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The interior layout of passenger cars and light trucks is substantially aided by SAE occupant packaging tools, which include the SAE J941 eyellipse, SAE J287 reach curves, and the seating accommodation model in SAE J4004. Most of these tools were developed based on posture and position data from drivers, although an eyellipse and head contour are available for fixed-seat passenger positions. This paper reviews the current SAE occupant packaging tools and related industry practice in the context of current concepts for highly automated vehicles, considering SAE levels 4 and 5. Concepts that have driver controls for occasional use and vehicles with no driver controls are examined. Gaps in the current knowledge and tools are reviewed to establish priorities for research and development of new standards and recommended practices.

Driver upper-extremity postures and activities were manually coded in 9856 video frames from 165 drivers in 100 vehicles that were instrumented with interior cameras as part of the Connected Vehicle Safety Pilot Model Deployment study. Drivers had left, right, and both hands on the steering wheel in 64%, 46%, and 28%, respectively, of frames in which the hand placements could be determined. The driver’s left elbow was in contact with the door or armrest in 18% of frames, and the driver’s right elbow was contacting the center console armrest in 29% of frames. Men were more likely than women to use both the left and right armrests. Women had approximately the same percentage of armrest use across vehicles, but men’s usage differed widely, suggesting that armrest design may influence whether people of different statures can use the armrests comfortably.

A person's ability to perform a task is often limited by their ability to maintain balance. This is particularly true in lateral work performed in seated environments. For a truck driver operating the shift lever of a manual transmission, excessive shift forces can necessitate pulling on the steering wheel with the other hand to maintain balance, creating a potentially unsafe condition. An analysis of posture and balance in truck shifter operation was conducted using balance limits to define the acceptable range of shifter locations. The results are dependent on initial driver position, reach postures, and shoulder strength. The effects of shifter force direction and magnitude were explored to demonstrate the application of the analysis method. This methodology can readily be applied to other problems involving hand-force exertions in seated environments.

The potential of digital human modeling to improve the design of products and workspaces has been limited by the time-consuming manual manipulation of figures that is required to perform simulations. Moreover, the inaccuracies in posture and motion that result from manual procedures compromise the fidelity of the resulting analyses. This paper presents a new approach to the control of human figure models and the analysis of simulated tasks. The new methods are embodied in an algorithmic framework developed in the Human Motion Simulation (HUMOSIM) laboratory at the University of Michigan. The framework consists of an interconnected, hierarchical set of posture and motion modules that control aspects of human behavior, such as gaze or upper-extremity motion. Analysis modules, addressing issues such as shoulder stress and balance, are integrated into the framework.

Cyclical stepping (gait) has been studied extensively. Some of these results are reflected in the straight and curved path step-following algorithms in commercial digital human modeling (DHM) implementations. With the aid of these algorithms, DHM users define start, intermediate, and end path points and the software generates a walking-like motion along the path. Most of these algorithms have substantial limitations, among them that the figures exhibit “foot skate,” meaning that the kinematic constraint of foot contact with the ground is not respected. Turning is accomplished by pivoting the entire figure, rather than through realistic lower-extremity motions. The simulation of the non-cyclical stepping motions accompanying manual material handling pickup and delivery tasks requires manual manikin manipulation. This paper proposes a paradigm for the simulation of stepping behavior in digital human models based on a model of foot placements and motions.

A major limitation of ergonomic analyses with current digital human models (DHM) is the speed and accuracy with which they can simulate worker postures and motions. Ergonomic analysis capabilities of DHM would be significantly improved with the addition of a fast, deterministic, accurate movement simulation model for the upper extremities. This paper describes the development of an important component of such a model. Motion data from twelve men and women performing one-handed, push-button reaches in a heavy truck seat were analyzed to determine patterns of motion of the clavicle relative to the thorax. Target direction and reach distance were good predictors clavicle segment motion, particularly for fore-aft clavlcle motion.

Occupant packaging practice relies on statistical models codified in SAE practices, such as the SAE J941 eyellipse, and virtual human figure models representing individual occupants. The current packaging approach provides good solutions when the problem is relatively unconstrained, but achieving good results when many constraints are active, such as restricted headroom and sightlines, requires a more rigorous approach. Modeling driver needs using continuous models that retain the residual variance associated with performance and preference allows use of optimization methodologies developed for robust design. Together, these models and methods facilitate the consideration of multiple factors simultaneously and tradeoff studies can be performed. A case study involving the layout of the interior of a passenger car is presented, focusing on simultaneous placement of the seat and steering wheel adjustment ranges.

