Sleeping Pod

Reyou capsule for rest, sleep, quick recovery and improved psycho-emotional state during the working day.

Industry:

IoT

Deeptech & Sciences

Medical Devices

TRL:

3 → 5

Project duration:

18 months

Challenge

The chair's load-bearing frame must be able to hold the person's weight as well as the dome fastened to the back of the chair. A solid frame was problematic to create due to weight and dimensional constraints.

Each actuator increased the cost by 10-15%. EnCata coordinated the mechanics for unfolding the chair and the dome in time, computed the required movements.

Our Role

  • Requirements analysis, preparation of terms of reference, feasibility study, competitor analysis, benchmarking
  • Concept development, composition
  • Mechanical engineering
  • Mock-up and prototyping of assemblies at the design stage
  • Production a full fledged prototype
  • Drawing up design and technological documentation
  • Technical support after the project is handed over to the Customer

Technologies Used

Industrial Design

Reverse Engineering

3D-modeling

CNC milling

Lathe processing

Water  CNC

Laser cutting CNC

Welding

Bending

Polymer coating

FEA

EnCata offers comprehensive hardware and IoT product development services at a fraction of the cost

For Enterprises

R&D + design + manufacturing under ONE roof
Scale up and down your team
Intergrated hardware + software development
New technologies and research 

CORPORATIONS click HERE for more info

For Startups

MVP and POC prototypes
Affordable consultancy rates
All IP is yours
In-house batch production

STARTUPS click HERE for more info

Approach & Solution

We began the project by calculating the load frame in statics in order to determine the loads on the folding mechanism and optimize the load frame's material and design. The frame must be constructed to accommodate people of various heights and physiques. Large levers are created by the weight of a tall and hefty person, which cannot be compensated for by adding more crossbars and ribs, as this would increase the product's size, weight, and cost. As a result, we selected the cross-section of the pipe and the position of the cross pieces and reinforcements after calculating the frame loads. At the same time, we calculated each adjustment to ensure that the safety margin was enough but not excessive. Computer simulations helped us to optimize the design and choose the sufficient production techniques.

Power Nap, New product development, Encata, NPD, Mechancal engineering

The chair's load-bearing frame was welded from a bent round tube. The chosen cross-section provided adequate structural stiffness and weight savings, while the avoidance of welding reduced manufacturing costs. Strength-testing calculations were performed in order to assure the structure's reliability.

In order to strike a balance between the Customer's financial constraints and the product's functional needs, our engineers used a solid bar with milled slots to locate the frame actuator lugs. This method had no effect on prototype development speed or cost, but it did simplify the assembly process in mass production. Due to its simplicity and efficiency, the milled bar approach was also employed to place the capsule's center plate.

To coordinate the chair’s unfolding mechanism, we carried out: computer simulation of the chair's operation, kinematic and force calculations of all components of the unfolding mechanism. As a consequence, the best dimensions for the mechanism components were found.

New product development, metlworks, Encata, Power nap, Manufcturing.

We have developed a lever system that minimized the number of linear actuators required. The levers allow you to adjust the seat inclination and unfold the footrest at the same time.

Results

As a result, EnCata delivered the chair’s load frame to the Customer that met all of the requirements, as well as reliability and safety standards. The proposed solution saved from additional expenditures for installation fixtures while meeting the production cost requirements. This reduces the investment when starting production because less money is wasted on unprofitable warehouse components, organization costs are lowered, and the start-up team can do some of the work themselves because complex equipment is not required.

Master models for the chair’s enclosure (dome, base, and backrest) were also created and can be used in the first batch production. This tooling was put through its paces in our manufacturing facility. After installation, we produced the enclosure and tested the mechanism's operation. The testing confirmed the results of the mechanism's calculations and CAD modeling in practice.

3 605

spent to design, calculate and optimize the construction

3

hours have been prototypes presented to the Customer with the desired parameters.

90 kg

the  weight of the chair’s load frame with fiberglass enclosure.

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