U.S. patent application number 10/899790 was filed with the patent office on 2006-02-02 for sensor equilibration and calibration system and method.
This patent application is currently assigned to Tekscan Incorporated. Invention is credited to Christopher George, Charles Malacaria.
Application Number | 20060021418 10/899790 |
Document ID | / |
Family ID | 34966502 |
Filed Date | 2006-02-02 |
United States Patent
Application |
20060021418 |
Kind Code |
A1 |
George; Christopher ; et
al. |
February 2, 2006 |
SENSOR EQUILIBRATION AND CALIBRATION SYSTEM AND METHOD
Abstract
A system and method for equilibrating and calibrating a pressure
or force sensor is provided. The system includes a flexible bag
arranged to receive the sensor, and a vacuum source, connectable
with the flexible bag, adapted to reduce the pressure within the
flexible bag. By reducing the pressure within the flexible bag,
such that the pressure inside of the bag is less than the pressure
outside of the bag, the resultant uniform pressure acting on the
sensor is used to calibrate and equilibrate the sensor. The system
may include a porous material in the flexible bag to facilitate the
evacuation of air from within the flexible bag as the pressure is
reduced. The system may also include an opening, such that when the
sensor is placed in the bag, a portion of the sensor extends
outside of the bag to communicate with a controller. The opening
may be provided either on the flexible bag, or on a clamp attached
to the flexible bag. The system and method for calibrating and
equilibrating a sensor may be employed to correct for sensor
variations and/or to correlate sensor output to force or
pressure.
Inventors: |
George; Christopher; (Lynn,
MA) ; Malacaria; Charles; (Medfield, MA) |
Correspondence
Address: |
Neil P. Ferraro;Wolf, Greenfield & Sacks, P.C.
600 Atlantic Avenue
Boston
MA
02210
US
|
Assignee: |
Tekscan Incorporated
South Boston
MA
|
Family ID: |
34966502 |
Appl. No.: |
10/899790 |
Filed: |
July 27, 2004 |
Current U.S.
Class: |
73/1.15 ;
73/1.08; 73/1.58 |
Current CPC
Class: |
G01L 25/00 20130101 |
Class at
Publication: |
073/001.15 ;
073/001.58; 073/001.08 |
International
Class: |
G01L 25/00 20060101
G01L025/00; G01L 27/00 20060101 G01L027/00 |
Claims
1. A system for calibrating and/or equilibrating a force or
pressure sensor, comprising: a flexible bag, forming a chamber
within, the flexible bag constructed and arranged to receive the
sensor; a vacuum source, connectable to the chamber, adapted to
reduce the pressure in the chamber; and a controller constructed
and arranged to communicate with the sensor placed within the
chamber, wherein the controller is adapted to receive at least one
signal from the sensor, representative of a force or pressure
applied to the sensor upon application of external pressure acting
on the sensor when the pressure within the chamber is reduced by
the vacuum source so as to calibrate and/or equilibrate the
sensor.
2. The system of claim 1, further comprising a porous material
disposed within the chamber, the porous material constructed and
arranged to facilitate evacuation of air from within the chamber as
the pressure within the chamber is reduced.
3. The system of claim 2, wherein the porous material is
constructed and arranged to extend at least partially around the
outer perimeter of the sensor.
4. The system of claim 2, wherein the porous material comprises at
least one of foam, felt or fabric.
5. The system of claim 1, further comprising a base disposed within
the chamber, the base constructed and arranged to support the
sensor when the sensor is within the chamber.
6. The system of claim 5, further comprising a porous material
supported by the base, wherein the porous material is constructed
and arranged to facilitate evacuation of air from within the
chamber as the pressure within the chamber is reduced.
7. The system of claim 1, further comprising a clamp cooperating
with the flexible bag.
8. The system of claim 7, wherein the clamp comprises an opening
therethrough, such that when the sensor, having an electronic lead
adapted to be coupled to the controller, is placed within the
chamber, at least a portion of the electronic lead extends out of
the chamber through the opening in the clamp, when the clamp is in
a closed position.
9. The system of claim 1, in combination with the sensor, wherein
the sensor comprises: at least one substrate layer; and a plurality
of individual sensor elements operatively arranged with respect to
the substrate layer.
10. The combination of claim 9, wherein the sensor further
comprises at least one electronic lead adapted to be coupled to the
controller.
11. The system of claim 1, wherein the flexible bag comprises at
least two layers of a conformable non-porous material, wherein at
least a portion of the two layers are sealed together.
12. The system of claim 11, wherein the at least a portion of the
two layers are welded together.
13. The system of claim 1, wherein the flexible bag further
comprises at least one port adapted to communicate with the vacuum
source.
14. The system of claim 13, wherein the vacuum source comprises a
pump and conduit adapted to connect to the at least one port.
15. The system of claim 11, wherein the two layers of non-porous
material are formed from one folded-over piece of conformable
non-porous material.
