Automotive Design

with Respect to

Ergonomics

Ehsan Naseri 81178607

Soudeh Yektaee 81195404
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 Content
 What is Design?
 Design Process
 Design process For Automotive
 Design process For automotive with
respect to Human Factors

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 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).

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 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

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 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.

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 Over the Wall Engineering
Product concept Product specs. Design specs. Manufacturing specs.

Customers Marketing Design Manufacturing Production

engineering engineering

Roles of system engineer

Need identification & customer linkage, Management (spec, process, risk,
information), System design, Integration, R&D, leading & coordinating

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 Integrate Product Design
 Integrate People
– Build concurrent engineering teams R&D

– Negotiation in engineering design

Manufac- Marketing
 Integrating Processes turing

– Process Modeling Design

– Process Reengineering
Suppliers Customers
 Integrating Information
– Database Management Systems Finance

– Information and data mining

 Building a Concurrent Engineering Design Process

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 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.

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Engineering Models of Design

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 Design process 1
 Recognition of a customer’s need
– Market research identifies customers and needs
– R&D creates ideas that are relevant to an organization’s 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

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Designs vs Needs

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 Design process 2
 Product definition
– Function SOURCES

CONSUMER COMPANY
– Preliminary requirements list
– Solution requirements SITUATION ANALYSIS

– Cost target and budget PROCEDURE FOR SEARCH

DEFINE THE PRODUCT

QUALITATIVE DESCRIPTION

DESIGN

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 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

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 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
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 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 competitor’s products
– Early bird gets the profit

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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.

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 Information
 Space below of car

 Jack point & car size

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Available Means

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List of Demands

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 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

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 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.
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Alternative subsystems

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Possible combinations

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Decision Table

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Embodiment design

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Detail design

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Review of Design

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Results

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Automotive
Design
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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

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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.)

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Occupant Packaging

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Occupant Packaging

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Occupant Packaging

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Occupant Packaging

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Occupant Packaging

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Driver workspace design
and
evaluation models
 Task Oriented Percentile  Manikin Oriented Models
Models
- Uses anthropometric data to
- Use anthropometric data to define 95 percent male and
Define a user population 5 percent female
startified across stature ,
weight and…

- uses manikins or selected

- Conduct test for specific
large (95%) male and small
task(reach, eye location) to
(5%) female to define
develop statistical models
spatial requirements
defining spatial requirements
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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
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Driver workspace design
and
evaluation models
- many level of - Many task are measured
accommodation are and evaluated , but only for
described , but only for the a defined small and large
task studied user

- Result in questionably
- Results in well defined defined geometric manikin
statistical model that models that predict
defines accommodation accommodation for only
levels for specific task two extreme percentile
people

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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.
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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 stops—
without the need to involve the actual drivers.

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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 42
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

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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
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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.
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 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

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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 47
decellerating over a small distance, instead of ZERO
distance
 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. 48
 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). 49
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.
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Displays

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Displays

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Displays

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Displays

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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 55
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