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    Ergonomics and Packaging

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    Waseem Anwar
    This document discusses various aspects of car body design and aerodynamics, including: 1. It covers key factors that influence car body design such as packaging/ergonomics, structural aspects, and passive safety. 2. The course covers these topics through classroom lectures, presentations on industrial practice, facility visits, and case studies where students conduct packaging and structural analysis of a car body. 3. Important considerations for packaging include establishing interior space, arranging components for safety and comfort, and meeting anthropometric and regulatory requirements.

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    Ergonomics and Packaging

    Uploaded by

    Waseem Anwar
    72 views63 pages
    This document discusses various aspects of car body design and aerodynamics, including: 1. It covers key factors that influence car body design such as packaging/ergonomics, structural aspects, and passive safety. 2. The course covers these topics through classroom lectures, presentations on industrial practice, facility visits, and case studies where students conduct packaging and structural analysis of a car body. 3. Important considerations for packaging include establishing interior space, arranging components for safety and comfort, and meeting anthropometric and regulatory requirements.

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    This document discusses various aspects of car body design and aerodynamics, including: 1. It covers key factors that influence car body design such as packaging/ergonomics, structural aspects, and passive safety. 2. The course covers these topics through classroom lectures, presentations on industrial practice, facility visits, and case studies where students conduct packaging and structural analysis of a car body. 3. Important considerations for packaging include establishing interior space, arranging components for safety and comfort, and meeting anthropometric and regulatory requirements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    72 views63 pages

    Ergonomics and Packaging

    Uploaded by

    Waseem Anwar
    This document discusses various aspects of car body design and aerodynamics, including: 1. It covers key factors that influence car body design such as packaging/ergonomics, structural aspects, and passive safety. 2. The course covers these topics through classroom lectures, presentations on industrial practice, facility visits, and case studies where students conduct packaging and structural analysis of a car body. 3. Important considerations for packaging include establishing interior space, arranging components for safety and comfort, and meeting anthropometric and regulatory requirements.

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    Car Body Design and

    Aerodynamics
    Automotive Engineering

    Prof. Andrea Tonoli


    Politecnico di Torino,
    Dipartimento di Ingegneria Meccanica e
    Aerospaziale
    andrea.tonoli@polito.it
    Aim of the course
    Introduction of the main aspects that influence the car body
    design taking the mutual constraints into account.
    Packaging ergonomics
    Ergonomics
    Visibility (direct and indirect)
    Structural aspects
    Structure configurations
    Structural analysis
    Noise and vibration
    Passive Safety
    Restraint system
    Crash and energy dissipation
    Course organization
    Classroom lectures exercice
    Keynote presentations Case study:
    (industrial practice) Packaging of a vehicle
    Visits Visual requirements
    verification
    Structural analysis (FEM) of a
    car body (static parameters)
    Case study results
    Technical reports and
    drawings to illustrate the
    Exam: obtained results
    Oral and/or written discussion
    (the exercice reports are integral part of
    the exam and of the evaluation)
    Packaging
    Establishing the required interior
    space, and arranging interior and
    structural components (seats,
    controls displays, ...) to guarantee
    driver and passenger safety,
    comfort, convenience and
    accomodation.

    Comfort
    Controls accessibility
    Cabin and trunk accessibility
    Powertrain, suspension and
    structure positioning
    Requirements (standards)
    Front side Back side

    Cervical

    Thoracic

    Lumbar

    Sacrum

    2.2 -1
    2.2 - 2
    Anthropometric data

    Anthropometric measurements are statistically distributed


    ( approx. Gaussian distribution). The distribution can be defined
    from the average and standard deviation.

    Percentile: if 100 people are ordered from the least to the


    greatest for any given measurement, the 1st percentile is that
    exceeded by 99% of the group, the 70th percentile is that exceeded
    by 30% of the group....

    Different databases (and percentiles) can be gathered for male and


    female population. To reduce complexity dimensions used for
    automotive anthropometry are based on 50% male 50% female
    population.
    The anthropometric data change with time !
    2.3 - 3
    2.3 - 4
    Manikin percentile models
    SAE J826 manikin (H-point machine)
    EU manikin for R point definition

    Percentile 10th 50th 90th 95th 99th

    A [in] 15.37 16.40 17.46 18.10 18.74

    B [in] 16.05 16.99 17.94 17.99 18.69


    Task oriented models
    Task oriented: head contours
    Task oriented: eyellipse
    Task oriented: control reach
    Body base grid for vehicle measurement

    USA
    EU
    Basic postures

    seated reclined cramped

    + longitudinal size + vertical size


    + vertical size
    + control reach + load on backbone
    + longitudinal size
    + visibility + vibration and fatigue