16. A method of calibrating and/or equilibrating a pressure or
force sensor, comprising the steps of: providing a flexible bag;
placing the sensor within the flexible bag to calibrate and/or
equilibrate the sensor; applying a first pressure within the
flexible bag, wherein the first pressure is less than the pressure
outside of the flexible bag; measuring a signal from the sensor,
representative of a force applied to the sensor upon application of
the pressure outside of the bag acting on the sensor when the
pressure within the flexible bag is reduced by the application of
the first pressure, so as to calibrate and/or equilibrate the
sensor under the first pressure; and removing the sensor from the
flexible bag.
17. The method of claim 16, wherein the sensor comprises at least
one electronic lead, adapted to be coupled to a controller, the
electronic lead constructed and arranged to transmit a signal from
the sensor, representative of a force applied to the sensor, to the
controller, and wherein the sensor is placed within the flexible
bag such that at least a portion of the electronic lead is
positioned outside of the flexible bag when the first pressure is
applied within the bag.
18. The method of claim 16, further comprising the steps of:
applying a second pressure within the flexible bag, wherein the
second pressure is less than the pressure outside of the flexible
bag; and measuring a signal from the sensor, representative of a
force applied to the sensor upon application of the pressure
outside of the bag acting on the sensor when the pressure within
the flexible bag is reduced by the application of the second
pressure, so as to calibrate and/or equilibrate the sensor under
the second pressure.
19. The method of claim 16, wherein the sensor comprises a
plurality of individual sensor elements, the method further
comprising the steps of: providing a controller constructed and
arranged to communicate with the sensor, wherein the controller is
adapted to receive at least one signal from the individual sensor
elements representative of a force applied to the sensor elements;
and adjusting the output of at least one sensor element based upon
the at least one signal from the sensor elements and the average of
the signals from multiple sensor elements.
20. The method of claim 16, wherein the sensor comprises a
plurality of individual sensor elements, the method further
comprising the step of: providing a controller constructed and
arranged to communicate with the sensor, wherein the controller is
adapted to receive at least one signal from the individual sensor
elements representative of a force or pressure applied to the
sensor elements; and converting the output of at least one sensor
element from a signal to a force or pressure, based upon the area
of the sensor and the first applied pressure.
21. The method of claim 16, wherein the sensor comprises an
electronic lead, adapted to be coupled to a controller to transmit
at least one signal from the sensor to the controller, the method
further comprising the step of: providing an opening into the
flexible bag such that at least a portion of the electronic lead is
positioned outside of the flexible bag while calibrating and/or
equilibrating the sensor.
22. The method of claim 21, further comprising the steps of:
providing a clamp positioned on a portion of the flexible bag; and
securing the clamp in a closed position after the sensor is placed
at least partially within the flexible bag.
23. The method of claim 22, wherein the opening is provided on the
clamp, such that at least a portion of the electronic lead is
positioned outside of the flexible bag, through the opening on the
clamp.
24. The method of claim 16, wherein the pressure outside of the
flexible bag is atmospheric pressure.
25. The method of claim 16, wherein the first pressure is
substantially a vacuum.
26. The method of claim 18, wherein the second pressure is less
than atmospheric pressure but greater than the first pressure.
27. The method of claim 16, further comprising the step of:
providing a porous material disposed within the flexible bag,
constructed and arranged to facilitate evacuation of air from
within the flexible bag as the pressure within the flexible bag is
reduced.
28. The method of claim 16, further comprising the step of:
providing a base disposed within the flexible bag, the base
constructed and arranged to support the sensor when the sensor is
in the flexible bag.
29. The method of claim 27, wherein the porous material is
supported by a base, and wherein the porous material extends at
least partially around the outer perimeter of the sensor.
30. A system for calibrating and/or equilibrating a pressure or
force sensor, comprising: a flexible bag, forming a chamber within,
the flexible bag constructed and arranged to receive the sensor; a
clamp cooperating with the flexible bag, adapted to seal the
chamber when the clamp is in a closed position; a vacuum source,
connectable to the chamber, adapted to reduce the pressure in the
chamber; and instructions for calibrating and/or equilibrating the
sensor by placing at least a portion of the sensor into the
flexible bag, and thereafter receiving at least one signal from the
sensor, representative of a force or pressure applied to the sensor
upon application of a pressure outside of the chamber acting on the
sensor when the pressure within the chamber is reduced by the
vacuum source.
31. The system of claim 30, wherein the clamp further comprises an
opening therethrough, adapted to hold a portion of the sensor
inside of the chamber and a portion of the sensor outside of the
chamber when the clamp is in the closed position.
32. The system of claim 30, in combination with the sensor, wherein
the sensor comprises: at least one substrate layer; and a plurality
of individual sensor elements operatively arranged with respect to
the substrate layer.
33. The system of claim 31, in combination with the sensor, wherein
the sensor comprises: at least one substrate layer; a plurality of
individual sensor elements operatively arranged with respect to the
substrate layer; and at least one electronic lead adapted to be
coupled to a controller, to transmit at least one signal from the
sensor to the controller, and wherein at least a portion of the
electronic lead extends out of the flexible bag, through the
opening in the clamp when the clamp is in the closed position.
34. The system of claim 30, further comprising a porous material
adapted to be disposed within the chamber, the porous material
constructed and arranged to facilitate evacuation of air from
within the chamber as the pressure within the chamber is
reduced.
