Pneumatic Cushion Module for Variable Contour and Firmness Testing
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Solution Overview
Problem
Current devices for testing the comfort of seat cushions require costly prototypes and are inadequate in providing accurate pressure and deflection data, limiting their ability to assess comfort effectively.
Innovation Solution
A cushion module utilizing an array of double-acting pneumatic cylinders with variable pressurized air supply, allowing the piston rods to define a support surface with variable contour and firmness, which can be adjusted to simulate different comfort levels by modulating air pressure, and equipped with sensors to collect data on pressure and position for comfort assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If costly prototypes of each desired contour and firmness are used for testing cushion comfort, then accurate comfort assessment data can be obtained, but the cost and time required for testing increases significantly
Solution Approach 1:
The cushion is divided into multiple independent pneumatic cylinders arranged in an array, where each cylinder can be independently controlled to simulate different regions of a cushion. This segmentation allows a single device to replace multiple full-scale prototypes by creating various cushion configurations through different pressure combinations in each cylinder.
Solution Approach 2:
The pneumatic cylinders provide dynamic adjustability of cushion contour and firmness through variable air pressure control. The system can transition between different cushion states (contours and firmness levels) in real-time, eliminating the need for multiple static prototypes and enabling comprehensive comfort testing with a single adaptable device.
2Adaptability or versatility
If multiple prototypes with different contours and firmness are manufactured for comfort testing, then various cushion configurations can be evaluated, but the complexity and cost of the testing system increases
Solution Approach 1:
A single testing device with an array of pneumatic cylinders serves multiple functions by simulating various cushion contours and firmness levels. The system can configure different cushion types (soft, firm, contoured, flat) using the same hardware platform, making the testing equipment universal and eliminating the need for multiple specialized prototypes.
Solution Approach 2:
The use of pneumatic cylinders with controllable air pressure provides a efficient mechanism for adjusting cushion properties. By varying the air pressure in each cylinder, the system can dynamically change cushion firmness and contour without mechanical reconfiguration, simplifying the overall system architecture compared to multiple physical prototypes.
3Measurement precision
If traditional cushion testing devices are used, then simple device structure is maintained, but accurate pressure and deflection data cannot be provided for comfort assessment
Solution Approach 1:
The system incorporates sensors that provide real-time feedback on the forces applied to and deflections of the piston rods. This feedback mechanism enables accurate measurement of pressure and deflection data, which are essential for comprehensive comfort assessment. The measured data can be used to adjust and optimize cushion designs based on actual performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective simulation of various cushion contours and firmness levels, providing accurate data for assessing comfort, thereby improving the evaluation of support surfaces without the need for multiple prototypes.
Implementation Method 1
an array of double acting pneumatic cylinders, each having a piston rod and configured to receive pressurized air for moving the piston rod to a selected position
Data Source
AI summary
A cushion module is provided herein and includes a mounting manifold and a retaining plate. An array of pneumatic assemblies is coupled to and disposed between the mounting manifold and the retaining plate. Each pneumatic assembly includes a pneumatic cylinder having a piston rod and configured to receive pressurized air for moving the piston rod to a selected position. The pressurized air supplied to each pneumatic cylinder is variable and the piston rods collectively define a support surface having variable contour and firmness, and on which an object is rested to assess the comfortability of the support surface.