Unit-2

Shaping and Packaging

Product Design
Product design is the process of creating a new product to be sold by a
business to its customers. A very broad concept, it is essentially the efficient and
effective generation and development of ideas through a process that leads to
new products.
The product designer's role is to combine art, science, and technology to create
new products that other people can use.
A drawing of an automotive body has some aspects and features that make it
different from those of other industrial products, deriving not only from its
technical characteristics and production technology, but also from the aesthetic
appearance of its shape which plays a fundamental role in determining the
commercial success of a car.
Body drawings should be available sufficiently in advance with respect to the
start of production
Simultaneous engineering or concurrent engineering provides a means for
organizing each elementary operation in such a way so as to produce results
consistent with the need to initiate the related successive operations with
minimum delay.

Product Design Methods and Strategies

Design criteria differ by system, although vehicle cost has
substantial influence currently
For body panels, the three most influential design criteria currently are
aesthetics, ease of manufacture, and vehicle cost.
For chassis and suspension, the most influential criteria currently are
performance, safety, and vehicle cost. But now ease of manufacture
joins these, and recyclability and standardized design show the largest
increase.
For engines and transmissions, the most influential criteria for both the
present and future include performance, meeting government
regulations, and vehicle cost. Recyclability might influence latter.
For interiors; safety, aesthetics, vehicle cost and ease of assembly and
manufacture.
For HVAC; performance, packaging constraints

Concept Design

Concept Attributes for coupe

Stages of Product Design and Development

Development process

Computers in Development
processes
Today an overall development time in the order of 24months, from style model
choice to start of production, represents the best performance level achieved
by major car manufacturers, although this is only possible thanks to the wide
ranging application of computers regularly utilized for:
Computer Aided Styling (CAS) applied to develop visible shapes.
Computer Aided Drafting (CAD) applied to engineering activities related to
final product or production tools.
Computer Aided Manufacturing (CAM) applied to the design of some aspects
of the production process.
Digital Mock-Up (DMU) applied to represent complex assemblies for virtual
testing or develop production and assembly plant lay-out.

Computer Aided Styling

When a new model development is started, a series of
general vehicle specifications are defined, essentially
consisting in the following information:
The type of car, market segment and expected production
volumes.
Relevant exterior and interior dimensions.
Engines, gearboxes and tires to be adopted.
Parts to be carried-over from previously developed models.
Manufacturing and assembling technologies to be adopted
in connection with the production plant selected.
Performance and cost targets.

There are two different phases in styling of an automobile or surface

development :
1. Form Generation
2. Mathematical Model Generation
Form Generation:
. Style development is a balanced mix of intuition and scientific
approach, where the success of the development process requires an
appropriate equilibrium between creative and structured activities.
. These sketches do not have all the characteristics required for an
objective representation, but rather represent the idea as interpreted
by the designer.

Free Hand Sketching

Mathematical Model
Generation

A CAD mathematical model usually

enables the effective evaluation of the car
exterior shape, using for instance virtual
reality.
Nevertheless, improvements in these
systems are still necessary to allow each
person involved in decisions regarding the
appearance of the car to be familiar with
them.
This is why physical models are still in use
to confirm decisions taken on virtual
models. Sometimes direct viewing, and the
sense of touch on a full scale object, are
useful to perceive the correct impression.

CAD (Computer Aided Design/Drafting)

Computer-aided design/drafting (CAD) is the use of computer systems to assist in
the creation, modification, analysis, or optimization of a design.
There are different techniques resembling CAD Model
1. Wire Frame Model: Wire frame models are 3 D models where solid bodies are
represented by spatial curves describing their edges; between one curve and
the next, the surface shape is unknown and must be interpolated.
2. Surface Models: A surface model is again a 3 D model where a part is described
through its contour surfaces; the coordinates of each points are fully
determined.
3. Solid Models: A solid model includes a complete description of the space
included between the boundaries of the model and can represent every detail of
a part, including its physical properties such as mass, moments of inertia, etc.
4. Conventional Drawing: A conventional drawing is a paper print-out, similar to a
pencil drawing, used for communication only and unsuitable for further
development.