35. The system of claim 30, wherein the flexible bag further
comprises at least one port adapted to communicate with the vacuum
source.
36. The system of claim 35, wherein the vacuum source comprises a
pump and conduit adapted to connect to the at least one port.
37. A system for calibrating and/or equilibrating a pressure or
force sensor, comprising: a flexible bag, forming a chamber within,
the flexible bag constructed and arranged to receive the sensor;
and a porous foam material disposed within the chamber, the porous
foam material constructed and arranged such that when the sensor is
placed within the chamber and the pressure within the chamber is
reduced to below atmospheric pressure, the porous foam material
facilitates the evacuation of a gas within the chamber.
38. The system of claim 37, further comprising a base disposed
within the chamber, the base constructed and arranged to support
the sensor when the sensor is within the chamber.
39. The system of claim 37, wherein the system is adapted to be
rolled or folded into a smaller configuration for travel or
storage.
40. The system of claim 38, wherein the porous foam material is
supported by the base, and wherein the porous material is
constructed and arranged to extend at least partially around the
outer perimeter of the sensor.
41. The system of claim 37, further comprising a clamp positioned
along an edge of the flexible bag.
42. The system of claim 41, wherein the clamp comprises an opening
therethrough, such that when the sensor, having an electronic lead
adapted to be coupled to a controller, is placed within the
chamber, at least a portion of the electronic lead extends out of
the chamber through the opening in the clamp, when the clamp is in
a closed position.
43. The system of claim 37, in combination with the sensor, wherein
the sensor comprises: at least one substrate layer; and a plurality
of individual sensor elements operatively arranged with respect to
the substrate layer.
44. A method of calibrating and/or equilibrating a pressure or
force sensor, comprising the steps of: providing a flexible bag;
placing a porous material into the flexible bag; placing the sensor
into the flexible bag adjacent the porous material, to calibrate
and/or equilibrate the sensor; applying a first pressure within the
flexible bag, wherein the first pressure is less than the pressure
outside of the bag, and wherein the porous material facilitates the
evacuation of a gas within the flexible bag; and measuring the
force or pressure applied to the sensor upon application of
atmospheric pressure acting on the sensor when the pressure within
the bag is reduced by the application of the first pressure, so as
to calibrate and/or equilibrate the sensor under the first
pressure.
45. The method of claim 44, wherein the first pressure is
substantially a vacuum.
46. The method of claim 44, wherein the pressure outside of the
flexible bag is atmospheric pressure.
47. The method of claim 44, wherein the gas within the flexible bag
is air.
48. The method of claim 44, further comprising the steps of:
applying a second pressure within the flexible bag, wherein the
second pressure is less than the pressure outside of the flexible
bag and greater than the first pressure, and wherein the porous
material facilitates the evacuation of a gas within the flexible
bag; and measuring the force or pressure applied to the sensor upon
application of the pressure outside of the bag acting on the sensor
when the pressure within the bag is reduced by the application of
the second pressure, so as to calibrate and/or equilibrate the
sensor under the second pressure.
49. The method of claim 44, further comprising the step of:
providing a base disposed within the flexible bag, the base
constructed and arranged to support the sensor when the sensor is
in the flexible bag.
50. The system of claim 49, wherein the porous material is
supported by the base and extends at least partially around the
outer perimeter of the sensor.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a system and
method of standardizing a sensor, and more particularly to a system
and method of equilibrating and calibrating a force or pressure
sensor by placing the sensor in a relatively negative pressure
environment.
DISCUSSION OF RELATED ART
[0002] Various types of sensors exist to measure and record forces
or pressures on surfaces. One such sensor includes a plurality of
sensor elements arranged on a substrate layer in some form of a
pattern or matrix. Measurements obtained at each sensor element may
be used to determine the force distribution across the surface.
[0003] In particular, as shown in the exemplary sensor of FIG. 1,
sensor 10 includes row and column electrodes 20a, 20b. To form the
sensor elements 30, a pressure sensitive ink is deposited at the
intersection of and between row and column electrodes 20a, 20b.
Forces acting at the intersection cause a corresponding change in
the electrical resistance of the pressure sensitive ink, which, by
way of the column and row electrodes, is subsequently detected by a
control circuit. This type of sensor is further described in
commonly assigned U.S. Pat. No. 4,856,993, which is herein
incorporated by reference in its entirety. Another example of a
similar type of sensor is described in commonly assigned pending
U.S. patent application Ser. No. 10/748,718, filed Dec. 30, 2003,
which is also herein incorporated by reference in its entirety.
[0004] To maintain the measurement accuracy of a sensor having a
plurality of sensor elements, the sensor may be standardized prior
to use, wherein variations between sensor elements are accounted
for (equilibration) and wherein the outputs of each sensor element
is assigned a force or pressure value (calibration). In the
equilibration step, a uniform pressure is applied to the sensor
elements. With a perfect sensor under a uniform pressure, the
resulting signal from each sensor element is identical. However,
due to fabrication tolerances and/or handling of the sensor through
general use, the sensor elements may not actually respond uniformly
under a uniform pressure. Therefore, in the equilibration step, to
assure that the sensor is capable of accurately measuring a force
or pressure, any signal variations between the sensor elements
under the application of a uniform pressure are detected. These
detected signal variations are used to adjust the recorded local
force or pressure acting on each sensor element, to compensate for
any variations. In the calibration step, data from the sensor is
obtained to convert the output signal of a sensor element into a
force or pressure measurement. For example, if the sensor uses a
pressure resistive material that varies as a function of the local
pressure or force, such as the sensors described with reference to
FIG. 1, the measured resistance at a sensor element is converted
into the corresponding force or pressure with the data obtained
during the calibration step.