A new approach to driver seat-position modeling is presented. The equations of the Seating Accommodation Model (SAM) separately predict parameters of the distributions of male and female fore/aft seat position in a given vehicle. These distributions are used together to predict specific percentiles of the combined male-and-female seat-position distribution. The effects of vehicle parameters-seat height, steering-wheel-to-accelerator pedal distance, seat-cushion angle, and transmission type-are reflected in the prediction of mean seat position. The mean and standard deviation of driver population stature are included in the prediction for the mean and standard deviation of the seat-position distribution, respectively. SAM represents a new, more flexible approach to predicting fore/aft seat-position distributions for any driver population in passenger vehicles. Model performance is good, even at percentiles in the tails of the distribution.

Static deployments of driver-side airbags into the legs of human subjects were used to investigate the effects of inflator capacity, internal airbag tethering, airbag fabric, and the distance from the module on airbag-induced skin abrasion. Abrasion mechanisms were described by measurements of airbag fabric velocity and target surface pressure. Airbag fabric kinematics resulting in three distinct abrasion patterns were identified. For all cases, abrasions were found to be caused primarily by high-velocity fabric impactrather than scraping associated with lateral fabric motion. Use of higher-capacity inflators increased abrasion severity, and untethered airbags produced more severe abrasions than tethered airbags at distances greater than the length of the tether. Abrasion severity decreased as the distance increased from 225 to 450 mm. Use of a finer-weave airbag fabric in place of a coarser-weave fabric did not decrease the severity of abrasion.

In recent investigations of airbag deployments, drivers h v c reported abrasions to the face, neck, and forearms due to deploying airbags, A study of the airbag design and deployments parameters affecting the incidence and severity of abrasions caused by driver-side airbags has led to the development of a laboratory test procedure to evaluate the potential of an airbag design m cause skin injury This report describes the procedure, which is based an static deployments of airbags into a cylindrical lest fixture. The target area is covered with a material that responds to abrasion-producing events in a manner related to human skin tolerance. Test results show excellent correlation with abrasion injuries produced by airbag deployments into the skin of human volunteers.

The reach capability of drivers is currently represented in vehicle design practice in two ways. The SAE Recommended Practice J287 presents maximum reach capability surfaces for selected percentiles of a generic driving population. Driver reach is also simulated using digital human figure models. In typical applications, a family of figure models that span a large range of the target driver population with respect to body dimensions is positioned within a digital mockup of the driver's workstation. The articulated segments of the figure model are exercised to simulate reaching motions and driver capabilities are calculated from the constraints of the kinematic model. Both of these current methods for representing driver reach are substantially limited. The J287 surfaces are not configurable for population characteristics, do not provide the user with the ability to adjust accommodation percentiles, and do not provide any guidance on the difficulty of reaches that are attainable.

Vehicle motions can adversely affect the ability of a driver or occupant to quickly and accurately push control buttons located in many advanced vehicle control, navigation and communications systems. A pilot study was conducted using the U.S. Army Tank Automotive and Armaments Command (TACOM) Ride Motion Simulator (RMS) to assess the effects of vertical ride motion on the kinematics of reaching. The RMS was programmed to produce 0.5 g and 0.8 g peak-to-peak sinusoidal inputs at the seat-sitter interface over a range of frequencies. Two participants performed seated reaching tasks to locations typical of in-vehicle controls under static conditions and with single-frequency inputs between 0 and 10 Hz. The participants also held terminal reach postures during 0.5 to 32 Hz sine sweeps. Reach kinematics were recorded using a 10-camera VICON motion capture system. The effects of vertical ride motion on movement time, accuracy, and subjective responses were assessed.

