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Title: Automotive Design with Respect to Ergonomics


1
Automotive Design with Respect toErgonomics
  • Ehsan Naseri
    81178607
  • Soudeh Yektaee 81195404

2
Content
  • What is Design?
  • Design Process
  • Design process For Automotive
  • Design process For automotive with respect to
    Human Factors

3
Introduction to Design
  • A goal- directed problem solving activity (Archer
    1965).
  • Design is a interplay between what we want to
    achieve and how we want to satisfy them (Suh
    1990).
  • Design is a process of converting information
    that characterize the needs and requirements for
    a product into knowledge about the product
    (Mistree 1992).

4
Definition of Design
  • Design is
  • An art, not a science
  • Problem solving, Decision making, Applying
    science
  • Creativity imagination vs Heuristic search
  • Directing, leading organizing
  • Dealing with people team-building
  • Negotiating to achieve a satisfactory solution
    optimizing
  • Foresight towards production, assembly, testing
    and other processes
  • Considering the "bottom line" of costs and
    profit,
  • Satisfying needs satisfying the customer
  • Ethical and professional conduct

5
Various Design
  • New Design New tasks and problems are solved by
    new solution principles.
  • Revised Design The embodiment design is
    customized/adapted to fit new requirements. The
    employed solution principles are known and
    field-proven .
  • Variant Design Size and/or structure of parts
    and assemblies are varied within the limits of
    the already planned system.
  • Repeat Design A new start of the production run
    with an unchanged design.
  • Robust design A systematic engineering based
    methodology (which is part of quality engineering
    process) that developes and manufactures high
    reliability products at low cost with reduced
    delivery cycle.

6
Over the Wall Engineering
  • Roles of system engineer
  • Need identification customer linkage,
    Management (spec, process, risk, information),
    System design, Integration, RD, leading
    coordinating

7
Integrate Product Design
  • Integrate People
  • Build concurrent engineering teams
  • Negotiation in engineering design
  • Integrating Processes
  • Process Modeling
  • Process Reengineering
  • Integrating Information
  • Database Management Systems
  • Information and data mining
  • Building a Concurrent Engineering Design Process

8
Design Process
  • System, subsystem and component design
  • Sequential iterative process
  • Starts and Ends with the customer
  • Comparison and contrast to scientific method
  • Need ? Concepts ? Feasibility ? Produce ? Sell
  • Time and cost as key factors
  • Process of converting information that
    characterizes the needs and requirements for a
    product into knowledge about the product and its
    implied processes.

9
Engineering Models of Design
10
Design process 1
  • Recognition of a customers need
  • Market research identifies customers and needs
  • RD creates ideas that are relevant to an
    organizations capabilities
  • Needs arise from dissatisfaction
  • Technology push (examples computers, audio)
  • Definition of a problem or Task
  • Design specification
  • Selecting product ideas
  • Compiling the requirement list
  • Acquire apply technical knowledge
  • Identify resources
  • Prioritize design goals continue to refine

11
Designs vs Needs
12
Design process 2
  • Product definition
  • Function
  • Preliminary requirements list
  • Solution requirements
  • Cost target and budget

13
Design process 3
  • Conceptual design
  • This phase looks at the function requirement of
    the Product.The function are listed complex
    functions are broken into simpler sub-functions.
  • Determines the Principle of Solution.
  • It is preceded by a Decision
  • Procedure
  • Abstract to identify essential problems
  • Establish function structures
  • Search for working principles to fulfill the
    sub-functions
  • Combine working principles into working
    structures
  • Select suitable combinations
  • Evaluate against technical cost criteria

14
Design process 4
  • Design embodiment
  • It starts from the concept and develops the
    definitive layout for the project
  • Evaluate against Technical Economic criteria
  • Preliminary layout
  • Optimize and complete form designs
  • Check for errors and disturbing factors
  • Prepare preliminary part list and production
    documents
  • Embodiment design is characterized by repeated
    deliberation and verification.
  • This requires approach that is progressive as
    well as iterative.
  • The checklist
  • Function, Working Principle, Layout, Safety,
    Ergonomics, Production, Assembly, Transport,
    Recycling, Maintenance, Costs, Quality control