[0005] Many conventional sensor calibration and/or equilibration
systems apply pressure across a sensor by either mechanically
applying a load across the sensor, or with the use of pressurized
air. However, these systems typically include a large support
structure, resulting in a heavy and/or cumbersome system. Examples
of other arrangements to calibrate and/or equilibrate sensors are
disclosed in U.S. Pat. No. 6,032,542 and U.S. Pat. No. 5,131,259,
each of which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0006] In one embodiment of the invention, a system for calibrating
and/or equilibrating a force or pressure sensor is provided. The
system includes a flexible bag which forms a chamber arranged to
receive the sensor within, a vacuum source to reduce the pressure
inside of chamber, and a controller arranged to communicate with
the sensor. The controller is adapted to receive at least one
signal from the sensor, representative of a force and/or pressure
applied to the sensor upon application of external pressure acting
on the sensor when the pressure within the chamber is reduced by
the vacuum source.
[0007] Another embodiment of the invention is a method of
calibrating and/or equilibrating a force or pressure sensor. A
flexible bag is provided, and the sensor is placed within the bag.
A first pressure, less than the pressure outside of the flexible
bag, is applied within the bag, and a signal from the sensor,
representative of a force or pressure applied to the sensor, is
measured. The sensor is then removed from the bag.
[0008] In yet another embodiment of the invention, a system for
calibrating and/or equilibrating a force or pressure sensor is
provided. The system includes a flexible bag which forms a chamber
arranged to receive the sensor within, a clamp cooperating with the
flexible bag to seal the chamber, and a vacuum source adapted to
reduce the pressure in the chamber. The system is further provided
with instructions for calibrating and/or equilibrating the sensor
by placing at least a portion of the sensor into the flexible bag,
receiving at least one signal from the sensor, representative of a
force or pressure applied to the sensor upon application of the
pressure outside of the chamber acting on the sensor when the
pressure within the chamber is reduced by the vacuum source.
[0009] In yet another embodiment of the invention, a system for
calibrating and/or equilibrating a force or pressure sensor is
provided. The system includes a flexible bag which forms a chamber
arranged to receive the sensor. A porous material is disposed
within the chamber and arranged to facilitate the evacuation of air
in the chamber when the sensor is placed in the chamber and the
pressure in the chamber is reduced to below atmospheric
pressure.
[0010] Another embodiment of the invention is a method of
calibrating and/or equilibrating a force or pressure sensor. A
flexible bag is provided with a porous material disposed within the
bag, and the sensor is placed inside of the bag, adjacent the
porous material. A first pressure, less than the pressure outside
of the bag, is applied while the porous material facilitates the
evacuation of a gas within the flexible bag. The force and/or
pressure applied to the sensor upon application of atmospheric
pressure acting on the sensor is measured when the pressure within
the bag is reduced by the application of the first pressure.
[0011] Various embodiments of the present invention provide certain
advantages. Not all embodiments of the invention share the same
advantages and those that do may not share them under all
circumstances.
[0012] Further features and advantages of the present invention, as
well as the structure of various embodiments of the present
invention are described in detail below with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Various embodiments of the invention will now be described,
by way of example, with reference to the accompanying drawings, in
which:
[0014] FIG. 1 is a diagrammatic representation of a portion of a
conventional pressure sensor;
[0015] FIG. 2 is a diagrammatic perspective view of a system for
equilibrating and/or calibrating a sensor;
[0016] FIG. 3 is a top view of the system of FIG. 2, with a sensor
partially within a chamber of the system;
[0017] FIG. 4 is a cross-sectional view of the system taken along
the line 4-4 of FIG. 3;
[0018] FIG. 5 is a cross-sectional view of FIG. 4, with reduced
pressure within the chamber;
[0019] FIG. 6 is a top view of a portion of the system;
[0020] FIG. 7 is a cross-sectional view of the system taken along
the line 7-7 of FIG. 3, showing a closure arrangement according to
one embodiment;
[0021] FIG. 8 is a cross-sectional view of the closure arrangement
of FIG. 7 in an open position;
[0022] FIG. 8a is a perspective view of the closure arrangement of
FIG. 7;
[0023] FIG. 9 is a cross-sectional view of a closure arrangement
according to another embodiment;
[0024] FIG. 9a is a perspective view of the closure arrangement of
FIG. 9; and
[0025] FIG. 10 is a cross-sectional view of the chamber according
to another embodiment.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0026] Oftentimes, it is necessary to standardize a sensor prior to
use. This may entail either or both equilibrating the sensor, such
that sensors employing multiple sensing elements have substantially
equal electrical signal outputs, and calibrating the sensor, where
sensor output is correlated to the measured characteristic, e.g.,
force and/or pressure. It has been found that fabrication
tolerances and/or general handling of the sensor may lead to
sensitivity variations among sensor elements in a sensor leading to
the need to standardize the sensor. However, as noted, prior art
calibration and/or equilibration systems are cumbersome to use and
not readily portable. Aspects of the present invention are directed
to overcoming these shortcomings.
