Car Design Presentation

7/23/2019 Car Design Presentation

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Automotive Design with Respect to

Ergonomics



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Content

What is Design?

Design Process

Design process For Automotive

Design process For automotive withrespect 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 (!h 199").

Design is a process of converting information thatcharacteri#e the needs and re$!irements for a prod!ctinto %nowledge abo!t the prod!ct (&istree 199').



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Definition of Design

Design is

An art not a science* +roblem solving Decision ma%ing Applying science

,reativity imagination vs e!ristic search Directing leading organi#ing

* Dealing with people team-b!ilding* /egotiating to achieve a satisfactory sol!tion

optimi#ing* 0oresight towards prod!ction assembly testing and

other processes* ,onsidering the bottom line of costs and profit* atisfying needs satisfying the c!stomer

2thical and professional cond!ct



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Various Design

New Design: New tasks and problems are solved by new solutionprinciples.

Revised Design: The embodiment design is customied!ada"ted to

fit new requirements. The em"loyed solution principles are knownand field-proven .

Variant Design: Size and/or structure of "arts and assemblies arevaried #ithin the limits of the already "lanned system.

Repeat Design: $ ne# start of the "roduction run #ith anuncanged design.

Robust design: $ systematic engineering based methodology%#hich is "art of &uality engineering "rocess' that develo"es andmanufactures high reliability "roducts at lo# cost #ith reduceddelivery cycle.



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)ver the *all +ngineeringProduct concept Product specs. Design specs. Manufacturing specs.

Customers Marketing Design

engineering

Manufacturing

engineering

Production

Roles of system engineer

/eed identification c!stomer lin%age &anagement (spec process ris%information) ystem design 3ntegration 4D leading coordinating



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Integrate -roduct Design

DesignDesign

R&DR&D

FinanceFinance

MarketingMarketing

CustomersCustomers

ManufacManufac--turingturing

SuppliersSuppliers

DesignDesign

R&DR&D

FinanceFinance

MarketingMarketing

CustomersCustomers

ManufacManufac--turingturing

SuppliersSuppliers

Integrate -eo"le

/uild concurrent engineering teams

0egotiation in engineering design

Integrating -rocesses

-rocess odeling

-rocess eengineering

Integrating Information

Database anagement ystems

Information and data mining

/uilding a oncurrent +ngineering Design -rocess



Design -rocess

ystem6 subsystem and com"onent design e&uential 7 iterative "rocess

tarts and +nds #ith the customer

om"arison and contrast to scientific method 0eed → once"ts → 8easibility → -roduce → ell

Time and cost as 9ey factors -rocess of converting information that characteries the needs

and re&uirements for a "roduct into 9no#ledge about the

"roduct and its im"lied "rocesses.



+ngineering odels of Design



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Design "rocess 1

ecognition of a customer<s need ar9et research identifies customers and needs

7D creates ideas that are relevant to an organiation<s ca"abilities

0eeds arise from dissatisfaction

Technology "ush %e=am"les : com"uters6 audio' Definition of a "roblem or Tas9

Design s"ecification

electing "roduct ideas

om"iling the re&uirement list

$c&uire 7 a""ly technical 9no#ledge Identify resources

-rioritie design goals 7 continue to refine



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Designs vs 0eeds



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Design "rocess 2

-roduct definition

8unction

-reliminary re&uirements list

olution re&uirements ost target and budget

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Design "rocess 3

once"tual design This "hase loo9s at the function re&uirement of the -roduct.The

function are listed 7 com"le= functions are bro9en into sim"ler sub>functions.

Determines the -rinci"le of olution. It is "receded by a Decision

-rocedure $bstract to identify essential "roblems

+stablish function structures

earch for #or9ing "rinci"les to fulfill the sub>functions

ombine #or9ing "rinci"les into #or9ing structures

elect suitable combinations

+valuate against technical 7 cost criteria



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Design "rocess 4

Design embodiment It starts from the conce"t and develo"s the definitive layout for the

"ro?ect +valuate against Technical 7 +conomic criteria

-reliminary layout )"timie and com"lete form designs hec9 for errors and disturbing factors -re"are "reliminary "art list and "roduction documents

+mbodiment design is characteried by re"eated deliberation andverification.

