Transcript of Math based product design in cad using biomechanics for comfort in car seats
- 1. Math-based Product Design in CAD using Biomechanics for
Comfort in Car Seats ERL LLCOctober 25, 2011
- 2. Can you imagine a cardesigned without wheels for the road?2
ERL LLC 10/25/2011
- 3. Then, how are cars designed without people sitting in the
seats?3 ERL LLC10/25/2011
- 4. A feeling of seated comfort for all driversbegins with good
vision of the road; easy reach to controls; sitting in their
preferred back posture.4 ERL LLC10/25/2011
- 5. A Typical Result from the Current ProcessReal female driver
after driving a car says:Cushion- a little long, pressing against
my knees; Head rest- a little hard tomove, orientation bad; Too
close to steering wheel; Back rest lateral too low andare pushing
my arms5ERL LLC US Patents: #6,840,125, #7,047,831, #7,347,114,
#7,797,138 10/25/2011
- 6. Root causes of these problems come from anold design process
that relies upon:1.Core focus on package design without
seat;2.Subjective feedback near end of development;3.One back
posture in design process;4.One design for driving USA
interstates.6ERL LLC10/25/2011
- 7. FirstThe current design process beginswith Oscar in Design
Position; seattravel, eye position and reach are statisticalmodels
relative to Oscar in Design Position.7ERL LLC10/25/2011
- 8. ThenSafety establishes design criteria for head
restraint(FMVSS 202a) and child seat anchor latch (FMVSS 225) with
Oscar in Design Position.8 ERL LLC 10/25/2011
- 9. And SafetyStyling developsseat appearance from experience
andOscar in Design Position.9 ERL LLC10/25/2011
- 10. Safety And StylingErgonomics evaluatesreach and vision
withmath models based on Oscar in Design Position.10 ERL
LLC10/25/2011
- 11. Safety AndStylingErgonomics Seat Engineering manages seat
design with Oscar in Design Position11 ERL LLC 10/25/2011
- 12. Next Safety Supplier buildsStyling prototype seat for
Oscars Design ErgonomicsPosition and drivingSeat Eng. tests for
driver comfort.12 ERL LLC10/25/2011
- 13. LastSafetyDrivers Styling test seat nearErgonomics end of
vehicle development. Seat Eng.13 ERL LLC 10/25/2011
- 14. Solution to this design process problem:Add virtual people
to decades old Oscar system with objective, optimizedmath-based
design in CAD at start of vehicle design.14 ERL LLC 10/25/2011
- 15. Virtual people atthe beginning of vehicledevelopment will
designthe seats and evaluate effects of safety, styling, ergonomics
and seat engineering on everyones comfort!15 ERL LLC
10/25/2011
- 16. Virtual people define comfort objectively. US Patents:
#6,840,125, #7,047,831, #7,347,114, #7,797,13816 ERL
LLC10/25/2011
- 17. Safety, Styling, Ergonomics,Math model and Seat Engineering
share the math-based virtual tools for workon optimal design of the
car interior.17ERL LLCUS Patents: #6,840,125, #7,047,831,
#7,347,114, #7,797,13810/25/2011
- 18. Virtual drivers seat design model defines seating
specifications for suppliers!18ERL LLC10/25/2011
- 19. Safety, Styling, Supplier buildsMath modelErgonomics and
seat for population andSeat Engineering objective comfort tests. US
Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,13819ERL LLC
10/25/2011
- 20. US Patents: #6,840,125, #7,047,831, #7,347,114,
#7,797,138Safety, Styling, Ergonomics andSupplierReal driversMath
model Seat Engineering builds seatconfirm comfort!20 ERL
LLC10/25/2011
- 21. The current design process without drivers in the seatbegan
in the 1960s when 3D math for CAD, computers, biomechanics, and
ergonomics were in their infancy.21ERL LLC 10/25/2011
- 22. The auto culture has locked intoOscar, use of statistics,
and Departmentof Transportation Regulations with 1960s process.
