1. 1. Math-based Product Design in CAD using Biomechanics for Comfort in Car Seats ERL LLCOctober 25, 2011
2. 2. Can you imagine a cardesigned without wheels for the road?2 ERL LLC 10/25/2011
3. 3. Then, how are cars designed without people sitting in the seats?3 ERL LLC10/25/2011
4. 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. 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. 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. 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. 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. 9. And SafetyStyling developsseat appearance from experience andOscar in Design Position.9 ERL LLC10/25/2011
10. 10. Safety And StylingErgonomics evaluatesreach and vision withmath models based on Oscar in Design Position.10 ERL LLC10/25/2011
11. 11. Safety AndStylingErgonomics Seat Engineering manages seat design with Oscar in Design Position11 ERL LLC 10/25/2011
12. 12. Next Safety Supplier buildsStyling prototype seat for Oscars Design ErgonomicsPosition and drivingSeat Eng. tests for driver comfort.12 ERL LLC10/25/2011
13. 13. LastSafetyDrivers Styling test seat nearErgonomics end of vehicle development. Seat Eng.13 ERL LLC 10/25/2011
14. 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. 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. 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. 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. 18. Virtual drivers seat design model defines seating specifications for suppliers!18ERL LLC10/25/2011
19. 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. 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. 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. 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. 23. Today, best-in-class engineering processes rely on robust math systems.23ERL LLC10/25/2011
24. 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. 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. 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. 27. Globally, body sizes rangefrom a small woman to a large man.27 ERL LLC 10/25/2011
28. 28. Drivers use back postures to get vision, reach and position comfort!28 ERL LLC 10/25/2011
29. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 39. Biomechanical model is usedto design sitting surfaces for all driving postures and passenger positions.39 ERL LLC10/25/2011
40. 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. 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. 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. 43. Experience in engineeringcommittees manages thousands of dimensions for driver and passenger comfort.43 ERL LLC 10/25/2011
44. 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. 45. Real drivers comment in market surveys but virtual drivers explain discomfort!45 ERL LLC 10/25/2011
46. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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