This re&uires a""roach that is "rogressive as #ell as iterative. The chec9list

8unction6 *or9ing -rinci"le6 @ayout6 afety6 +rgonomics6-roduction6 $ssembly6 Trans"ort6 ecycling6 aintenance6 osts6Auality control



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Design "rocess 5

!repare production documents " +laborate detailed dra#ings and "arts list

om"lete "roduction6assembly6trans"ort and o"eratinginstructions

hec9 all documents

Design review evie# and redesign focuses on achieving the "erformance6

"roducibility6 reliability and cost %$s com"ared to #hat'ob?ectives.

om"etitive benchmar9ing everse +ngineering of com"etitor<s "roducts

+arly bird gets the "rofit



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+=am"le design "rocess: Bac9

y car #as not in very bad condition6 but the original ?ac9 #as soslender 6 that I didnCt dare cree" under the car #hen it #as lifted by this

?ac9. There #as no s"ace for me6 any#ay The floor of the car #as badly rusted6 because the car had been effected by some se#er gas in

the garage. I had to cut large sections out of the floor and cover them#ith ne# steel "late.



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Information

"ace belo# of car

Bac9 "oint 7 car sie



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$vailable eans



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@ist of Demands



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Definition of -roblem

*e must design a ?ac96 #hich is able to lift a car6 #hich has a #eightof 13;; 9g6 a #idth of 1;; mm an a #heel base of 2,;; mm. The

?ac9 must be safe enough6 that re"air and service o"erations belo#the lifted car are "ossible.

#e must design a s$stem% wic makes repair and service

operations possible below a car& 'unctions



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Decom"osing into subsystem

nes m!scle power hasto be transformed tolifting force with the s!bf!nction 1. !b f!nction 'is !sed to transmit thecombination of lift and

lifting force directly or intransformed form into theconnection points of thecar. !b f!nction = ma%esthe connection with thecar. !b f!nction > %eepsthe system steady on thegro!nd. !b f!nctions 5and 6 sec!re the lift andthey ma%e operationsbelow the car safe.



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$lternative subsystems



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-ossible combinations



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Decision Table



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+mbodiment design



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Detail design



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evie# of Design



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esults



2

(utomotive

Design



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$s"ects of Designing ar

)ccu"ant -ac9aging

om"uter>$ided +rgonomics Design )f car

Visual $s"ects in vehicle Design

$utomotive eat Design for sitting comfort

-hysical $s"ect of ar Design

Design of symbols for automobile ontrol and

Dis"lays Informational as"ect of vehicle Design



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)ccu"ant -ac9aging

#orkspace (ntropometr$ : Conventional Static Measurements

anthro"ologist%are ta9en on the human body in rigid 6 standaried "osition'

Functional Task Oriented Measurements

+ngineer Designer

%are ta9en #ith the human body at #or9 6 in motion or in#or9s"ace attitude and ty"ically are e="ressed as 3dimensions.'



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)ccu"ant -ac9aging



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)ccu"ant -ac9aging



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)ccu"ant -ac9aging



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)ccu"ant -ac9aging



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Driver workspace design

and

evaluation models )ask *riented !ercentile

+odels

- Ese anthro"ometric data to

Define a user "o"ulation

startified across stature 6

#eight andF

> onduct test for s"ecific

tas9%reach6 eye location' to

develo" statistical models

defining s"atial re&uirements

+anikin *riented +odels

> Eses anthro"ometric data

to define 5 "ercent male

and 5 "ercent female

> uses mani9ins or selected

large %5G' male andsmall %5G' female to

define s"atial re&uirements



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> $ssume that sam"le "o"ulations defined userre&uirements

> assumes user needs are e="ressed by a central

tendency

#ith e=clusion

at both ends 6 for e=am"le 5 "ercent accommodation

#ith 2.5 "ercent e=cluded ateach end.

> $ssume that "ecifiedlarge males and smallfemale com"rehend all userre&uirements

> $ssume that 2>D %or 3>D'mani9ins can "redict ormodel human re&uirements

> $ssume that a given "ercentile "erson isdefinable from the some of "arts


and

evaluation models



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> many level ofaccommodation aredescribed 6 but only for thetas9 studied

> esults in #ell definedstatistical model that

defines accommodationlevels for s"ecific tas9

> any tas9 are measuredand evaluated 6 but onlyfor a defined small and

large user

> esult in &uestionablydefined geometricmani9in models that "redict accommodationfor only t#o e=treme "ercentile "eo"le


and

evaluation models



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Computer (ided ,rgonomic

Design of automobile

engineers will simulatedriver behavior andmeasure key criteria suchas reach, visibility,

comfort, posture, biomechanics, strengthand anthropometrics!his analysis will enablethe team to make driver"

oriented decisions aboutcockpit design, whilerespecting the overallaerodynamics of theracecar body



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Simulation wit computer

To o"timie coc9"it ergonomics6 engineers #ill first

create a digital model of each driver using a

combination of laser scanning and manual

anthro"ometrical techni&ues. The resulting virtualmodels #ill be used to analye and im"rove s"ecific

accommodation issues such as driver comfort and

security6 and accessibility and serviceability of

com"onents inside the coc9"it during "it sto"sH

#ithout the need to involve the actual drivers.



