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Efficient methods for simulating operators performing part handling tasks in manufacturing plants are needed. The simulation of part handling motions is an important step towards the implementation of virtual manufacturing for the purpose of improving worker productivity and reducing injuries in the workplace. However, industrial assembly tasks are often complex and involve multiple interactions between workers and their environment. The purpose of this paper is to present a series of industrial simulations using the Human Motion Simulation Framework developed at the University of Michigan. Three automotive assembly operations spanning scenarios, such as small and large parts, tool use, walking, re-grasping, reaching inside a vehicle, etc. were selected.

Assessments of reach capability using human figure models are commonly performed by exercising each joint of a kinematic chain, terminating in the hand, through the associated ranges of motion. The result is a reach envelope determined entirely by the segment lengths, joint degrees of freedom, and joint ranges of motion. In this paper, the validity of this approach is assessed by comparing the reach envelopes obtained by this method to those obtained in a laboratory study of men and women. Figures were created in the Jack human modeling software to represent the kinematic linkages of participants in the laboratory study. Maximum reach was predicted using the software's kinematic reach-envelope generation methods and by interactive manipulation. Predictions were compared to maximum reach envelopes obtained experimentally. The findings indicate that several changes to the normal procedures for obtaining maximum reach envelopes for seated tasks are needed.

This paper describes the design and development of a family of surrogate child restraints that are intended for use in developing and testing occupant sensing and classification systems. Detailed measurements were made of the geometry and mass distribution characteristics of 34 commercial child restraints, including infant restraints, convertibles, combination restraints, and boosters. The restraints were installed in three test seats with appropriately sized crash dummies to obtain data on seat-surface pressure patterns and the position and orientation of the restraint with belt loading. The data were used to construct two surrogates with removable components. The convertible surrogate can be used to represent a rear-facing infant restraint with or without a base, a rear-facing convertible, or a forward-facing convertible. The booster surrogate can represent a high-back belt-positioning booster, a backless booster, or a forward-facing-only restraint with a five-point harness.

Current anthropomorphic test device (ATD) positioning procedures for drivers and front-seat passengers place the crash dummy within the vehicle by reference to the seat track. Midsize-male ATDs are placed at the center of the fore-aft seat track adjustment range, while small-female and large-male ATDs are placed at the front and rear of the seat track, respectively. Research on occupant positioning at UMTRI led to the development of a new ATD positioning procedure that places the ATDs at positions more representative of the driving positions of people who match the ATD's body dimensions. This paper presents a revised version of the UMTRI ATD positioning procedure. The changes to the procedure improve the ease and repeatability of ATD positioning while preserving the accuracy of the resulting ATD positions with respect to the driving positions of people matching the ATD anthropometry.

Workstation design is one of the most essential components of proactive ergonomics, and digital human models have gained increasing popularity in the analysis and design of current and future workstations (Chaffin 2001). Using digital human technology, it is possible to simulate interactions between humans and current or planned workstations, and conduct quantitative ergonomic analyses based on realistic human postures and motions. Motion capture has served as the primary means by which to acquire and visualize human motions in a digital environment. However, motion capture only provides motions for a specific person performing specific tasks. Albeit useful, at best this allows for the analysis of current or mocked-up workstations only. The ability to subsequently modify these motions is required to efficiently evaluate alternative design possibilities and thus improve design layouts.

Most human figure models used in ergonomic analyses present postural comfort ratings based on joint angles, and present a single comfort score for the whole body or on a joint-by-joint basis. The source data for these ratings is generally derived from laboratory studies that link posture to ratings. Lacking in many of these models is a thorough treatment of the distribution of ratings for the population of users. Information about ratings distributions is necessary to make cost-effective tradeoffs when design changes affect subjective responses. This paper presents experimental and analytic methods used to develop distribution models for incorporating subjective rating data in ergonomic assessments.

Effective application of human figure models to truck interior design requires accurate data on the postures and positions of truck drivers. Errors in positioning of figure models propagate to errors in reach, visibility, and other analyses. This paper describes methods used in a recent study to measure in-vehicle driving postures in Class 6, 7, and 8 trucks. A three-dimensional coordinate measurement machine was used to measure body landmark locations after a driver completed a short road course. The data were used to validate posture-prediction models developed in a previous laboratory study. Vehicle calibration, driver selection, and testing methods are reviewed.

