CEV Seat Concept Design                                                                                   The CEV Seat:   ...
CEV Seat Concept DesignMotivation•   Seat design does not fully support the occupant for off-nominal landings.     – Lack ...
CEV Seat Concept DesignSeat Design Basic Requirements and Needs1. Occupant Protection     1. Conformal support     2. Hip ...
CEV Seat Concept DesignBaseline Seat Concept•   90/90 hip/thigh angles•   Non-operator legs must be raised toward chest to...
CEV Seat Concept DesignWhat Can We Learn from Industry?•   Highly conformal, custom-fit seats save lives and improve perfo...
CEV Seat Concept DesignBut…•   You can’t get out of them when you are on your back or in a space-suit…    •   And they onl...
CEV Seat Concept DesignChallenge - Leg Curvature•   Problem: Flat seats are flat, humans are not.     – Models cannot adeq...
CEV Seat Concept Design             Challenge Leg Length Differences                   •   Problem: We have to accommodate...
CEV Seat Concept DesignSeat Concept•   Pulls together the best features of the designs that we examined, and modified the ...
CEV Seat Concept DesignSmall Female vs. Large Male Fit•   Spacer pads added at shoulders and hips to provide    semi-custo...
CEV Seat Concept DesignLateral Support•   Full lateral support at primary load paths of pelvis and shoulders     – Exact p...
CEV Seat Concept DesignThigh Panel Extension Assembly•   Curved thigh extension•   Mates to curved groove of hip panel—cur...
CEV Seat Concept DesignShoulder and Head Support Assembly•   Single assembly that provides:     – Headrest – lateral suppo...
CEV Seat Concept DesignHand Controller Mounts•   Hands naturally fall at knees when seated recumbently.•   Seat structure ...
CEV Seat Concept DesignAdjustability        Large Occupant Configuration                          Small Occupant Configura...
CEV Seat Concept DesignACES Suited FitNASA 2009 Project Management Challenge   EC5/D. Gohmert/281-483-9350                ...
CEV Seat Concept Design    Tips that Helped in the Process•   Keep an Open Mind      – It is easy to become close-minded w...
CEV Seat Concept DesignConcept Testing•   High G Sled Testing at Wright Patterson AFBNASA 2009 Project Management Challeng...
CEV Seat Concept DesignConcept Testing•   0 Gravity Testing                                                               ...
CEV Seat Concept Design3D Human Scanning:•   I know I said I hated computer models, but…     – This was more accurate than...
CEV Seat Concept DesignWhere We Have Gone From ThereLockheed Martin/NASA Orion Seat Design Evolution                      ...
CEV Seat Concept DesignExamples of Design Concept Exploration•     Currently searching for a way to integrate auxiliary   ...
CEV Seat Concept DesignExamples of Design Concept Exploration•   Heel Mounting Design Concept Exploration     – Cycling Sh...
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Gohmert.dustin

  1. 1. CEV Seat Concept Design The CEV Seat: Seeking a Custom Fit in an Off-the-Rack World Dustin Gohmert CREW AND THERMAL SYSTEMS DIVISION NASA Project Management Challenge 24 Feb. 2009 EC5/D.Gohmert 281-483-9350NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 1 OF 23
  2. 2. CEV Seat Concept DesignMotivation• Seat design does not fully support the occupant for off-nominal landings. – Lack of lateral support – Lack of full leg support for all occupants• Race-car seat concepts are supportive—but require customization to fit occupant. – Do not provide leg supports – Do not allow for feasible egress in emergency scenario• No design exists that meets implicit and explicit needs of a CEV seat system.• I needed something to do over the holidays…OBJECTIVE• To design a simple seat concept that provides full occupant support in all axes for the full range of occupant sizes without fully custom components for each person.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 2 OF 23
  3. 3. CEV Seat Concept DesignSeat Design Basic Requirements and Needs1. Occupant Protection 1. Conformal support 2. Hip bolsters 3. Shoulder bolsters 4. Head bolsters 5. Load-distributing harness Seat Layout2. Adjustable Fit for All Sizes Views 1. Seated height (shoulder height) 2. Shoulder breadth 3. Buttocks to popliteal 4. Popliteal height 5. Hip breadth3. Stowable 1. Reconfigurable for on-orbit maximization of volume4. Multipurpose 1. Operator seats 2. Non-operator seats5. Reliable 1. Technologies and materials proven for spaceflight 2. Minimal failure modes6. Lightweight NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 3 OF 23
  4. 4. CEV Seat Concept DesignBaseline Seat Concept• 90/90 hip/thigh angles• Non-operator legs must be raised toward chest to fit in vehicle spacing• Minimal lateral support• Stowable• Lightweight• HOWEVER, IT DID MEET THE MINIMAL REQUIREMENTS WE HAD SET FORTHNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 4 OF 23
  5. 5. CEV Seat Concept DesignWhat Can We Learn from Industry?• Highly conformal, custom-fit seats save lives and improve performanceNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 5 OF 23
  6. 6. CEV Seat Concept DesignBut…• You can’t get out of them when you are on your back or in a space-suit… • And they only fit the person they were designed for.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 6 OF 23
  7. 7. CEV Seat Concept DesignChallenge - Leg Curvature• Problem: Flat seats are flat, humans are not. – Models cannot adequately convey the conformity of a human. – In a +Z impact the body is going to find those empty spaces and fill them.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 7 OF 23
  8. 8. CEV Seat Concept Design Challenge Leg Length Differences • Problem: We have to accommodate varying thigh and lower leg lengths—but the seat and Orion inner mold line (the walls) do not move. – Means that legs of persons with longer lower legs must have thighs pulled farther toward chest.IML Spacing Line Seat Bottom NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 8 OF 23