Oscar (1965) US Patent #3,147,617DOT (1967)(1964)NHTSA (1970)22 ERL
LLC 10/25/2011
- 23. Today, best-in-class engineering processes rely on robust
math systems.23ERL LLC10/25/2011
- 24. Math tools available since 1980s but only ERLdesigns &
evaluates the seat, package and comfort. PackageSeat SeatComfort
Design ToolsDesign Design Evaluation Score SAE (1960s-present) YES
NoNo No JACK (1980s)YES NoNo (YES) SAFEWORK (1980s)YES NoNo (YES)
RAMSIS (1990s)YES NoNo (YES) MADYMO (1990s)NoNo(YES) No PAM Comfort
(2000s) NoNo(YES) (YES) ERL (2000s)YES YESYESYESJoint angle comfort
only.Pressure distribution evaluation only.24 ERL LLC
10/25/2011
- 25. Elements of a math-based model for use at start of vehicle
development. Virtual human body models Biomechanical seat design
model Optimization Software and CAD display Comfort score of
interior25 ERL LLC10/25/2011
- 26. Virtual human body models: Nine Small to Large drivers in
different back posturesSmall Female (>5th %)Medium Male (50th
%)Large Male (>95th %) Erect NeutralSlumped US Patents:
#6,840,125, #7,047,831, #7,347,114, #7,797,13826 ERL LLC
10/25/2011
- 27. Globally, body sizes rangefrom a small woman to a large
man.27 ERL LLC 10/25/2011
- 28. Drivers use back postures to get vision, reach and position
comfort!28 ERL LLC 10/25/2011
- 29. Globally, drivers sit more alert when driving conditions
are challenging! Erect PostureCulture & Weather US Patents:
#6,840,125, #7,047,831, #7,347,114, #7,797,13829ERL
LLC10/25/2011
- 30. Globally, drivers relax whenthe driving conditions are
easy! Slumped PostureInterstate/Autobahn US Patents: #6,840,125,
#7,047,831, #7,347,114, #7,797,13830 ERL LLC 10/25/2011
- 31. As a result, seat and package designmust fit a variety of
normal back postures. Lumbar ChestERECT US Patents: #6,840,125,
#7,047,831, #7,347,114, #7,797,138 J. S. Milne & I. J. Lauder,
Annals of Human Biology, 1974 1(3):327-337. Slumped31ERL
LLC10/25/2011
- 32. Small drivers sit upright to raise their eye heightfor good
vision but often sit too close to the airbag! Erect Neutral Slumped
US Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,13832 ERL
LLC10/25/2011
- 33. Medium sized drivers sit for comfortablereach to controls
and prefer a neutral back posture! Erect Neutral Slumped US
Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,13833 ERL
LLC10/25/2011
- 34. Large drivers often sit slumped to keep theirhead from
hitting the roof but want more leg room! Erect Neutral Slumped US
Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,13834 ERL
LLC10/25/2011
- 35. Oscar is the 10th driver andhe is used in Federal
Regulations to represent the driver for safety. Head Restraint
Measurement Device (HRMD) added for FMVSS 202a35 ERL
LLC10/25/2011
- 36. Virtual Drivers are used to design for ergonomics, comfort,
safety & Regulations! Small Female (>5th %) Medium Male
(50th %)Large Male (>95th %) ErectVision & SRS Safety
Posture & Neutral Controls FederalHeadroom &Reach
Regulations Seat TravelSlumped36 ERL LLC US Patents: #6,840,125,
#7,047,831, #7,347,114, #7,797,13810/25/2011
- 37. With the changefrom large to small energyefficient cars,
space in the vehicle must be designed for the population!37 ERL
LLC10/25/2011
- 38. As cars grow smaller, body size becomes critical. Small
Driver & Large Passenger Large Driver & Small Passenger38
ERL LLC US Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,138
10/25/2011
- 39. Biomechanical model is usedto design sitting surfaces for
all driving postures and passenger positions.39 ERL
LLC10/25/2011
- 40. Biomechanical seat design model Everyone wants same Contact
& Support in seat.CHead C ShoulderSChest C S SLumbar S
CButtocksThigh Pelvis40 ERL LLC US Patents: #6,840,125, #7,047,831,
#7,347,114, #7,797,138 10/25/2011
- 41. Everyone, worldwide, has same skeletal anatomy for
biomechanical sitting model. Chest VertebraeLumbar Vertebrae Pelvis
Reynolds, H. M., Brodeur, R. R., and Aljundi, S. SAE 2001-01- 0393:
DOI 10 4271/2001-01-0393, In: Human Factors in Automotive Design
(SP-1591). SAE, Warrendale, PA, 2001.41ERL LLC US Patents:
#6,840,125, #7,047,831, #7,347,114, # 7,797,138 10/25/2011
- 42. All ERL virtual models have seated tissue shapes to design
seat for contact & support. Seated Tissue ShapesBrodeur, R. R.
