SURFACE MODELLING ERGONOMIC EVALUATION RAPID PROTOTYPING

REPORT BY VINCENT ASHIKORDI 8 DECEMBER 2011

CONTENTS

EXECUTIVE SUMMARY SURFACE MODELLING

01 02 03 04 05 06 07 08 INSERTING REFERENCE IMAGES THE DOOR FRAME THE TYRE FRAME THE CAR BONNET THE WINDSHIELD, ROOF & BONNET THE DETAILS SURFACE CONTINUITY EVALUATION RENDERING

5 5 6 6 6 6 7 7

VIRTUAL HUMAN EVALUATION

09 10 11 12 13 14 AIM THE HUMAN SETTING THE PARAMETERS & TASKS IN JACK 6.0 SIMULATION ERGONOMIC EVALUATION SIMULATION RESULTS 9 9 9 10 10 11

RAPID PROTOTYPING
15 RAPID PROTOTYPING TO 3D PRINTER CAPACITY 13 14

CONCLUSION

EXECUTIVE SUMMARY
The project sets the task to evaluate and select appropriate computer-aided design techniques and tools for the design project herein. Lamborghini Gallardo has been selected as the car of choice of which a surface model has been produced in SolidWorks. Its design has been evaluated ergonomically with a virtual human in Jack 6.0. A defined scale model of the car has been produced via Rapid Prototyping. This report presents a detailed process through which the project objectives have been managed.

SURFACE MODELLING

01

INSERTING REFERENCE IMAGES

Figure 1 - Lamborghini Gallardo blueprint used for surface modelling in SolidWorks

The blueprint employed in the modelling of the Lamborghini Gallardo was obtained from carblueprints.com and then separated into four different elevations in Photoshop and then saved in their respective .tiff formats. Each elevation was placed on a plane as a sketch in SolidWorks using >plane>Sketch>Tools>Sketch Tools>Sketch Image and then adjusting the image properties based on the given reference dimensions.

02

THE DOOR FRAME

Figure 2 - Car frame modelling

Objective To model the door frame from a single boundary surface for surface continuity. Method Select the Right plane, select the right elevational view Select Sketch and then sketch the area around the top of the door frame starting from the bonnet to the boot of the car, adjust the spline control arms to align the splines to the corresponding lines on the reference image. Exit the sketch. Select the Top plane and sketch the same line as sketched on the Right plane applying the same methodology Exit the sketch and select the two sketches, click Features and go to the drop-down menu of the Curve tool, select Project Curve to generate the profile of both sketches in 3D space. Do the same for the other line needed to generate the boundary surface Use 3D Sketch to join the two projected curves by selecting the whole car body first Use the Boundary Surface tool to connect all the 3D lines to generate the overall surface as shown in Figure 2 Sketch the inner outlines of the door frame on the Right plane, this should be used for the windows later on Exit the sketch and then trim the unwanted surface to generate the door frame.

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THE TYRE FRAME

Figure 3 - Tyre frame modelling

The tyre frames were modelled next with the intention of producing an aspect of the extreme edge of the side of the car in 3D space to provide an anchor for 3D sketching. This was produced from a boundary surface produced on two planes (see fig. 3) then trimmed to the desired form using a sketch produced earlier on the Right plane as the trim tool.

04

THE CAR BONNET

Modelling the bonnet involved creating an extruded surface outwards from the area being modelled, this was created with the intention of producing an anchor for - a 3D sketch of the required bonnet and tangency.

Figure 4 - Car bonnet modelling

05

THE WINDSHIELD, ROOF & BOOT

Modelling these aspects of the car was made possible by mirroring the right side of the car. Both sides served as anchors for 3D sketching. The 3D sketches were made tangent to the door frames and then readjusted to the desired profiles. Boundary surfaces were created from the 3D sketch profiles and the door frames.
Figure 5 - Windshield, roof and booth modelling

06

THE DETAILS
Adding the details involved utilising the 3D Sketch tool, Trim Surface tool, making 3D sketches tangent to existing surfaces as needed, the Boundary surface tool, the Type tool and the Extruded Boss/Base tool.

Figure 6 - Car model detailing

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SURFACE CONTINUITY EVALUATION

Figure 7 - Zebra stripes showing details of surface continuity

Surface continuity evaluation was performed to check for surface tangency and alignment and if necessary, sketches or boundary surfaces that make up the surfaces were made tangent to the corresponding/continuing surfaces.

08

RENDERING

Figure 8 - Rendered view of Lamborghini Gallardo

The main options selected for the rendered visualisation in PhotoView 360 included: Courtyard background for the scene, Car paint - Black for the car body, Frosted glass for the headlights, Tinted clear glass for the windshield and windows, Textured aluminium for the radiator grills and Textured rubber for the tyres.