Body Modelling
Break down structure definition: The first step is the definition of
technological and design solutions that will be adopted for the body
under development. To shorten development times, including modelling,
virtual and physical validation, solutions are preferred that have already
been applied on other cars.
Definition of main sections: According to the selected archetype,
including the breakdown structure, architecture, material, applicable
forming and assembling technologies, characteristic cross sections of the
skeleton are defined.

Modelling of exterior panels: Once a number of sections have been

positioned and sized in sufficient quantity to define the body shell critical
areas, engineers proceed with modelling the remaining body shell parts,
doors, hood, etc. Critical areas usually include the structural skeleton and
doors hinges.
The upper beam to be modelled is logically connected to the aesthetic
surface (it is associated with the surface) and its size is defined by the
measurements as a function of a limited number of fundamental
dimensions.

Detailed analysis of junctions: When structural beam elements of the

body are modelled, the junctions at beam intersections can be defined in
detail. To designate these junctions, a standard nomenclature has been
defined.

Consider, for instance, junction A, at the intersection of body side with

windshield
and roof:
The components of the body shell involved are the roof, upper
windshield cross member, exterior body side, A pillar cross section and
reinforcement member.
The eyelet surrounded by a dotted line allows access to the electrode of
the welding tool from the inside of the body and therefore makes the
junction between roof and body side possible.

Test Validation
Once the body has been defined, including doors, hood, hatch and
removable parts, together with all detail interfacing body components
(such as weather strips, locks, hinges, etc.), a complete 3 D model is
available that can be easily tested with respect to different
perspectives.
Each virtual test will result in modifications for surfaces or sections; with
a parametric associative CAD system, each will be implemented in a
very short time, sometimes automatically, and transferred also to
associated entities such as stamps, assembly fixtures or other
dedicated production tools.
Again, using dedicated software tools, mathematical modelling enables
investigation into the effect of dimension variations on the assembling
process and compatibility with product performance.

Clay Modelling of prototype

Aesthetics
The term 'aesthetics' concerns our senses and our
responses to an object.
Aesthetics of automobile include:
1. Outer body components and styling
2. Windshield and wiper
3. Lightening and signalling
4. Interiors
5. Seats
6. Dash board design

Outer Body components

1. Bumpers
Today most production vehicles have plastic
bumpers painted in the same colour as the body
metal painted or plastic coated bars are used in
cheap cars, chromatic body linings and grills are
used.
Bumper shapes, gaps, colour and roughness are
specified by the styling centre. Skin radius must
comply with regulation limit >2.5mm or >5mm.
Even the plastic blend used to mould bumper should
have appropriate colour.
Apart from aesthetics it should have energy
absorption, friendly contact in case of pedestrian
impact, aerodynamics and supporting hooks to hold
or toe the car.

Grills
The main technical goal for a radiator grille is air
flow control through an adequate intake duct,
between the radiator grille and radiators
Size of grills, mesh style are defined by the
styling team and it is verified by having
aerodynamics and thermal analysis.

Sill Covers and spoilers

The main purpose being to protect the lower
body side (rocker panels and doors) from
corrosion caused by abrasion due to stones, salt
and mud projected from the wheels.
The most used thermoplastics are blend of
Polycarbonate and ABS.
Position and type of fasteners used, amount of
surface covered.

Sill covers and spoilers

Windshield and wiper

Windshields are usually made of two annealed glass panes of same or
two different thickness, with inserted thermoplastic layer.
Dimensions of this is varied with the styling of the car, it differs with
hatch, sedan MPV and SUV.
It is designed according to the aerodynamics and visibility of the
vehicle. Style completely depends on aerodynamics and visibility.
Rear windshield is also differs with type and reversing visibility angles.

Wipers
It doesn't have a huge impact on aesthetics and only rear wiper has a
bit impact as it helps in reducing visibility problems.

Lightening and signalling

Seats

Dashboard
Since the dashboard is noticed immediately after opening the door and
entering the car, it becomes the key element in the aesthetic
judgement, important in determining the rating of the vehicle;
furthermore, while driving, the dashboard is the primary interface
between the driver and the vehicle.
Ergonomic function, consisting, for instance, in the easy operation of
the controls located on the dashboard and, to see correctly the
instruments on the dashboard.