and Reynolds, H. M. SAE 2001-01-2106;DOI 100 4271/2001-01-2106,
Digital HumanModeling Conference, Washington, D.C., 200142US
Patents: #6,840,125, #7,047,831, #7,347,114, # 7,797,138
10/25/2011
- 43. Experience in engineeringcommittees manages thousands of
dimensions for driver and passenger comfort.43 ERL LLC
10/25/2011
- 44. ERL Optimization Software supports Experience Optimize
thousands of dimensions for driver & passenger!Controls Package
Seat Driver & PassengersDesign Position & Track Material
Properties (Stiffness) Population (Small to Large)SeatTravel
WindowsSeat Centerline, Insert & Wings Joint Angles
(Comfort)IP, Mirror & HeadlinerHead Restraint, Lumbar &
Cushion Length Seat (Biomechanics model)Accelerator Meat-to-Metal
& Manufacturability Controls: Contact with hand or footSteering
WheelFrame: Size, Adjusters & ReclinersVision: Downward &
Upward Sight Lines4,744 Dimensions 860 Dimensions 2,518
Dimensions44ERL LLC US Patents: #6,840,125, #7,047,831, #7,347,114,
# 7,797,13810/25/2011
- 45. Real drivers comment in market surveys but virtual drivers
explain discomfort!45 ERL LLC 10/25/2011
- 46. CAD Display ERL Comfort Viewer and ReportReal Female Driver
says:Cushion- a little long, pressing against my knees; Head rest-
a little hard to move; orientation bad; Too close to steering
wheel; Back rest lateral too low and are pushing my arms Virtual
Female Driver outputs: Cushion too long; Head restraint too close;
SW too close; Seatback wings wide; Cushion wide; Pedal too far46
ERL LLCUS Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,138
10/25/2011
- 47. With virtual driversin design at vehicle
conception,manufacturer knows comfort years before J D Powers
releases survey results.47 ERL LLC10/25/2011
- 48. Comfort Scores ERL and drivers comfort scores have high
correlation (r=0.8)SmallFullMid Mid Compact Entry Prem. Vehicle
SegmentSportSize Utility Sedan X over Utility SedanSedan
UtilityERLVirtual Score4.34.54.23.9 4.44.54.3 Small Female
3.93.53.43.4 3.63.73.6 Medium Male4.54.64.44.0 4.64.84.5 Large Male
3.64.44.13.6 3.94.44.2 Drivers Score4.04.14.13.63.9 4.53.9J D Power
APEAL4.54.3---4.34.1 4.54.4 Survey of drivers who purchased vehicle
and returned survey (5 pt scale) Drivers subjective rating average
comfort score after 2 hr. drive (5 pt scale).48 ERL
LLC10/25/2011
- 49. Comfort Score Formula Comfort (Seat + Package) Joint Angle
Penalties Seat: Cushion and Seatback Length and Height Stiffness
Support Wing Support Lumbar Support Head Restraint Packaging Line
of sight vision Track angle Seat travel Head room Joint Angles
Penalties Head/Neck angles (Head Restraint) Hip angle (Seat
Centerline Shape) Elbow & Knee angles (Controls Reach)49ERL LLC
US Patents: #6,840,125, #7,047,831, #7,347,114, #7,797,138
10/25/2011
- 50. Advantages of using virtual people in seat at start of
vehicle development: 1) Reduces time and cost of engineering
designand development; 2) Seat design fits market for global car
interior; 3) Improves customer satisfaction with vehicle.50 ERL
