Problem with seat wiring

[Prophet]

Craig,

So I was having a problem with intermittent function of the seat. The software was showing it working but nothing coming from the seat. I saw a similar post where the guy found some bad wiring.

So I opened up my seat and it appears almost every wire appears to be pinched and has a break. I think it would be a good idea to look at a method to reinforce the the cable where the seat bends, it appears to be where the fault is happening.

Should be a simple repair, I just gotta find the time. In Japan ATM.

[gjcame]

Hi Prophet

Iam probably the one in the post you mention. I am still having problems with mine and have sent various emails to Craig suggesting modifications to the seat in this area with no responses including one a week or so ago.

Up until now my support for Craig has been unwavering but find my interest is pretty much exhausted. I know he is flat out and been through a terrible time but I do expect the courtesy of some response.

Regards

Graeme

[gjcame]

Further to the above post once again my seat malfunctioned because of this wiring problem and after some more delicate soldering had the seat back on air for a day only to find the same breakage issues . There is simply just not enough slack wiring to continually make these repairs.

Still no response from Craig so I GIVE UP !!!!!

Graeme

[craig]

Hellol Graeme, apologies for not replying sooner. I am scrambling to get the TFS3 into production. We are nearly done with the circuit board testing and later in the week i should be sending the files overseas. Also we are arranging to ship the injection molds so we can start making the plastic housing for the TFS3. As well I am preparing the new labels for the plastic surface of the circuit board housing. So it is a large amount of work to get done and generally speaking it's a hurry up and wait type of deal, where once you put everything in motion the fruits of that labor take time to appear, so once the heavy lifiting is done I can be much more responsive to the type of problem you posted about!

As for this problem I think what we'll do is make available a small extension piece that can add slack to the cables there. Do you have a plastic tie strap holding that part of the cable to the bottom of the main back zipper on your seat? I think if you cut the plastic strap there it can let some slack develop. What do you think?

I'll reply sooner to your next post!

[gjcame]

Craig it is wonderfull to have your response and to know that you are again moving forward. You have been through a lot and it is good to have you back.

One day perhaps you may be able to tell us a little more about it.

As I presume you are still putting the final touches to the whole prototype package, including the seat, before a major product release as I have suggested in previous posts a small modification to the wiring to prevent this problem happening into the future needs to be made. Perhaps all the wires from the seat to the connection box could be grouped together in a protective sheath with enough slack for them to lie horizontally at the fold and then to the connector or even a simple relocation of the connection box. One idea but I am sure you could come up with a fairly simple solution which would help avoid warranty problems later when this thing really takes off, and it sure will.

Also of interest is that when the wires are broken, the installation all looks fine in device manager etc., but the digital fuses are out and under the TFS status Comms Failure comes up but in the control panel it shows as "Active". As I have noticed a few posts with the Comms Failure this could be a possible cause. I only found the problem initially in a last resort search. Remember that this seat has had a good work out as I got it around 2003 I think and your special massage files you made for me have had good use

I have gained some slack by freeing the wires from and cutting away some the foam which holds them but as I have now made repairs on about 4 occassions and each time lose a bit more wire, there is very little left and some of the joins are very close to the connection plugs. Each time I have thought the fix should last they invariably let go. They are very thin wires and my soldering probably isn't the best and there is very little space to work in given the location of the zips and the connection box. I must note that this invariably happens to all 4 seat connections

Ultimately I would consider buying another seat to replace this one as there is absolutely no other product like this one on the market. It is simple in design, easy to initially install and the immersion factor is way ahead of anything else out there. I have even considerd moving the seat between my computer chair and my wheelchair depending on the day I am having

Now being paralysed from the waist down I find it very difficult to make the repair as it is a pretty major balancing act with hot soldering iron etc with not much room to move.

Never the less when it is all working I get great enjoyment out of it as apart from my computers there is not much else I can enjoy with the exception of listening to good classical music.

Well I have got it working again but my fingers are crossed as to how long for.

Best Regards

Graeme

[gjcame]

Thought I would add a couple of pics which tell the story very well but kept getting this is not a valid image although both.gif and.jpg"s of the correct size were tried

Some advice please

Regards

Graeme

[gjcame]

Craig, it would be good if you could find time to answer my query . If I can upload the images you will get to see this will be a serious and ongoing problem for you

Graeme

Edit: Craig pics emailed to you

[gjcame]

Craig thank you for your PM response. I have sent a reply at the end of your message with some suggestions so please review your message . New at this PM stuff so not sure if I have answered in the correct way. I have also sent some more pics to you via email

Thanks again

Regards

Graeme

[Prophet]

Originally Posted by craig

Hellol Graeme, apologies for not replying sooner. I am scrambling to get the TFS3 into production. We are nearly done with the circuit board testing and later in the week i should be sending the files overseas. Also we are arranging to ship the injection molds so we can start making the plastic housing for the TFS3. As well I am preparing the new labels for the plastic surface of the circuit board housing. So it is a large amount of work to get done and generally speaking it's a hurry up and wait type of deal, where once you put everything in motion the fruits of that labor take time to appear, so once the heavy lifiting is done I can be much more responsive to the type of problem you posted about!

As for this problem I think what we'll do is make available a small extension piece that can add slack to the cables there. Do you have a plastic tie strap holding that part of the cable to the bottom of the main back zipper on your seat? I think if you cut the plastic strap there it can let some slack develop. What do you think?

I'll reply sooner to your next post!

I dont think an extension or zip ties would help. You need some sort of conduit as the bend in the seat creates a over 90deg bend, and the thin cable just dont handle it over time.

[gjcame]

Hi Prophet,

I agree. In the photos that I have sent to Craig I demonstrated this by simply using a 90 deg. bend from the polypipe watering system.

The seat is either folded flat for shipping or approx 90 deg on the chair. Together with the surrounding foam it would anchor the wires to the seat in a similar way to the wires on the back and prevent the micro bending that causes the thin wires to fatigue. Needs a bit of refinement but is on the way. For some reason I could not upload the photos here. Need a tutorial on how to do it !!!

Craig is keen to find an ongoing solution but at the moment the priority is TFS 3

Regards

Graeme