  9. 9. CEV Seat Concept DesignSeat Concept• Pulls together the best features of the designs that we examined, and modified the features to work in a recumbent posture with a space suit.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 9 OF 23
  10. 10. CEV Seat Concept DesignSmall Female vs. Large Male Fit• Spacer pads added at shoulders and hips to provide semi-custom, conformal lateral fit• Maximum shoulder spacer app. 3.5” each side Conformal Spacer PadsNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 10 OF 23
  11. 11. CEV Seat Concept DesignLateral Support• Full lateral support at primary load paths of pelvis and shoulders – Exact principles applied in race-car seat designs.• Additional lateral support at knees, head, and feet. Areas of Lateral SupportNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 11 OF 23
  12. 12. CEV Seat Concept DesignThigh Panel Extension Assembly• Curved thigh extension• Mates to curved groove of hip panel—curve is essential to maintain path of motion• As thigh panel is lengthened, knee pivot is moved up in the Z axis automatically.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 12 OF 23
  13. 13. CEV Seat Concept DesignShoulder and Head Support Assembly• Single assembly that provides: – Headrest – lateral support wings with fabric “hammock” for head support sized to helmet diameter NOTE: lateral wings should nominally be taller and the hammock should be deeper than in prototype. I estimated wrong in my first stab at it… – Lateral shoulder supports pads added to decrease span for smaller occupants – Shoulder belt anchor points – Anti-elongation support Provides support to keep occupant from elongating in a –Z impact• Adjusts as single unit to occupants seated mid-shoulder heightNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 13 OF 23
  14. 14. CEV Seat Concept DesignHand Controller Mounts• Hands naturally fall at knees when seated recumbently.• Seat structure is near hand area, so why not use it as a mounting point?• Eliminated need for separate armrest – Eliminates egress obstruction – Eliminates stability issues associated with cantilevered armrest• May rotate out of the way for egress• Hand controller mounts must be extendable down toward pallet to accommodate varying forearm lengths.NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 14 OF 23
  15. 15. CEV Seat Concept DesignAdjustability Large Occupant Configuration Small Occupant ConfigurationNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 15 OF 23
  16. 16. CEV Seat Concept DesignACES Suited FitNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 16 OF 23
  17. 17. CEV Seat Concept Design Tips that Helped in the Process• Keep an Open Mind – It is easy to become close-minded with a singular focus just because the status quo is comfortable. – Challenge yourself to step past that comfort zone to question if what you are doing can be improved.• Listen to the ideas of others – even if you think the idea is not sound – The conformal seat was a very good idea, but we knew it would not work so we discounted it for a while and settled into a comfort zone with what we had. – Had we not given the work of others a fair and fresh look, the current concept would have never emerged.• Don’t Fall into a Computer-Designed Trap – Computer tools like CAD and FEA are nice, but not without some good old-fashioned common sense behind them. They should not be the only tool in the toolbox. – Sometimes pure hands-on creativity and gruntwork allows you to find the hidden pitfalls that are buried behind the pixels.• Understand What You are Trying to Do – Fundamentally and in self-actualizing detail, not just the “lawyered-up” requirements language that is given to you. – Were we building a seat or was a seat the design solution to keeping the crew safe in a landing? Once the latter was understood, then the seat became something so much more than just a perch for a posterior.• Don’t Be Afraid to Take a Chance on Your Own to Make a Change – The squeaky wheel gets the grease, so sometimes it is okay to cause a ruckus. – But that wheel is still only part of the greater vehicle – don’t alienate others in the process, since you are still part of something greater than just you.• Have Fun! NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 17 OF 23
  18. 18. CEV Seat Concept DesignConcept Testing• High G Sled Testing at Wright Patterson AFBNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 Zoom Zoom! 18 OF 23
  19. 19. CEV Seat Concept DesignConcept Testing• 0 Gravity Testing 0g Spinal Growth Evaluations Seat Functionality EvaluationsNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 19 OF 23
  20. 20. CEV Seat Concept Design3D Human Scanning:• I know I said I hated computer models, but… – This was more accurate than tracing my rear-end on cardboard• Used to refine shape of seatpan to fit full crew complementNASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 20 OF 23
  21. 21. CEV Seat Concept DesignWhere We Have Gone From ThereLockheed Martin/NASA Orion Seat Design Evolution Lockheed Martin Export Controlled NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 21 OF 23
  22. 22. CEV Seat Concept DesignExamples of Design Concept Exploration• Currently searching for a way to integrate auxiliary breathing air onto a person seated in a semi- conformal seat. Legacy designs prevent proper integration to conformal fitting seats. Firetruck seat with integrated mounts for Self Contained Breathing Apparatus (SCBA) NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 22 OF 23
  23. 23. CEV Seat Concept DesignExamples of Design Concept Exploration• Heel Mounting Design Concept Exploration – Cycling Shoes and Clipless Pedals If all else fails I can now seek work as a cobbler…NASA 2009 Project Management Challenge EC5/D. Gohmert/281-483-9350 23 OF 23

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