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)e S(++, S$stem

The $I+ system is a com"uter based uman odeling tool. Itsca"abilities ma9e it an invaluable tool to designers and design teams #or9ingon "roducts that are used by "eo"le.The system offers the follo#ingadvantages:

3D analysis of fit6 reach6 vision and "osture.

reduced timescale. early in"ut of ergonomics e="ertise. ra"id interactive design. im"roved communication. cost effective ergonomics



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(utomotive Seat Design 'or

Sitting Comfort

kind of motor vehicles:

1. 8amily and "ersonal business sedan

2. inivan and off>road vehicle 3. "ort cars

Three different occupants in the vehicle:

1'Driver

2' 8ront seat "assenger

3' ear set "assengers



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(utomotive Seat Design 'or

Sitting Comfort

Criteria for a driver s seat :

1: the set should "osition the driver#ith unobstructed vision and #ithinreach of all vehicle control

2: the seat must accommodate thedriver s sie and sha"e

3: the seat should be comfortable fore=tended "eriod

4: the seat should "rovide a safeone for the driver in a crash



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#$ sould respect

,rgonomics n Design.

Safet$

afety in a race car is the art of protecting theh!man occ!pant at whatever cost to the car.Designing the car to be damaged minimallywhile hindering driver safety is definitely the

wrong approach.o how do we protect the driver? @ell first weneed to consider the basic physiological wea%

points of the h!man body.



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afety

The diagram above sho#s that "retty much any "artof the body e="osed to the chassis of the race car is atris9. In?uries occur because the body sustains im"acts

beyond the J %gravities' level that it can sustain. The brain is "articularly succe"tible to in?ury6

because it is really ?ust a soft tissue mass storedinside a very solid bone container6 the s9ull. The 9eyto avoiding in?ury in the brain is to avoidinstantaneous decelleration of the s9ull. That is6 #henthe s9ull stri9es something hard6 it decelleratesinstantaneously. The brain inside unfortunately 9ee"son moving6 causing head trauma.

0ec9 and s"inal in?uries also "resent a serious threatto life and career. These KonnectorK ty"e elementsin our body are fle=ible and stretchable6 to a "oint6and can sustain tremendous J loads before brea9ing.o#ever6 de"ending on angle of im"act6 they can

brea9 rather easily. )ther bone in?uries %brea9ages' are not as life>

threatening or career ending6 but still are to be "revented. The bones in our arms6 legs and s"ine aredesigned to be stressed in tension and com"ressionalong their length. In the case of im"acts they areoften stressed in shear or bending6 and therefore sna"relatively easily



4,

afety In rash

8irst6 the driver needs to be su""orted6 so movement undernormal driving is very limited. This means a seat #ith lateralhead su""ort6 a head rest6 and good lo#er and u""er bodylateral su""ort. ost racing seats "rovide these threeelements

econdly6 the carCs chassis needs to hold the seat and driverin "lace6 in all situations6 driving and crashing. This is ofcourse accom"lished #ith a chassis mount for the seat6 and a

5 or ( "oint harness.

Thirdly6 measures must be ta9en to "revent intrusion into orthe crushing of the driverCs limbs and e=tremities. )nformula cars6 the "roblem of sus"ension #ishbones brea9ingand "iercing the driverCs legs is solved by anti>intrusion "anels that "revent "ieces of the car from intruding into thedriverCs coc9"it. $s #ell6 the coc9"it Kafety cellK needs to be very strong. The Kafety cellK is the last "iece of material bet#een danger and the driver6 and so should be #ell

constructed6 and not "rone to colla"sing onto the driver.

