those linked to normal operation.

[0029] For this purpose, MEMS (Micro Electro-Mechanical Systems) nanotechnology chips are used, which allows a three-axis accelerometer to be created in a single low-cost, low-power circuit.

[0030] Considering that both the deformation of the foam and the integrity of the covering can be obtained by conducting a statistical impact analysis on the data produced from the weight measurement, nevertheless, integrity takes on a much more important role than deformation because it affects not only the comfort but also the safety of the seat.

[0031] In general, the solution adopted is essentially to use a sensor obtained through the creation of a continuous conducting path which is integral with the coating and allows the integrity of the fabric in which the said path is embedded to be evaluated by measuring the electrical continuity of the conducting path.

[0032] Thus, a first embodiment involves the use of what are known as 'smart fabrics' to create a sensor which is integrated directly into the covering fabric using warps and wefts constituted of materials with particular electrical characteristics. This type of fabric is formed, contemporaneously, of conductive yarns, insulating yarns, and yarns made of materials that change their electrical characteristics depending on the pressure exerted thereupon. This type of fabric has the characteristic of allowing both measurement of pressure and testing of the integrity of the covering to be integrated into the same system, which is advantageous because laceration of the said fabric would have repercussions on the electrical continuity of the yarn.

[0033] A further embodiment is based on the use of yarns and conductive strips (derived from smart textiles) which can be used, either sewn or glued onto fabrics, in order to produce a simple circuit, a sensor whose mesh is tight enough to detect a cut or laceration of a specific extent in the covering.

[0034] The basic concept is to create a mesh like the one intended to signal the integrity of the covering shown schematically on both seats in Figure 4, where the mesh is formed of two perpendicularly crossed circuits which are continuously connected so as to be able to check, using an appropriate electronic circuit, that the said path is not interrupted by a laceration or cut.

[0035] In essence, the invention envisages creating a mesh sensor using available materials. Among the various solutions described, the most convenient technique, certainly from an economic perspective, appears to be that envisaging the use of conductive strips to form a mesh sensor which can be glued directly onto the covering fabric (upholstery) or onto the foam rubber or onto the flame retardant layer or onto a removable cushion cover.

[0036] The measurement of the backrest tilt range is essentially obtained by using a sensor for measuring the backrest tilt angle by means of a magnetic microswitch which operates between the seat frame and the backrest or by measuring the length of extension of the hydraulic cylinder piston (where featured) which connects the backrest to the frame.

[0037] In either case, the information provided by the sensors concerning the extension generates an alert signal if the said extension remains unchanged or does not return to the rest position for a specific time.

[0038] In the event that a sensor is integrated for measuring the position, the said sensor may be associated with a magnetic microswitch to determine whether the backrest is in the rest position or not.

[0039] In order to determine the position of the backrest (albeit in a less precise manner than direct measurement of the extension angle), the vibration sensor can be used, which provides useful information for analysis for maintenance purposes. The aim of testing the state of microbial alteration is to test the viral, bacterial, and fungal load on the external surface of the seat, i.e. on the surface that comes into contact with the passenger.

[0040] Although in this case, as already mentioned, indirect measurements are used, which involves monitoring humidity and temperature to estimate bacterial proliferation and associating the tracking of the seat to provide a history of the measurements and tests conducted with conventional tests and analyses on the levels of contamination detected, it is nevertheless envisaged that two types of sensor can be utilised:

[0041] A first type of sensor consists of a smart fabric for measuring live bacteria in antimicrobial hospital fabrics. The ability to measure viable bacteria is based on the use of Prussian Blue (PB) as an electrochromic compound, with a clear reversible colour change from Prussian Blue (PB) to Prussian White (PW) after reduction by means of a bacterial metabolism process. The PB nanoparticles are incorporated into cotton and polyester fabrics by ultrasonic deposition thereof.

[0042] A second type is based on a fibre optic sensor to identify contamination on a fabric or rubber foam. In addition to the optical fibre, the system includes a light source to generate light with a certain intensity and consistency over time and a measuring device. The accumulation of a contamination-causing medium that becomes attached to the fibre causes attenuation of light intensity in the optical fibre due to leakage.

[0043] The various sensors are connected to a central processing unit 8 whose task is to collect, store, and sort the data transmitted thereto in order to process and organise the said data in order to make the said data available to the end user via specific software.