[0027] According to one aspect of the invention, the system for
calibrating and/or equilibrating a sensor (such as that described
above) includes a vacuum chamber in the form of a flexible bag,
within which the sensor may be placed. A vacuum source, connectable
to the flexible bag, is capable of reducing the pressure within the
bag. Once the sensor is temporarily sealed in the bag, and as the
pressure within the bag is reduced, the pressure outside of the bag
begins to press down on the sensor, due to the pressure
differential. Thus, a uniform pressure may be applied to the sensor
within the bag to calibrate and equilibrate the sensor. Utilizing
such a system is easier and less cumbersome than conventional
systems which require the application of a mechanical load or
pressurized air, and are thus heavier and bulkier systems.
[0028] As will be described in further detail below, the system may
include a porous material placed within the flexible bag to
facilitate air evacuation. The system may further include a
releasable sealing clamp that cooperates to seal the flexible bag,
thereby reducing outside air infiltration.
[0029] It should be appreciated that the method and system for
calibrating and/or equilibrating a sensor described herein is not
limited for use with any particular type of sensor. Thus, the
system and method may be used to calibrate and/or equilibrate any
type of sensor, such as resistive, capacitive, ultrasonic, and
piezoresistive pressure and/or force sensors, etc. Further, the
present invention is not limited to both equilibrating and
calibrating, as the system may be employed to perform only one of
these processes. Also, the system and/or method may be used to
standardize (i.e., calibrate and/or equilibrate) pressure or force,
as the present invention is not limited in this respect. Thus, the
term "sensor", as used herein, may refer to a sensor configured to
detect either force or pressure or both.
[0030] Turning now to the drawings, and in particular with
reference to FIG. 2, a sensor calibration and equilibration system
100 according to one aspect of the invention will now be described.
The system 100 includes a flexible bag 40 and a vacuum source, such
as vacuum pump 50, which as shown in FIG. 2 is connected to vacuum
port 54 on the flexible bag 40 through conduit 52. In one
embodiment, the vacuum source is an electric pump. Alternatively, a
venturi pump may be employed, as the present invention is not
limited in this respect. Conduit 52 may be any suitable coupling,
such as a flexible hose, as the present invention is not limited in
this regard. In the embodiment shown in FIG. 2, a resealable clamp
56 cooperates with the flexible bag 40, providing access to
position a sensor within the bag, while also providing an
arrangement to seal the bag.
[0031] The flexible bag 40 itself may be made of two thin plastic
sheets 40a, 40b sealed on three sides, or the bag may consist of
one thin sheet folded over onto itself. Further, in one embodiment,
the bag 40 is made from a pair of urethane sheets which are RF
welded on at least three sides. More generally, the flexible bag
may be made of any conformable non-porous flexible material capable
of forming a varying volume chamber within, as the present
invention is not limited in this respect. The formed flexible bag
may be rectangular-shaped, with dimensions of about 23 inches by
about 24 inches.
[0032] Although the pressure within the chamber may be effectively
reduced when only the sensor is in the bag, other
pressure-reduction enhancing arrangements may be employed. In one
embodiment, the system may also include a porous material 58
disposed in the flexible bag 40. As the vacuum source reduces the
pressure, the porous material may act as a channel through which
the air can flow out, thereby reducing the occurrence of any
entrapped air in the chamber. It has been found that it may be
advantageous to eliminate air pockets from inside the flexible bag
40, as their occurrence may disrupt the accuracy of the
equilibration and/or calibration of the sensor.
[0033] The porous material may extend along at least a portion of
the perimeter of the sensor 60, as shown in FIG. 3, or it may
extend completely around the perimeter of the sensor, as shown in
FIG. 6, as the present invention is not limited in this respect.
Further, the porous material may be arranged to extend just along
the perimeter of the sensor 60, or all or portions of the porous
material may extend under portions (such as at the sensor edge) or
all of the sensor. The porous material 58 may be removable from or
fixed within the flexible bag 40, as the present invention is not
limited in this respect.
[0034] The porous, air permeable material can be formed of any
suitable material, for example, foam, felt or other non-woven
material, fabric, or solid material formed with air channels, or
any combination thereof, as the present invention is not limited in
this respect. The porous material may have any suitable length,
width or thickness, as the present invention is not limited in this
respect. In one embodiment, the porous material is less than about
1/2 inch thick. In another embodiment, the porous material is less
than or equal to about 1/8 inch thick. In one embodiment, the
porous material is less than about 2 inches wide. In another
embodiment, the porous material is less than or equal to about 1
inch wide. In one embodiment, the length of the porous material is
about equal to the length and/or width of the sensor.