LLC10/25/2011
- 51. Safety Advantage for seat and driver.Comfortable Head
Restraint meets FMVSS 202a!Airbag (SRS) is not too close to small
driver! Passengers do not sit onchild seat latch anchor US Patents:
#6,840,125, #7,047,831, #7,347,114, #7,797,138(FMVSS 225)!51 ERL
LLC10/25/2011
- 52. Styling Advantage for DesignMannequin If Design Center
wishes for Dressto be responsible forDress for surface development
ofWoman seat systems on futureprograms, designers andsculptors will
need a toolto gather reliable comfortinformation and to
insureconsistent, transferablelearnings. (Quote from anMath
provides size &Automotive Industrial Designer) shape of seat
forStylistERL LLCUS Patents: #6,840,125, #7,047,831, #7,347,114,
#7,797,138 10/25/201152
- 53. Ergonomics Advantage for Driver Virtual Score:
3.4/5.0Virtual Score: 4.0/5.0 Cushion 2.7 Cushion 4.0 Seatback
3.2Seatback 3.7 Package 3.7 Package 4.3US Patents: #6,840,125,
#7,047,831, #7,347,114, #7,797,138 Current Production Vehicle
Virtual Design for Driver53 ERL LLC 10/25/2011
- 54. Seat Engineering Advantage for OEM Maximize shared use of
parts in all vehicles US Patents: #6,840,125, #7,047,831,
#7,347,114, #7,797,138300.00 Chest Patch StiffnessObjective
250.00200.00specifications for seat Force (N)150.00 Benchmark
Stiffness Lower Bound contract with suppliers100.00 50.00 Upper
Bound ERLRUN Stiffness0.00 0 5 10 15 20 25 30 35 40 45 50 55 60 65
70Displacement (mm)54 ERL LLC 10/25/2011
- 55. Financial Advantages in Expenses & Sales Greater global
acceptance of interior design. Reduce engineering design and
development time. Increase shared use of parts, Reduce seat
supplier expense (fewer iterations), Faster time to market,
Corporate memory in personnel and math,55ERL LLC 10/25/2011
- 56. Only ERL includes seat, package and comfort.PackageSeat
SeatComfort Design Tools Design Design EvaluationScore SAEYES No
NoNo RAMSIS YES No No(YES) SAFEWORK (CATIA) YES No No(YES) JACK
(UG)YES No No(YES) PAM ComfortNoNo (YES)(YES) MADYMO NoNo
(YES)NoERLYES YES YES YES Joint angle comfort only. Pressure
distribution evaluation only.56 ERL LLC 10/25/2011
- 57. Virtual drivers in the design at thestart of vehicle
development brings success. ERL LLC US Patents: #6,840,125,
#7,047,831, #7,347,114, # 7,797,13857 10/25/2011
- 58. We all sit comfortably in the car! ERL LLC US Patents:
#6,840,125, #7,047,831, #7,347,114, # 7,797,13858 10/25/2011
- 59. ERL Business Model Deliverables Interior Package Design
Interior Package Evaluation Benchmark Interior Package Evaluation
Price as negotiated for Deliverables Design & evaluation
service supplied by ERL LLC License Software & Hardware from
ERL LLC Optimizer (optimization algorithm for interior package
design) Viewer (integrated with CAD package) Stiffness measurement
tools for benchmarking Training in Optimizer (Design and
Evaluation) and Viewer59 ERL LLC10/25/2011
- 60. Thanks for your time and interest!For additional
information:Go to www.erlllc.com orContact ERL LLC at
reynolds@erlllc.com60 ERL LLC 10/25/2011