Although driver-side airbag systems provide protection against serious head and chest injuries in frontal impacts, injuries produced by the airbag itself have also been reported. Most of these injuries are relatively minor, and consist primarily of skin abrasions and burns. Previous investigations have addressed the mechanisms of airbag-induced skin abrasion. In the current research, laboratory studies related to the potential for thermal burns due to high-temperature airbag exhaust gas were conducted. A laboratory apparatus was constructed to produce a 10-mm-diameter jet of hot air that was directed onto the leg skin of human volunteers in time-controlled pulses. Skin burns were produced in 70 of 183 exposures conducted using air temperatures ranging from 350 to 550°C, air velocities from 50 to 90 m/s, and exposure durations from 50 to 300 ms.

An appropriately contoured lumbar support is widely regarded as an essential component of a comfortable auto seat. A frequently stated objective for a lumbar support is to maintain the sitter's lumbar spine in a slightly extended, or lordotic, posture. Although sitters have been observed to sit with substantial lordosis in some short-duration testing, long-term postural interaction with a lumbar support has not been documented quantitatively in the automotive environment. A laboratory study was conducted to investigate driver posture with three seatback contours. Subjects† from four anthropometric groups operated an interactive laboratory driving simulator for one-hour trials. Posture data were collected by means of a sonic digitizing system. The data identify driver-selected postures over time for three lumbar support contours. An increase of 25 mm in the lumbar support prominence from a flat contour did not substantially change lumbar spine posture.

Prominent, longitudinally convex lumbar supports are frequently recommended for auto seats based on the assumption that such supports will induce sitters to choose postures with substantial lumbar lordosis. Lumbar lordosis has been associated with reduced spine loading as measured by pressure in the intervertebral disks. Data from a laboratory study of the influence of lumbar support on driving posture demonstrate that, on average, lumbar lordosis is not strongly affected by large increases in lumbar support prominence. These findings, and their implications for seat design, are reviewed.

Data from the 1990 U.S. Nationwide Personal Transportation Survey were analyzed to determine the distribution of trip durations and sitting times for use in the design of automobile seat comfort studies. Two measures relating to the incidence and prevalence of long-term sitting were calculated and presented for the U.S. population and various subgroups. The information can be used to select an appropriate test duration for comfort studies. The subgroup data allow the test duration to be tailored for specific market segments.

For many industrial tasks (push, pull, lift, carry, etc.), restrictions on grip locations and visibility constrain the hand and head positions and help to define feasible postures. In contrast, foot locations are often minimally constrained and an ergonomics analyst can choose several different stances in selecting a posture to analyze. Also, because stance can be a critical determinant of a biomechanical assessment of the work posture, the lack of a valid method for placing the feet of a manikin with respect to the task compromises the accuracy of the analysis. To address this issue, foot locations and orientations were captured in a laboratory study of sagittal plane and asymmetric manual load transfers. A pilot study with four volunteers of varying anthropometry approached a load located on one of three shelves and transferred the load to one of six shelves.

The development of a new carrier route vehicle for the U.S. Postal Service began with the design of the vehicle interior from an operator-centered perspective. A task analysis of the postal worker while driving and while performing mail-handling operations guided the layout of the vehicle interior. The Jack™ human modeling software was used, along with SAE Recommended Practices and other tools, to create a vehicle environment that will accommodate a large percentage of the operator population. The challenges of designing for this unique work environment provided a good opportunity to evaluate the relative strengths and weaknesses of the available human factors tools, including the Jack™ digital human figure model. This paper describes the development of the vehicle interior, discusses some lessons learned, and concludes with recommendations for increased functionality and improved integration of vehicle interior design tools.

This panel provided a forum for discussion of future research and development desired by users and potential users of DHM technologies. The discussion was based on the experiences of users from various sectors and industries. Panelists provided written statements and delivered short presentations prior to opening the session to audience discussion. The panel was designed to inform and drive research and development plans to fill these needs.

In many task analyses using digital human figure models, only the terminal or apparently most stressful posture is analyzed. For reaches from a seated position, this is generally the posture with the hand or hands at the target. However, depending on the characteristics of the tasks and the people performing them, analyzing only the terminal posture could be misleading. This possibility was examined using data from a study of the reaching behavior of people with spinal cord injury. Participants performed two-handed forward reaching tasks. These reaches were to three targets located in the sagittal plane. The terminal postures did not differ significantly between those with spinal cord injury and those without. However, motion analysis demonstrated that they employed distinct strategies, particularly in the initial phase of motion.