[0035] In one embodiment as shown in more detail in FIG. 6, a base
70 may be positioned within the flexible bag. The base may be
employed to support the sensor and in one embodiment, may be used
to fix the porous material. The porous member may be attached to
the base at its perimeter, such that the sensor can nest within at
least some of the boundaries defined by the porous member. The base
may be permanently installed in the flexible bag or may be
removable. The base may be formed of any material, and in one
embodiment, the base 70 is formed from a relatively thin
polycarbonate material, as the present invention is not limited in
this respect. In one embodiment, the base is less than about 1/8
inch thick. In another embodiment, the base is less than about 1/16
inch thick. In yet another embodiment, the base is less than about
1/32 inch thick. In still another embodiment, the base is less than
about 1/64 inch thick. The base can be more than, substantially
equal to or larger than the length and width of the sensor, as the
present invention is not limited in this respect. In one
embodiment, the base is rectangular shaped, with length and width
dimensions of about 21 inches by about 23 inches.
[0036] In one embodiment a releasable sealing clamp 56 is
positioned along an edge of the flexible bag 40 to seal the sensor
within the bag. As described in more detail below, the clamp 56 may
include an opening 74, 88 to allow a portion of a sensor 60 placed
within the flexible bag 40 to extend outside of the bag 40, as
illustrated in FIG. 3. The opening 74, 88 in the clamp 56 permits
the sensor 60 in the sealed bag 40 to communicate with a controller
65, outside of the chamber 62, via sensor lead 64, connector 63 and
communications cable 67. Controller 65 may be merely a data
acquisition device (DAQ), or may include additional processing
capabilities, as the present invention is not limited in this
respect.
[0037] In one embodiment, the clamp 56 may include a hinged closure
as shown in FIGS. 7-8, having a stationary bottom portion 82 and a
pivotable top portion 84 that pivots at hinge 86. In one
embodiment, the clamp, including top and bottom portions 82, 84, is
formed of extruded plastic, wherein the hinge 86 is formed as a
living hinge. However, it should be appreciated that the present
invention is not limited in this respect, as the clamp 56 may be
made from numerous other suitable materials, and may be formed
utilizing other suitable manufacturing processes.
[0038] In the embodiment described with reference to FIGS. 7-8, the
clamp 56 may include a plurality of projections 96, 97, 98. One or
more of these projections may cooperate with the top and/or bottom
portions to help to provide a snap-fit relationship as the top
portion 84 rotates about hinge 86 into a closed position. A first
projection 96 prevents further rotation as it abuts a surface of
the bottom portion 82, as shown in FIG. 7. Second clamping
projection 97 acts on the flexible bag to pinch it against the base
portion 82 at location 99. A groove 101 (see FIG. 8) may be formed
in the bottom portion 82 to receive the tip of the clamping
projection. The flexible bag may be held between the tip and the
groove. Third projection 98 may also act to prevent further
rotation, as shown in FIG. 7. As illustrated, the clamp 56 may also
include an opening 88 sized such that lead 64 of the sensor 60 can
extend outside of the flexible bag to couple to a controller.
[0039] In another embodiment shown in FIG. 9, the clamp 56 is
formed as a generally U-shaped fixed frame 72 having upper leg 72a
and lower leg 72b and also having an opening 74 therethrough sized
to allow a portion of the sensor 60 (such as sensor lead 64) to
extend out from the bag. The frame may be formed of metal (such as
aluminum), plastic or any other suitable material, as the present
invention is not limited in this respect. To maintain an adequate
seal around the opening 74, as well as to clamp the bag closed,
biasing portions 66, 68 may be disposed within the clamp. The
biasing portions 66, 68 may be any type of flexible member or
biased clamp, as the present invention is not limited in this
respect. In one embodiment, the biasing member 66 is formed of a
flexible plastic material. In one embodiment, the upper member 66
is formed as a tubular material (although it may be formed with a
solid cross-section) that is made of an elastomeric material. As
shown, the upper member 66 is slightly compressed to impart a
closing force on the flexible bag. In one embodiment, the upper
member 66 may be inflatable to exert an outward pressure to further
seal the bag. Upper member 66 may be removable to aid in inserting
the lead through the opening 74 and to allow easier placement on
the bag. In one embodiment, the lower member 68 is formed of a felt
or felt-like material. Although the embodiment shown in FIG. 9
includes a lower member 68, it need not be included, as the upper
biasing member 66 may press the flexible bag against the lower leg
72b directly.
[0040] In one embodiment, a lower support member 73 may be fixed
between the lower leg 72b and the lower member 68. The lower
support member 73 may act to further support the flexible bag when
the clamp is secured thereto so as to reduce the chance that the
bag will slip from the clamp. Of course, the present invention is
not limited in this respect, as the lower support member 73 need
not be employed. In one embodiment, the lower support member 73 is
formed of a thin polycarbonate material, which may be similar to
the base 70.