Claims

CLAIMS1) This invention relates to a system for diagnosing the current state of a seat, or of a part thereof, comprising the application to each seat of a plurality of sensors characterised by the fact that the said sensors are connected to a central unit whose task is to collect, store, and sort the data transmitted thereto in order to process and organise the data in order to make the data available to the end user via specific software.2) A system according to Claim 1 characterised by the fact that the said system comprises the placement or arrangement, in various parts of the seats (10, 11), of sensors for measuring sinking caused by weight, and / or sensors for measuring vibrations occurring in the seats (4), gyroscopic position sensors in the backrest and armrests, sensors for checking the integrity of the covering materials, sensors for measuring the deformation of the padding (foam), sensors for measuring the backrest reclining range, and sensors for detecting microbial alteration.3) A system according to Claims 1 or 2 characterised by the fact that the said sensors for measuring the sinking caused by weight are applied to the individual seat bases D of the seats 10, 11 and consist of load cells which operate by means of an integrated support or sub-base in the structure of the seat (10,11)4) A system according to Claims 1 or 2 characterised by the fact that the said sensors for measuring the sinking caused by weight are applied to the individual seat bases of the seats 10, 11 and consist of piezoresistive thin film systems.5) A system according to Claims 1 or 2 characterised by the fact that the said sensors for measuring the sinking caused by weight are applied to the individual seat bases of the seats 10, 11 and consist of mesh sensors distributed over the seats for identifying peak loads and any tears in or loss of integrity of the covering.6) A system according to Claims 1 or 2 characterised by the fact that the said sensors for analysing and measuring the vibrations in parts or components of the seats 10 and 11 comprise low power consumption MEMS (nanotechnological) chips equipped with a three-axis accelerometer.7) A system according to Claims 1 or 2 characterised by the fact that the deformation of the foam and in particular the integrity of the covering are essentially linked to the use of a sensor obtained from the production of a continuous conductive path which is integral with the covering and allows the integrity of the carrier fabric to be evaluated by measuring the electrical continuity of the conductive path.8) A system according to Claim 7, characterised by the fact that the said sensor comprises the use of what are known as "smart textiles", which are produced by integrating the sensor directly into the covering fabric by having the weft and the warp consisting of materials with particular electrical characteristics.9) A system according to Claim 8, characterised by the fact that the said type of sensor integrated directly into the covering fabric comprises conductive yarns, insulating yarns, and yarns made of materials which change their electrical characteristics according to the pressure applied.10) A system according to Claim 7, characterised by the fact that the production of a continuous conductive path integral with the covering is based on the use of yarns and conductive strips (derived from smart textiles) which can be used, either sewn or glued onto fabrics, in order to produce a simple circuit, a sensor whose mesh is tight enough to detect a cut or laceration of a specific extent in the covering.11 ) A system according to Claim 10, characterised by the fact that the said sensor is a mesh sensor consisting of a mesh that can be glued directly onto the covering fabric (upholstery) or onto the foam rubber or onto the flame retardant layer or onto a removable cushion cover.12) A system according to Claim 1 , characterised by the fact that the measurement of the backrest tilt range is essentially obtained by using a sensor for measuring the backrest tilt angle by means of a magnetic microswitch which operates between the seat frame and the backrest.13) A system according to Claim 1 , characterised by the fact that the measurement of the backrest tilt range is essentially obtained through the use of a measurement sensor which operates by measuring the length of extension of the hydraulic cylinder piston which connects the backrest to the frame.14) A system according to Claim 1 characterised by the fact that a first type of sensor for measuring microbial alteration consists of a smart textile for measuring live bacteria in antimicrobial hospital textiles in which the ability to measure viable bacteria is based on the use of Prussian blue (PB) as an electrochromic compound with a clear reversible colour change from Prussian Blue (PB) to Prussian White (PW) after reduction through a bacterialmetabolism process, the PB nanoparticles being incorporated into cotton and polyester fabrics by ultrasonic deposition thereof.15) A system according to Claim 1 characterised by the fact that a second type of sensor for measuring microbial alteration is a fibre optic sensor for identifying contamination of a fabric or foam rubber, the said fibre optic sensor comprising, in addition to the optical fibre, a light source for generating light with a certain intensity and constancy over time and a sensor that calculates build-up of medium that causes contamination and which adheres to the fibre, causing a reduction in the intensity of the light in the optical fibre due to leaks.

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