15
Design process 5
  • Prepare production documents
  • Elaborate detailed drawings and parts list
  • Complete production,assembly,transport and
    operating instructions
  • Check all documents
  • Design review
  • Review and redesign focuses on achieving the
    performance, producibility, reliability and cost
    (As compared to what) objectives.
  • Competitive benchmarking
  • Reverse Engineering of competitors products
  • Early bird gets the profit

16
Example design process Jack
  • My car was not in very bad condition, but the
    original jack was so slender, that I didn't dare
    creep under the car when it was lifted by this
    jack. There was no space for me, anyway! The
    floor of the car was badly rusted, because the
    car had been effected by some sewer gas in the
    garage. I had to cut large sections out of the
    floor and cover them with new steel plate.

17
Information
  • Space below of car
  • Jack point car size

18
Available Means
19
List of Demands
20
Definition of Problem
  • We must design a jack, which is able to lift a
    car, which has a weight of 1300 kg, a width of
    1800 mm an a wheel base of 2700 mm. The jack must
    be safe enough, that repair and service
    operations below the lifted car are possible.
  • We must design a system, which makes repair and
    service operations possible below a car.
  • Functions

21
Decomposing into subsystem
Ones muscle power has to be transformed to
lifting force with the sub function 1. Sub
function 2 is used to transmit the combination of
lift and lifting force directly or in transformed
form into the connection points of the car. Sub
function 3 makes the connection with the car. Sub
function 4 keeps the system steady on the ground.
Sub functions 5 and 6 secure the lift and they
make operations below the car safe.
22
Alternative subsystems
23
Possible combinations
24
Decision Table
25
Embodiment design
26
Detail design
27
Review of Design
28
Results
29
AutomotiveDesign
30
Aspects of Designing Car
  • Occupant Packaging
  • Computer-Aided Ergonomics Design Of car
  • Visual Aspects in vehicle Design
  • Automotive Seat Design for sitting comfort
  • Physical Aspect of Car Design
  • Design of symbols for automobile Control and
    Displays
  • Informational aspect of vehicle Design

31
Occupant Packaging
  • Workspace Anthropometry
  • Conventional Static Measurements

  • anthropologist
  • (are taken on the human body in rigid ,
    standarized position)
  • Functional Task Oriented Measurements

  • Engineer Designer
  • (are taken with the human body at work , in
    motion or in workspace attitude and typically are
    expressed as 3 dimensions.)

32
Occupant Packaging
33
Occupant Packaging
34
Occupant Packaging
35
Occupant Packaging
36
Occupant Packaging
37
Driver workspace design
and evaluation models
  • Task Oriented Percentile Models
  • - Use anthropometric data to Define a user
    population startified across stature , weight
    and
  • - Conduct test for specific task(reach, eye
    location) to develop statistical models defining
    spatial requirements
  • Manikin Oriented Models
  • - Uses anthropometric data to define 95 percent
    male and 5 percent female
  • - uses manikins or selected large (95) male
    and small (5) female to define spatial
    requirements

38
Driver workspace design
and evaluation models
  • - Assume that sample populations defined user
    requirements
  • - assumes user needs are
  • expressed by a central
  • tendency
  • with exclusion
  • at both ends , for example
  • 95 percent accommodation with 2.5 percent
    excluded at each end.
  • - Assume that Specified large males and small
    female comprehend all user requirements
  • - Assume that 2-D (or 3-D) manikins can
    predict or model human requirements
  • - Assume that a given percentile person is
    definable from the some of parts

39

Driver workspace design
and evaluation models
  • - many level of accommodation are described ,
    but only for the task studied
  • - Results in well defined statistical model
    that defines accommodation levels for specific
    task
  • - Many task are measured and evaluated , but
    only for a defined small and large user
  • - Result in questionably defined geometric
    manikin models that predict accommodation for
    only two extreme percentile people