VIRTUAL HUMAN ERGONOMIC EVALUATION

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AIM
The major objective for undertaking the Virtual Human Ergonomic Evaluation was to test the impact that the size of the Lamborghini Gallardo would have on a 95th percentile human. As the Lamborghini Gallardo is a compact sports car designed for high performance and aerodynamic efficiency, features such as its low centre of gravity and reduced overall height to give the car more traction to the tarmac are trade-offs for interior space available to the occupant. This evaluation will test for comfortability and the impact of the low-to-ground nature of the car on the driver/occupant.

10

THE HUMAN
The human is a 95th percentile male with anthropometric data as follows: Height: 185cm (6ft 1.6in) Weight: 79kg

Figure 9 - Virtual human anthropometric data

11

SETTING THE PARAMETERS & TASKS IN JACK 6.0

The objective here was to set the scene for the evaluation, selecting the objects within the environment that would serve as actors during the simulation of the set parameters.

Figure 10 - Selecting actors in Jack 6.0

The tasks to be performed by the human in the environment would help assess how comfortable it would be for a 95th percentile man to get out of the vehicle and carry out the task of moving a tool-kit to fix any fault in the vehicle.

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SIMULATION
The simulation tasks were set in the TSB simulation environment within Jack. With the actors added, the major tasks performed by the human (Worker) for the simulation included: A series of poses set to enable the Worker position himself to get out of the car; Go task - to enable the Worker get out of the car; Get Object - to enable him get the tool-kit; Go task - to enable the Worker move the tool-kit into the car or to an area where he can repair the car; Put_Object task - to enable the Worker place the tool-kit on where it is needed.

Figure 11 - Simulation human tasks

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ERGONOMIC EVALUATION

01

02

03

04

05

06

Figure 12 - Ergonomic evaluation

01 02 03 04 05 06

Car interior space evaluation - car interior space in relation to 95th percentile body size Upper body movement in the sitting position - can the occupant move freely? Getting out of the car evaluation - how possible is it? Get tool-kit to perform task inside or outside the car Moving object into the car evaluation - how difficult is it considering the workers height? Bending down low to perform task on a low-to-ground car evaluation - what are the implications for the worker?

10

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SIMULATION RESULTS

INTERPRETATION
The results show that the low back compression of 1074N is below the NIOSH Back Compression Action Limit of 3400N. It represents a nominal risk of low back injury. All other forces are very minimal with Internal Oblique tension more profound than the other muscle tensions.

Figure 13 - Getting out of the car simulation results

INTERPRETATION
Here, the results show that the low back compression of 2702N is still below the NIOSH Back Compression Action Limit of 3400N. It represents a nominal risk of low back injury for most healthy workers. Figure 14 - Bending down low to carry out task on a low-to-ground vehicle simulation results Figure 15 - Comfort range simulation results

GETTING OUT OF THE CAR COMFORT RANGE Key:

Green: within comfort range Yellow: out of comfort range

BENDING DOWN LOW COMFORT RANGE

CONCLUSION The results indicate that for a 95th percentile man, the experience of driving the car comfortably or carrying out tasks inside or outside the car would be compromised by his size and the overall size of the car. 11

RAPID PROTOTYPING

15

RAPID PROTOTYPING TO 3D PRINTER CAPACITY

Figure 16 - Rapid prototyping process

In order to get a 3D printing outcome that was more defined for better aerodynamic efficiency and easier for the 3D printer to cope with, another surface model was made in SolidWorks and then exported as a .stl file (this time reducing the model to its main features). The 3D printer capacity required the model to be split into two equal halves and then joined together after printing. All surfaces were knit to ensure there were no gaps in the model. The model was scaled down to the ratio 1:29. The car body and the tyres were rapid prototyped separately and then assembled after manufacture.

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CONCLUSION

The project has provided an opportunity to understand and apply the various computer-aided design methods utilised in design and manufacture. Modelling a car in SolidWorks provided an in-depth understanding of parametric surface modelling and the relationships that exist between the different surfaces that make up the outer structures of complex shapes. Modelling complex shapes via parametric surface modelling requires a methodical approach and must be undertaken with the final outcome in mind as mistakes made later in the modelling process could affect earlier features. Carrying out virtual human ergonomic evaluation in Jack 6.0 provides opportunities to evaluate the ergonomic performance of a given design in a virtual environment prior to user testing and manufacture saving time and costs in the design process. The whole process highlighted the need to understand ergonomic and manufacturing constraints early on in the design process. This is imperative for a well streamlined design and manufacturing process and cost-effective design outcome.

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