    - control reach
    - vertical load on backbone - longitudinal size
    - vibration and fatigue
    - vibration and fatigue - in/out of the cabin
    - in/out of the cabin
    - vertical size - visibility
    - visibility
    Angles for automotive postures

    () SAE Wisner Wyse RENAULT

    Alfa 85-95 85-95 90-110 90-110

    Beta 105-115 95-120 95-135 90-135

    Gamma 95-105 85-100 87-103 95-120

    Delta 15-28 15-25 20-30 25-30


    Packaging procedure

    1. Pedals setup and operation


    2. Mechanical constraints
    3. Definition of heel point (HP)
    4. R point definition (driver)
    5. Check Interference with steering column and dashboard
    6. H point definition (second and third row)
    7. Head contours
    a1) a2)

    HP HP

    b)

    c1) c2)
    T
    SR

    P
    GB

    FW
    SA

    TR
    3035
    25 27-30

    95th 95th

    R G

    330-400
    20-30

    HP

    150-200
    1000 800-850
    2.6 - 3
    148 9 Ergonomics and Packaging

    Fig. 9.11. SAE J1100 dimensions relative to drivers posture.

    The backbone is the structure that transmits the vertical load of the upper
    2.6 - 4verte-
    body to the legs. The transmitted force increases from the cervical
    brae to the lumbar ones that, in comparison, are the most heavily loaded
    as indicated by their larger size 9.1.
    2.6 - 5
    SAE J1100 Package dimensions

    elbow
    hip
    Package definition
    9.4 Pedals Functionality and Positioning 155

    Fig. 9.14. Test bench to investigate the postural seating comfort (seating buck ).
    The bench is representative of the position of the driver and the main cockpit ele-
    ments: pedals, seat, steering wheel and allows to measure the angles between the body
    segments.
    Factors influencing seat comfort
    Subjective and
    psycological
    Physical attributes
    10% Of the seat
    Pressure
    9%
    distribution
    9% Backbone support
    54%
    9% Thermal behavior

    9% Vibration isolation

    2.7 - 1
    Seat comfort
    Factors influencing comfort for still vehicle
    Body support
    Perceived contact stiffness;
    Lateral support
    Possibility to adjust the posture
    Tactile perception
    Aestetics

    Factors influencing comfort for moving vehicle


    Vibration isolation
    Avoid limitations to the drivers motion
    Reduce the dynamic loading of backbone and contact regions

    2.7 - 2
    Pressure distribution
    (comfort index for still vehicle)

    cushion Seat back

    rear

    front

    Seat back

    Upper
    y = 56,1 RA + 11,25 RD 16,16
    Lower
    Comfort index

    2.7 - 2
    2.7 - 3
    Vibration insulation of the seat
    (comfort index for moving vehicle)

    Power spectral density of the


    transmitted acceleration
    1
    Wi ( f )

    G SS ( f )Wi 2 ( f )df
    SEAT % =
    100
    G ff ( f )Wi 2 ( f )df

    Weight function

    Power spectral density of the vehicle


    structure (seat connections to the veh.
    Body)

    0.5 Hz < f < 80 Hz


    a b

    2.7 4
    Automotive climate
    Tester
    Front view
    Thermal Shield
    Control system
    Automotive climate
    Pump Tester
    Back view
    Sweating patch

    Temperature and
    humidity sensor

    2.7 - 5
    2.8 - 1
    2.8 - 2
    2.8 - 5
    2.8 - 6
    2.9 - 4
    2.10 - 1
    Eye structure
    Fig. 2.11-1
    Limits of visual fields, obstruction
    Fig. 2.11-2

    Min transparency = 70%


    source

    p = 0 A( )

    A0 n 2 sin 2


    A( ) = 1
    n 1 cos


    eye
    0 1.5'

    = 60 = 1.5'2.85 = 4.3'
    A(60) = 2.85

    Fig. 2.11-3
    source

    d
    c = B( )
    r
    eye d = 4.6 mm
    4.6
    r = 3000 mm = 3.57 = 5.46'
    3000
    B(60) = 3.57

    Fig. 2.11-4
    source

    eye

    Fig. 2.11-5
    Fig. 2.11-6
    Fig. 2.11-7
    Fig. 2.11-8
    Fig. 2.11-9
    Fig. 2.11-10
    Fig. 2.11-11
    Fig. 2.11-12
    Fig. 2.11-13
    Fig. 2.11-14
    Fig. 2.11-15
    Fig. 2.11-16
    Fig. 2.11-17
    Fig. 2.11-18
    Fig. 2.11-19
    Inside mirror
    h > 4 cm
    1
    a = 15cm
    1000
    1+
    r
    rmin + rmax
    r= > 1200 mm
    Outside mirror 2

    h > 4 cm
    1
    a = 13cm
    1000
    1+
    r
    Fig. 2.11-19

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