Robotic Mannequin Mattress Testing for Firmness and Durability
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Solution Overview
Problem
Conventional mattress testing procedures fail to fully simulate the typical use of a mattress over its life cycle, lacking comprehensive characterization of firmness and durability.
Innovation Solution
A robotic arm assembly coupled with a mannequin is used to apply forces simulating human movements, measuring load responses and fatigue on a mattress system, allowing for detailed analysis of firmness and durability through repeated cycles of movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional industry testing procedures are used to characterize mattress features, then testing can be performed with simple equipment, but the procedures fail to fully simulate typical use over the mattress life cycle
Solution Approach 1:
The patent uses a robotic arm to copy and replicate human movements and positions on the mattress. The robotic system mimics human sleeping and moving patterns, applying forces and positions that simulate actual use conditions. This allows the testing system to accurately reproduce typical mattress usage scenarios without requiring actual human subjects, thereby improving simulation accuracy while maintaining automated control.
Solution Approach 2:
The patent replaces manual human testing with an automated robotic system. The robotic arm assembly, controlled by a computer, substitutes for human operators who would manually apply forces and positions. This mechanical substitution enables more consistent, repeatable, and comprehensive testing cycles that can operate continuously without fatigue, improving reliability while the automation handles the complexity of simulating various human positions and movements.
2Measurement precision
If a robotic arm assembly with mannequin is used to simulate human movements, then comprehensive characterization of firmness and durability is achieved, but the device complexity increases
Solution Approach 1:
The patent divides the testing system into distinct functional segments: the robotic arm assembly for positioning, the mannequin for applying distributed forces, the computer for control and data acquisition, and various sensors for measurement. This segmentation allows each component to be optimized for its specific function while working together as an integrated system. The modular approach enables comprehensive measurement capabilities without requiring all complexity to be present in a single device.
Solution Approach 2:
The robotic arm assembly is designed to perform multiple functions: positioning the mannequin in various positions, applying different forces, and repeating test cycles. The system can simulate multiple human activities including sleeping positions, moving, and getting up. This multi-functionality allows a single robotic system to comprehensively characterize both firmness and durability through various test protocols, improving measurement precision while consolidating what could otherwise require multiple separate testing devices.
3Duration of action of stationary object
If repeated cycles of movement are applied to test mattress durability, then longevity characteristics are better characterized, but the testing time increases
Solution Approach 1:
The patent employs periodic action by repeating test cycles multiple times on the mattress. The robotic system applies standardized sequences of movements and forces in repeated cycles, simulating the cumulative effect of years of use. This periodic testing approach allows durability to be characterized through accelerated life testing, where many cycles are performed in a condensed timeframe. The computer controls the timing and repetition, enabling efficient data collection on how the mattress degrades over simulated years of use without requiring actual long-term field testing.
Solution Approach 2:
The robotic testing system operates continuously without interruption, performing repeated test cycles around the clock. Unlike manual testing that would require breaks and human operators, the automated system can maintain continuous useful action for extended periods. This continuity allows comprehensive durability assessment to be completed in less calendar time, as the system doesn't lose time to human fatigue, shifts, or interruptions. The computer-controlled system can run multiple days or weeks of equivalent real-time usage in a condensed testing period.
Data Source
AI summary
Apparatuses, systems, or methods for testing a mattress system are described herein. Apparatuses and systems can include a robotic arm assembly and a mannequin to simulate natural human motion or movements that occur during use of a mattress system. The apparatuses and systems described herein can test a mattress system for firmness and/or durability. Also described herein are methods for testing a mattress system with a robotic arm assembly and a mannequin.