[0041] Although the above-described embodiments include the sensor
lead extending through an opening in the clamp, the present
invention is not limited in this respect, as the lead 64 may extend
through a sealable opening in the bag 40. This opening may be made
through either the top or bottom sheets 40a, 40b of the bag 40, or
alternatively, the opening may be formed along an adjoining edge of
the two layers. Further, in another embodiment, the sensor 60 is
completely within the chamber 62 and there is no opening 74 in
either the bag 40 or the clamp 56. In this embodiment, the
controller may be either in the chamber 62 with the sensor 60, or
the controller may be outside of the chamber 62, communicating with
the sensor indirectly or remotely. In another embodiment, the bag
40 includes at least one opening to place the sensor within the
bag, and another opening or port to enable the controller to
communicate with the sensor in the bag. For example, the sensor may
be placed inside of the bag through a resealable edge on the bag
40. A controller, through a USB cable for example, may connect to
the sensor through the port.
[0042] Air within the chamber may be evacuated by any suitable
means, as the present invention is not limited in this respect. In
one embodiment, as illustrated in FIG. 2, a vacuum pump 50 is
connected to the chamber. Although the present invention is not
limited to any particular type of vacuum source, in one embodiment
the vacuum source may be a conventional OEM vacuum pump with a
12VDC connection. The vacuum pump 50 typically includes on its face
a vacuum gauge 92, a relieving valve knob 90, and a quick
disconnect receptacle 94.
[0043] As previously described, a controller 65 may be coupled to
the sensor via lead 64 extending outside of the chamber 62 through
opening 74 in the clamp 56, connector 63 and communications cable
67, as shown in FIG. 3. The controller receives signals from the
pressure sensor 60 which are representative of the force or
pressure applied to the sensor 60.
[0044] In one embodiment, the controller includes software which
can detect and store the signals from the sensor elements 30 during
the calibration and/or equilibration steps. Software adjustments
may be made in view of any sensitivity variations found in the
sensor elements during the equilibration step. In one embodiment,
the calibration and/or equilibration data may be formatted into a
chart, providing information specific to that particular sensor
and/or sensor element. Further, the controller may be used after
the sensor is removed from the calibration/equilibration system to
detect and store signals while the sensor is in use. The
calibration and/or equilibration data may also be transmitted to
additional devices and/or controllers that are in communication
with the sensor while the sensor is in use. For example, the sensor
may be calibrated and/or equilibrated at one location, saving the
data from the controller to a disk. The sensor data on the disk can
easily be transported along with the sensor to a different
location, such that the sensor may be used with its calibration
and/or equilibration data.
[0045] The process for equilibrating and calibrating the sensor
using embodiment(s) of the above described system will now be
described. In one embodiment, the sensor is placed at least
partially inside of the flexible bag. The flexible hose is coupled
to the connector formed on the flexible bag and to the vacuum
source. As explained above, a porous material 58 and/or a base 70
may also be included within the bag 40. A clamp 56 may be secured
to the flexible bag 40 to substantially seal the sensor 60 within
the chamber 62. In the embodiment shown in FIG. 3, a portion of the
sensor 60, such as sensor lead 64, extends out of the chamber
through opening 88 in the clamp 56. The sensor lead 64 may be
connected to a controller to compute the pressure distribution
based upon signals from the pressure sensor 60. Once the sensor 60
is secured within the chamber 62 and the clamp 56 is in its closed
position, substantially sealing any openings 74, 88 and sealing the
sensing portion of the sensor 60 within the bag 40, the vacuum
source begins to reduce the pressure within the chamber 62,
creating a pressure differential between the pressure inside and
outside of the chamber. Since the pressure inside of the bag is
less that the pressure outside of the bag, this differential
pressure creates an applied pressure on the portion of the sensor
placed within the bag.
[0046] As described above, the pressure applied to the sensor
elements results in an output signal for each sensor element
representative of the force applied at the location of that sensor
element. Thus, the controller coupled to the sensor can now read
the output of each sensor element to perform the equilibration
and/or calibration of the sensor, as will be further described
below. Because the sensor is now under a known uniform pressure,
the sensor may be accurately equilibrated and calibrated.
[0047] Prior to the application of the vacuum source to evacuate
the air, the pressure within the chamber 62 (see FIG. 4) is
substantially equal to the pressure outside of the chamber. In a
typical environment, this equilibrium pressure is atmospheric
pressure (.about.14.7 psi). However, the system of the present
invention may also be used in a controlled environment where the
pressure outside of the chamber is either higher or lower than
atmospheric pressure. In either case, as the air is evacuated from
the chamber 62, the outside pressure begins to act down onto the
flexible bag 40 and the sensor 60 within, as indicated by arrows F
in FIG. 5.
[0048] In one embodiment utilizing a vacuum pump 50, when the pump
is first turned on, the pump purges a majority of the air within
the chamber 62. This is immediately noticeable as the top sheet 40a
of the bag collapses onto the bottom sheet 40b as seen in FIG. 5.
Once this air is purged, the vacuum level in the chamber 62 rises
to the desired level set with the relieving valve 90 (see FIG. 2).
Depending on the desired pressure for the calibration and
equilibration steps, the relieving valve 90 may be set to reduce
the pressure within the chamber 62 such that it is a substantial
vacuum (.about.0 psi). Alternatively, the relieving valve 90 may be
set to maintain a pressure below atmospheric pressure, but greater
than a substantial vacuum.