40
Computer Aided Ergonomic Design of automobile

engineers will simulate driver behavior and
measure key criteria such as reach, visibility,
comfort, posture, biomechanics, strength and
anthropometrics. This analysis will enable the
team to make driver-oriented decisions about
cockpit design, while respecting the overall
aerodynamics of the racecar body.
41
Simulation with computer
  • To optimize cockpit ergonomics, engineers will
    first create a digital model of each driver using
    a combination of laser scanning and manual
    anthropometrical techniques. The resulting
    virtual models will be used to analyze and
    improve specific accommodation issues such as
    driver comfort and security, and accessibility
    and serviceability of components inside the
    cockpit during pit stopswithout the need to
    involve the actual drivers.

42
The SAMMIE System
  • The SAMMIE system is a computer based Human
    Modeling tool. Its capabilities make it an
    invaluable tool to designers and design teams
    working on products that are used by people. The
    system offers the following advantages
  • 3D analysis of fit, reach, vision and posture.
  • reduced timescale.
  • early input of ergonomics expertise.
  • rapid interactive design.
  • improved communication.
  • cost effective ergonomics

43
Automotive Seat Design For Sitting Comfort
  • kind of motor vehicles
  • 1. Family and personal business sedan
  • 2. Minivan and off-road vehicle
  • 3. Sport cars
  • Three different occupants in the vehicle
  • 1)Driver
  • 2) Front seat passenger
  • 3) Rear set passengers

44
Automotive Seat Design For Sitting Comfort
  • Criteria for a driver s seat
  • 1 the set should position the driver with
    unobstructed vision and within reach of all
    vehicle control
  • 2 the seat must accommodate the driver s size
    and shape
  • 3 the seat should be comfortable for
    extended period
  • 4 the seat should provide a safe zone for
    the driver in a crash

45
Why should respect Ergonomics In Design?
  • Safety

Safety in a race car is the art of protecting the
human occupant, at whatever cost to the car.
Designing the car to be damaged minimally while
hindering driver safety is definitely the wrong
approach. So how do we protect the driver? Well
first we need to consider the basic physiological
weak points of the human body.
46
Safety
  • The diagram above shows that pretty much any part
    of the body exposed to the chassis of the race
    car is at risk. Injuries occur because the body
    sustains impacts beyond the G (gravities) level
    that it can sustain.
  • The brain is particularly succeptible to injury,
    because it is really just a soft tissue mass
    stored inside a very solid bone container, the
    skull. The key to avoiding injury in the brain is
    to avoid instantaneous decelleration of the
    skull. That is, when the skull strikes something
    hard, it decellerates instantaneously. The brain
    inside unfortunately keeps on moving, causing
    head trauma.
  • Neck and spinal injuries also present a serious
    threat to life and career. These "Connector" type
    elements in our body are flexible and
    stretchable, to a point, and can sustain
    tremendous G loads before breaking. However,
    depending on angle of impact, they can break
    rather easily.
  • Other bone injuries (breakages) are not as
    life-threatening or career ending, but still are
    to be prevented. The bones in our arms, legs and
    spine are designed to be stressed in tension and
    compression along their length. In the case of
    impacts they are often stressed in shear or
    bending, and therefore snap relatively easily

47
Safety In Crash
  • First, the driver needs to be supported, so
    movement under normal driving is very limited.
    This means a seat with lateral head support, a
    head rest, and good lower and upper body lateral
    support. Most racing seats provide these three
    elements
  • Secondly, the car's chassis needs to hold the
    seat and driver in place, in all situations,
    driving and crashing. This is of course
    accomplished with a chassis mount for the seat,
    and a 5 or 6 point harness.
  • Thirdly, measures must be taken to prevent
    intrusion into or the crushing of the driver's
    limbs and extremities. On formula cars, the
    problem of suspension wishbones breaking and
    piercing the driver's legs is solved by
    anti-intrusion panels that prevent pieces of the
    car from intruding into the driver's cockpit. As
    well, the cockpit "Safety cell" needs to be very
    strong. The "Safety cell" is the last piece of
    material between danger and the driver, and so
    should be well constructed, and not prone to
    collapsing onto the driver.
  • Finally, the car needs to absorb the energy via
    structures that are crushable. As stated
    previously, the human body does not like to be
    decellerated from 80 or 100 km/h to 0 instantly.
    Therefore, we need to find a way that "quickly"
    decellerates the body. The only possibilities on
    a race car are the structures which surround the
    driver's safety cell. Designing these structures
    to collapse in an impact ensures that G levels
    are reduced because the car is literally
    decellerating over a small distance, instead of
    ZERO distance