As part of the Automotive Seat and Package Evaluation and Comparison Tools (ASPECT) program, UMTRI researchers developed a new H-point manikin that is intended to replace the current SAE J826 manikin. The original manikin is used in many automotive applications, including as a platform for a belt-fit test device (BTD). In the current project, components and procedures were developed to measure belt fit using the ASPECT manikin. Contoured lap and torso forms were constructed using anthropometric data from an earlier UMTRI study. Prototype forms were mounted on the ASPECT manikin for testing in a laboratory fixture and in vehicles. The testing demonstrated that the ASPECT-BTD produces consistent measures of belt fit that vary in expected ways with belt geometry.

Improvements in the accessibility and ease of use of seatbelts require an understanding of driver belt donning behavior. Participants in a study of driving posture were videotaped as they put on their belts in their own vehicles, either an SUV or a midsize sedan. The participants were unaware that the purpose of the videotaping was related to the seatbelt. Videos from 95 men and women were analyzed to identify several categories of belt-donning behavior and to analyze the influence of body dimensions. The results have applicability to seatbelt system design, including the use of human figure models to assess seatbelt accessibility.

As passenger car use becomes more common in developing countries, the number of child passengers killed and injuries also increases. Rates of child restraint use appear to be much lower in developing countries than in the U.S. or Europe. One barrier to increased restraint use is the relatively high cost of child restraints in low- and middle-income countries, where the cost of child restraints can be similar to the U.S. but incomes and typical vehicle prices are much lower. As part of a broader effort to improve child passenger safety worldwide, a team at the University of Michigan has begun development of a child restraint that is intended to be fabricated using low-cost technology in developing countries with minimal capital investment. Providing a design that has been tested successfully to regulatory standards may reduce barriers to entry and allow the restraints to be marketed at low prices.

Federal Motor Vehicle Safety Standard (FMVSS) 213 specifies a bench seat that is used in dynamic testing of child restraint systems. To assess the representativeness of the FMVSS 213 bench, data from 54 passenger cars, minivans, and SUVs were analyzed to quantify the side-view profile of the seat centerlines in second-row, outboard seats. SAE J826 H-point measurements were performed on all seats and on the FMVSS 213 bench. A landmark-based resampling method was used to obtain a meaningful average seat contour after aligning on H-point. Principal component analysis and regression were conducted to quantify the effects of seat cushion angle, cushion length, and back angle on the seat profile. When aligned on H-point, the cushion length and surface angles of the FMVSS 213 bench were similar to the mean contour, except that no seats were as flat as the bench profile.

Reliable, accurate data on vehicle occupant characteristics could be used to personalize the occupant experience, potentially improving both satisfaction and safety. Recent improvements in 3D camera technology and increased use of cameras in vehicles offer the capability to effectively capture data on vehicle occupant characteristics, including size, shape, posture, and position. In previous work, the body dimensions of standing individuals were reliably estimated by fitting a statistical body shape model (SBSM) to data from a consumer-grade depth camera (Microsoft Kinect). In the current study, the methodology was extended to consider seated vehicle occupants. The SBSM used in this work was developed using laser scan data gathered from 147 children with stature ranging from 100 to 160 cm and BMI from 12 to 27 kg/m2 in various sitting postures.

Automotive seats are commonly described by one-dimensional measurements, including those documented in SAE J2732. However, 1-D measurements provide minimal information on seat shape. The goal of this work was to develop a statistical framework to analyze and model the surface shapes of seats by using techniques similar to those that have been used for modeling human body shapes. The 3-D contour of twelve driver seats of a pickup truck and sedans were scanned and aligned, and 408 landmarks were identified using a semi-automatic process. A template mesh of 18,306 vertices was morphed to match the scan at the landmark positions, and the remaining nodes were automatically adjusted to match the scanned surface. A principal component (PC) analysis was performed on the resulting homologous meshes. Each seat was uniquely represented by a set of PC scores; 10 PC scores explained 95% of the total variance. This new shape description has many applications.

This paper reports on the development and validation of an automated seat-dimension extraction system that can efficiently and reliably measure SAE J2732 (2008) seat dimensions from 3D seat scan data. The automated dimension-extraction process consists of four phases: (1) import 3D seat scan data along with seat reference information such as H-point location, back and cushion angles, (2) calculate centerline and lateral cross-section lines on the imported 3D seat scan data, (3) identify landmarks on the centerline and cross-section lines based on the SAE J2732 definitions, and (4) measure seat-dimensions using the identified landmarks. To validate the automated seat measurements, manually measured dimensions in a computer-aided-design (CAD) environment and automatically extracted ones in the current system were compared in terms of mean discrepancy and intra- and inter-observer standard deviations (SD).