Ergonomics

Ergonomics
Ergonomics is applied to car body design with the aim of reducing the effort
required by the driver and passengers in the different conditions particularly as
regards driving the vehicle.
The important role of ergonomics in the safety of the vehicle justifies the presence
of regulations concerning related issues in different countries.
The first task is to define the positions of the occupants inside the vehicle which is
usually chosen in order to obtain a good compromise in terms:
Optimizing postural comfort,
Allowing easy access to the commands (steering wheel, pedals, gear shift
lever,...)
Reducing the effort to get in and out of the vehicle
Guaranteeing appropriate location of the powertrain and other mechanical subsystems without compromising the space given to the occupants inside the
vehicle too severely,
Respecting standard regulations concerning direct and indirect visibility.

Anthropometry
Its the scientific study of the measurements and
proportions of the human body.

Percentile in Anthropometry
To define the size of an occupant, or a human body parts, it is usual to
introduce the concept of percentile.
A given anthropometric measure (l) correspond to a percentile x (and
indicated as lxth) when a fraction equal to the percentile of the
population does not exceed that measure: i.e. l < lxth.
For example, the height corresponding to the 95th percentile is the
height that is not exceeded by 95% of the population taken into
account in the study.

Basic Postures

Reclined

Advantages:
Possibility to resist large vertical accelerations since most of the load is
supported by the seat. Reduced load on the blood circulation system.

Disadvantages:
Reduced visibility: after a time, the considerable effort on the neck to
maintain the upright position prevents free rotation of the head, thus
introducing serious limitations on the direct field of view.
Reduced accessibility to the commands: the stretched position of the
arms requires effort and reduces the amount of torque that can be
applied to the steering wheel.

Seated
Advantages:
Visibility: relative to the reclined position the neck directly supports the
head in upright position.
Accessibility: the torque that can be produced by the driver when the
steering wheel axis is almost vertical is the highest compared with
other positions, the accessibility to other commands such as the
gearshift and switches is better than in other postures.

Disadvantages:
Reduced capability to resist to vertical accelerations

Cramped
Very uncomfortable posture which can be maintained for only a
short duration.
Reduced capability to resist to vertical accelerations: The limited
curvature of the backbone induced by the position of the legs
increases the loads on the lumbar segment.
Accessibility: it is almost impossible to maneuver conventional
commands such as the steering wheel and pedals, while getting
in and out of the vehicle is highly uncomfortable

Interior Packaging
Front Row - Drivers Position

 As the pedals are one of the main interfaces between the driver and
the vehicle, the posture must be compatible with it, and its operation.
Once the anthropometric dimensions of the front and rear passengers
have been decided (in terms of percentiles), the interior packaging
usually starts with positioning the drivers right foot acting on the
accelerator pedal.
The contact point of the heel with the depressed floor is indicated as
AHP (accelerator heel point), it constitutes one of the milestones of
the interior and body design.
The rest of the driver posture can then be defined considering the
angles between body segments that allow a good postural comfort.

Steering Wheel
The steering wheel must be located in a region of easy accessibility, its position
can be evaluated to first approximation by considering the following hints:
The distance between the lower edge of the steering wheel rim to the centre
line of the brake pedal face, with the pedal in the undepressed position (L331,
SAE J1100 ) is about 650660 mm.
The angle between the vertical and the steering wheel plane (H18 SAE
J1100 ) depends on the type of posture: In seated positions (angle 9.3 or
L40 9.11 <15 deg) H18 40 deg, for 15 < < 20 deg H18 30 to 35 deg, for
more reclined positions (angle > 20 deg) it reduces to about H18 20 to 30
deg.
The maximum diameter of the steering wheel (W9 SAE J1100 ) is about 340
to 360 mm, with a diameter of the rim of about 30 mm.
The lower corner of the steering wheel should be sufficiently above the knee
to avoid interference during emergency braking and when during getting in
and out of the vehicle.

Seat Characteristics
The aspects that should be taken into account in static conditions (when the vehicle is
stationary) are:
the support to the body to maintain the driving posture at the desired optimal
configuration;
the perceived contact stiffness on the different contact surfaces.
the lateral support;
the adjustment possibilities and the effectiveness of the commands that act on them;
the tactile quality of the surface;
the style.

Instead, when in motion, the most important factors include:

the capability to attenuate the vibrations transmitted to the occupant;
the capability to maintain a good posture of the backbone and avoid excessive
stresses that could be harmful in the long term;
the distribution of the contact pressure.