[0049] Once the air begins to evacuate from the chamber, it may be
beneficial to delay the start of the equilibration or calibration
process until the desired pressure within the chamber has reached
it equilibrium state. Even though the vacuum gauge 92 may indicate
a constant pressure within the chamber, since the gauge 92 is
measuring the pressure in the pump 50, and the chamber 62 is
separated from the pump 50 by conduit 52, there may be a short lag
between the pressure reading at the gauge 92 and the actual
pressure in the chamber 62. Therefore, a delay may be necessary to
ensure that the pressure reading at the gauge 92 is representative
of the pressure in the chamber 62.
[0050] As discussed above, during the equilibration step, a uniform
pressure is applied to all of part of the sensor 60, and any
variations between the respective sensor elements 30 may be
detected and recorded based on the output signal from each of the
sensor elements 30 under the uniform pressure. Each signal may
further be compared to a collective average of the signals. This
data is then used to determine a base line under a uniform
pressure, to account for any variation in sensitivities among the
respective sensor elements 30.
[0051] In the calibration step, the output signals from the sensor
elements 30 are converted into equivalent force values. A
calibration value is determined by the product of the total sensor
area and the total pressure indicated by the pressure gauge 92 in
terms of force. This calibration value can be stored and used to
convert the output signals from the sensor elements 30 into local
force values. For example, with a sensor 60 made with a pressure
resistive material, the resistance, R, will decrease as a function
of the force applied to the sensor element. Thus, the calibration
value, which is equal to the total force on the pressure sensor 60,
can be used to calculate the forces at each sensor element 30 based
on the resistances at each sensor element.
[0052] When calibrating and/or equilibrating the sensor 60, it may
be advantageous to conduct these steps while the sensor 60 is under
a pressure that is similar to the pressure on the sensor while the
sensor is in operation. In addition, if the sensor will be utilized
under a wide range of pressures, it may be desirable to conduct the
calibration and/or equilibration steps under at least two different
pressure levels. This may help to account for errors, because, over
a larger range of pressures, a pressure sensor may be behave in a
non-linear nature.
[0053] Although the system 100 may be used to equilibrate and
calibrate a sensor 60 under a large range of pressures, in one
embodiment, the system 100 is used with a pressure sensor 60 that
typically measures pressures that range between 0.5-5 psi. If the
system 100 is used in atmospheric pressure (approximately 14.7
psi), it may be desirable to adjust the vacuum source to reduce the
pressure within the chamber to within a range of about 9.7-14.2
psi, to calibrate and/or equilibrate this sensor. As discussed
above, the pressure applied to the sensor within the chamber is
roughly equal to the outside pressure minus the pressure inside the
chamber. Thus, reducing the pressure within the chamber to between
9.7-14.2 psi will equate to an applied pressure on the sensor
between 0.5-5 psi, which is desirable because that is the specified
pressure range during operation of this sensor. As discussed above,
it may be advantageous to calibrate and equilibrate this sensor at
more than one applied pressure to ensure an accurate pressure
distribution.
[0054] When atmospheric pressure is the uniform pressure acting
outside of the chamber 62, the maximum differential pressure
between inside and outside of the chamber is equal to atmospheric
pressure (.about.14.7 psi). Therefore, in an uncontrolled
environment, where the pressure outside of the chamber is
substantially equal to atmospheric pressure, the system of the
present invention is limited for use with pressures of up to
approximately 15 psi. However, when atmospheric pressure is not a
restriction, the system may be used to apply forces greater than
atmospheric pressure. For example, if the system was placed in a
high pressurized environment where the pressure is greater than
atmospheric pressure, the system could be used to apply a pressure
greater than 15 psi.
[0055] Depending upon the application of the sensor, in one
embodiment, additional material may be placed in the chamber 62 to
more accurately simulate the sensor environment when in use. For
example, in FIG. 10, a cushion material 76 is placed in the chamber
62, positioned between the base 70 and the sensor 60. In this
particular embodiment, the pressure sensor 60 is used to measure
the pressure distribution across a seat cushion. Accordingly, this
additional material helps to simulate the seat cushion. However, in
another embodiment, the additional material may include fabrics,
foams, plastics, etc, as the present invention is not limited in
this respect. When utilizing such additional material, it is
important to recognize that any additional material in the chamber
may slow the process of evacuating the air within the chamber.
Therefore, a longer time period, or lag time, may be necessary for
the vacuum source to create a desired reduced pressure.
[0056] It should be appreciated that the present invention provides
a method and system for calibrating and/or equilibrating a sensor
without the use of large components and frames. The calibration and
equilibration system of the present invention may be a portable
system that fits into a travel bag. Depending on the material used
to make the flexible bag 40, the bag may be rolled up into a
compact travel form. In one embodiment, at least one of the bag 40,
the porous material 58, the base 70, and cushion material 76 are
flexible such that they can be rolled or folded up in a smaller
configuration for storage or travel.
[0057] It should be understood that the foregoing description of
the invention is intended merely to be illustrative thereof and
that other embodiments, modifications, and equivalents of the
invention are within the scope of the invention recited in the
claims appended hereto. Further, although each embodiment described
above includes certain features, the invention is not limited in
this respect. Thus, one or more of the above-described or other
features of the system or method, may be employed singularly or in
any suitable combination, as the present invention is not limited
to a specific embodiment.
* * * * *