8inally6 the car needs to absorb the energy via structures thatare crushable. $s stated "reviously6 the human body does notli9e to be decellerated from ; or 1;; 9m!h to ; instantly.Therefore6 #e need to find a #ay that K&uic9lyK decelleratesthe body. The only "ossibilities on a race car are thestructures #hich surround the driverCs safety cell. Designingthese structures to colla"se in an im"act ensures that Jlevels are reduced because the car is literally decellerating

over a small distance6 instead of L+) distance



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Safet$/,rgonomics

Design )ips

se energ$ absorbing materials in te collapsable crasstructure > In lo#er cost racing cars6 most of the car is usually built frommild steel. Esing that same mild steel in areas such as #ishbones means thatim"acts #ill bend the material long before it brea9s the material6 meaningenergy absor"tion ta9es "lace over a longer "eriod.

'or ligt weigt% use a stressed skin over a ligtweigtcore material > crushable ones such as the nose cone on a formula carcan be made from balsa6 honeycomb or high density styrofoam covered #ith a

stressed s9in of com"osites.

)riangulate te driver 0safet$ cell0 to prevent collapse - The safety cell can be designed in such a #ay that a catastro"hic im"act #hichcolla"ses the safety cell6 #ill ma9e the safety cell e="and a#ay from the driver6instead of colla"sing it onto the driver. In the case of a frontal im"act6 this#ould mean the sides of the coc9"it #ould e="and out#ard6 u"#ard anddo#n#ard6 instead of in#ard.



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se a clear windscreen or bod$work to increase vision > using le=anor other non>shattering clear material can hel" increase visibility #ithoutcom"romising the function of the body#or9. In some cases6 the driver can belo#ered for better J %center of gravity'6 and the normally o"a&ue body#or9re"laced #ith clear le=an6 to aid in re>establishing the vision field.

1eep te fuel cell and batter$ awa$ from te driver and danger& Mee"ing dangerous items a#ay from the driver is sometimes very difficult. Inorder to reduce the #eight balance change over a race6 designers #ill fre&uently

"ut the fuel cell at the J6 so that no matter ho# em"ty or full it is6 it does notcause a front!rear or side>to>side #eight bias. o#ever6 most drivers donCt li9eto sit ne=t to fuel. Ese secured6 sealed fire#alls bet#een the fuel cell and drivercom"artment6 and further6 use the safety cell to "rotect the fuel cell from

outside intrusions.

Don2t scrimp on safet$& Ese only to" &uality certified su""liers of safetye&ui"ment. The cost is "erha"s high6 but consider ho# much you value yourlife. 8uel cells %anctioning body certified'6 seat belts %5 or ( "oint sanctioning

body certified only'6 and driver safety #ear %0ome=6 2 or more layersminimum >> anything less is li9e #earing nothing'.

Safet$/,rgonomics

Design )ips



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Design *f S$mbols 'or

(utomobile Control and Displa$s

34 Digital metersDiscreet digital meters ma=imiefor#ard visibility and hel" create a senseof uncluttered s"aciousness.

54 )riangle-motif steering weelThe triangle>motif steering #heel hel"s

harmonie e=terior and interior design6for a feeling of unity throughout. 64 Centrall$ positioned audio panel

$ 2DI0 o"ening for audio com"onents iscentrally "ositioned at the to" of theinstrument "anel for easy access andvisibility.

74 )e8tured dasboard and console

The dashboard centre6 floor console6 andfront "illars are trimmed #ith a ne#te=tured material #ith a refined loo9 andfeel.

94 Sport$ two-tone fasciaThe s"orty t#o>tone fascia adds a touchof "ia to the @ianaCs interior.



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Dis"lays



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Dis"lays



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Dis"lays



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Dis"lays



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eading assignment

(estetics and ,ngineering Design htt":!!design.stanford.edu!-D!9base!$estheticsNandN+ngineeringNDesign."df

ntroduction of design htt":!!deed.ryerson.ca!Designcience!1.html

design basics in ) htt":!!###>3.ibm.com!ibm!easy!eouNe=t.nsf!-ublish!(

user engineering in ) htt":!!###>3.ibm.com!ibm!easy!eouNe=t.nsf!-ublish!1(

(utomotive ,rgonomics /rayan -eacoc9 7 *aldemar Maro#s9i

Sitting posture

+. Jran?in

http://design.stanford.edu/PD/kbase/Aesthetics_and_Engineering_Design.pdf

http://deed.ryerson.ca/DesignScience/1.html

http://www-3.ibm.com/ibm/easy/eou_ext.nsf/Publish/6




http://deed.ryerson.ca/DesignScience/1.html

http://design.stanford.edu/PD/kbase/Aesthetics_and_Engineering_Design.pdf



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Car Design Presentation

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