Current finite element (FE) human body models (HBMs) generally only represent young and mid-size male occupants and do not account for body shape and composition variations among the population. Because it generally takes several years to build a whole-body HBM, a method to rapidly develop HBMs with a wide range of human attributes (size, age, obesity level, etc.) is critically needed. Therefore, the objective of this study was to evaluate the feasibility of using a mesh morphing method to rapidly generate skeleton and whole-body HBMs based on statistical geometry targets developed previously. THUMS V4.01 mid-size male model jointly developed by Toyota Motor Corporation and Toyota Central R&D Labs was used in this study as the baseline HBM to be morphed. Radial basis function (RBF) was used to morph the baseline model into the target geometries.

Law enforcement officers (LEO) make extensive use of vehicles to perform their jobs, often spending large portions of a shift behind the wheel. Few LEO vehicles are purpose-built; the vast majority are modified civilian vehicles. Data from the field indicate that LEO suffer from relatively high levels musculoskeletal injury that may be due in part to poor accommodation provided by their vehicles. LEO are also exposed to elevated crash injury risk, which may be exacerbated by a compromise in the performance of the occupant restraint systems due to body-borne equipment. A pilot study was conducted to demonstrate the application of three-dimensional anthropometric scanning and measurement technology to address critical concerns related to vehicle design. Detailed posture and belt fit data were gathered from five law enforcement officers as they sat in the patrol vehicles that they regularly used and in a mockup of a mid-sized vehicle.

Among all the vehicle rollover test procedures, the SAE J2114 dolly rollover test is the most widely used. However, it requires the test vehicle to be seated on a dolly with a 23° initial angle, which makes it difficult to test a vehicle over 5,000 kg without a dolly design change, and repeatability is often a concern. In the current study, we developed and implemented a new dynamic rollover test methodology that can be used for evaluating crashworthiness and occupant protection without requiring an initial vehicle angle. To do that, a custom cart was designed to carry the test vehicle laterally down a track. The cart incorporates two ramps under the testing vehicle’s trailing-side tires. In a test, the cart with the vehicle travels at the desired test speed and is stopped by a track-mounted curb.

Seat fit is characterized by the spatial relationship between the seat and the vehicle occupant’s body. Seat surface pressure distribution is one of the best available quantitative measures of this relationship. However, the relationships between sitter attributes, pressure, and seat fit have not been well established. The objective of this study is to model seat pressure distribution as a function of the dimensions of the seat and the occupant’s body. A laboratory study was conducted using 12 production driver seats from passenger vehicles and light trucks. Thirty-eight men and women sat in each seat in a driving mockup. Seat surface pressure distribution was measured on the seatback and cushion. Relevant anthropometric dimensions were recorded for each participant and standardized dimensions based on SAE J2732 (2008) were acquired for each test seat.

Digital human models (DHM) are now widely used to assess worker tasks as part of manufacturing simulation. With current DHM software, the simulation engineer or ergonomist usually makes a manual estimate of the likely worker standing location with respect to the work task. In a small number of cases, the worker standing location is determined through physical testing with one or a few workers. Motion capture technology is sometimes used to aid in quantitative analysis of the resulting posture. Previous research has demonstrated the sensitivity of work task assessment using DHM to the accuracy of the posture prediction. This paper expands on that work by demonstrating the need for a method and model to accurately predict worker standing location. The effect of standing location on work task posture and the resulting assessment is documented through three case studies using the Siemens Jack DHM software.

The objective of this study was to optimize the occupant restraint systems for a light tactical vehicle in frontal crashes. A combination of sled testing and computational modeling were performed to find the optimal seatbelt and airbag designs for protecting occupants represented by three size of ATDs and two military gear configurations. This study started with 20 sled frontal crash tests to setup the baseline performance of existing seatbelts, which have been presented previously; followed by parametric computational simulations to find the best combinations of seatbelt and airbag designs for different sizes of ATDs and military gear configurations involving both driver and passengers. Then 12 sled tests were conducted with the simulation-recommended restraint designs. The test results were further used to validate the models. Another series of computational simulations and 4 sled tests were performed to fine-tune the optimal restraint design solutions.