Factors Considered for seat design

Body Size: At least 90th percentile is considered
Position of the body: Its depends on the AHP, HP and
BOF
Vibration and ride comfort
Geometric features

AHP: SAE standard J1100 refers it is as a point on the drivers shoes located at
intersection of heel and shoe and depressed to the floor of the vehicle.
Pedal Plane angle A47: It is defined as the angle of the accelerator pedal plane
in the side view measured in the degrees from the horizontal.
Ball of Foot: It is located on the 200mm of the AHP when it is measure along the
pedal plane.
Pedal Reference Point: It is on the accelerator pedal where BOF contacts the
pedal SAEJ4004 provides a procedure for locating it.
Seating Reference Point: It is a location of special hip point designated by the
manufactures as a key reference point to define seating location for each
designated seating position.

Entrance Height
It is the vertical distance from the drivers SgRP to the
upper trimmed body opening. This dimension is used to
evaluate head clearance as the driver enters the
vehicle.

Head Room

Effective head room is a distance along a line 8 degrees

from SgRP to the headline plus 102mm (to account for
SgRP to the bottom of the pelvic distance).

Leg Room

It is a max line along the line from the ankle pivot

centre to farthest H-point in travel path, plus 254mm.

Knee clearance
It is the min distance from the right leg k-point and
nearest interference , minus 51mm measured in side
view.

Thigh Room:
It is the min distance from the bottom of steering wheel
rim to thigh line

Ingress and Egress

CV/ Truck Ergonomic problems

Truck drivers often spend very long hours seated in the
cabin of the vehicle. This is their workstation.
For them to carry out their work tasks in a way that
minimizes the risk of crashes and injuries, a workstation
that offers optimal comfort, visibility and functionality is
needed.
While there have been some improvements in
ergonomic design of vehicle driver cabins, truck and bus
drivers are still experiencing lower back pains/injuries
(disproportional to other workers), discomfort with
safety belt use (often resulting in non-use), poor
visibility around the vehicle, lack of readily accessible
devices and objects in vehicle, and unsafe access to and
egress from the vehicle.

CV/ Truck Ergonomics

Primary work zone - The distance from elbow to hand. This
zone includes things those one touches on a daily basis.
Secondary work zone - Within arms reach. This zone is used to
position those items those one uses frequently, but not all the
time.
Reference zone - Outside of arms reach. This zone is use for
least used items

COE Design Interior

City Truck Cabin Interior

Cab Interior Layout

Sitting positions

The manikin, that was chosen for the

analysis is of 50th percentile. The data those were
considered are of Indian anthropometric data

Vision Analysis

The figure shows the binocular vision of a truck driver. The middle zone represents the
line of sight. It is clear from the analysis that the instrument panel and the rear view
mirror are within the line of sight of driver.

Reach Analysis

A reach envelope is a three dimensional surface that represents all the

possible positions of the required features the manikin can reach using
only the arm and forearm.
The reach envelop indicates that the right hand of driver can reach all
the controls on the door and switches on the right side of dash board.
The reach envelop indicates that the left hand of driver can reach all
the controls such as AC control panel, audio system, mobile, cup
holder, gear etc.
At the time of designing the interior, the focus was kept on the
positioning of the features, fabrics, colour combination, feature colour
based on their functionality.

CV/ Truck details and dimesions

Truck configurations

 A tractor semi-trailer while being used to transport poles, pipe or

material that cannot be dismembered must not exceed a length of 25
m.
A tractor semi-trailer designed and being used as an auto carrier must
not exceed a length of 23 m when not loaded and 25 m when loaded.
The load of a tractor semi-trailer designed and being used as an auto
carrier that overhangs the front or rear of the tractor semi-trailer must
not have an overall width that exceeds 2.1 m.
A tractor semi-trailer designed and being used as an auto carrier must
not have an overall height that exceeds 4.15 m when not loaded and
4.30 m when loaded. The driver must ensure there is a safe clearance
under any physical overpass, including structures and utility lines.
A tractor wheelbase can be up to a maximum of 7.2 m, if the
wheelbase of the semi-trailer is not greater than the wheelbase as set
out in Schedule A-1.
The minimum wheelbase for a semi-trailer, model year 2002 or earlier,
is 3.75 m.
A tractor semi-trailer designed and being used as an auto carrier must