48
Safety/Ergonomics Design Tips
  • Use energy absorbing materials in the collapsable
    crash structure - In lower cost racing cars, most
    of the car is usually built from mild steel.
    Using that same mild steel in areas such as
    wishbones means that impacts will bend the
    material long before it breaks the material,
    meaning energy absorption takes place over a
    longer period.
  • For light weight, use a stressed skin over a
    lightweight core material - crushable zones such
    as the nose cone on a formula car can be made
    from balsa, honeycomb or high density styrofoam
    covered with a stressed skin of composites.
  • Triangulate the driver "safety cell" to prevent
    collapse - The safety cell can be designed in
    such a way that a catastrophic impact which
    collapses the safety cell, will make the safety
    cell expand away from the driver, instead of
    collapsing it onto the driver. In the case of a
    frontal impact, this would mean the sides of the
    cockpit would expand outward, upward and
    downward, instead of inward.

49
Safety/Ergonomics Design Tips
  • Use a clear windscreen or bodywork to increase
    vision - using lexan or other non-shattering
    clear material can help increase visibility
    without compromising the function of the
    bodywork. In some cases, the driver can be
    lowered for better CG (center of gravity), and
    the normally opaque bodywork replaced with clear
    lexan, to aid in re-establishing the vision
    field.
  • Keep the fuel cell and battery away from the
    driver and danger. Keeping dangerous items away
    from the driver is sometimes very difficult. In
    order to reduce the weight balance change over a
    race, designers will frequently put the fuel cell
    at the CG, so that no matter how empty or full it
    is, it does not cause a front/rear or
    side-to-side weight bias. However, most drivers
    don't like to sit next to fuel. Use secured,
    sealed firewalls between the fuel cell and driver
    compartment, and further, use the safety cell to
    protect the fuel cell from outside intrusions.
  • Don't scrimp on safety. Use only top quality
    certified suppliers of safety equipment. The cost
    is perhaps high, but consider how much you value
    your life. Fuel cells (Sanctioning body
    certified), seat belts (5 or 6 point sanctioning
    body certified only!), and driver safety wear
    (Nomex, 2 or more layers minimum! -- anything
    less is like wearing nothing).

50
Design Of Symbols For Automobile Control and
Displays
  • 1) Digital meters Discreet digital meters
    maximize forward visibility and help create a
    sense of uncluttered spaciousness.
  • 2) Triangle-motif steering wheel The
    triangle-motif steering wheel helps harmonize
    exterior and interior design, for a feeling of
    unity throughout.
  • 3) Centrally positioned audio panel A 2DIN
    opening for audio components is centrally
    positioned at the top of the instrument panel for
    easy access and visibility.
  • 4) Textured dashboard and console The dashboard
    centre, floor console, and front pillars are
    trimmed with a new textured material with a
    refined look and feel.
  • 5) Sporty two-tone fascia The sporty two-tone
    fascia adds a touch of pizzazz to the Liana's
    interior.

51
Displays
52
Displays
53
Displays
54
Displays
55
Reading assignment
  • Aesthetics and Engineering Design
  • http//design.stanford.edu/PD/kbase/Aesthetics_and
    _Engineering_Design.pdf
  • Introduction of design
  • http//deed.ryerson.ca/DesignScience/1.html
  • design basics in IT
  • http//www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/
    6
  • user engineering in IT
  • http//www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/
    1996
  • Automotive Ergonomics

  • Brayan Peacock Waldemar Karowski
  • Sitting posture
  • E. Granjin

56
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