bmw motorade- internship training report munic bmw

UniversidadeFederaldeSantaCatarinaCentroTecnolgico

DepartamentodeEngenhariaMecnicaCoordenadoriadeEstgiodoCursodeEngenhariaMecnica

CEP88040970FlorianpolisSCBRASILwww.emc.ufsc.br/estagiomecanica

[email protected]

INTERNSHIPREPORT2/3ActivitiesdevelopedintheBodyVehicledepartment

BMWMotorcycleDevelopmentCenter03/04/2009to03/06/2009

BMWMotorradA.G.

Thisreportcontainsconfidentialinformationandprotectedfromdisclosure.Itmustbeusedonlyforthepurposeofevaluatingthestudent.

Student:ThiagoSchimmelpfennigBMWTutor:Dipl.Ing.HansWolfmllerUFSCTutor:Prof.Dr.Ing.LauroCsarNicolazzi

MunichGermany,June8th2009

InternshipReportThiagoSchimmelpfennigBMWMotorradProductDevelopmentUXEK1Page2of201. Introduction

ThisreportpresentstheactivitiesdevelopedbytheacademicThiagoSchimmelpfennigduring

his period of practical training at BMWs Research and Innovation Center inMunich,Germany. Theinternship takes place in theMotorcyclesDevelopmentDepartment, in the division of Body VehicleEngineeringUXEK1.

In summary, the second twomonthsof the internship involved theworkwithprojectanddevelopment of Motorcycles Seats. The activities included studies of ergonomics, tests andmeasurement of components, brainstorming of new solutions and 3Dmodeling of components andsurfaceswiththesoftwareCATIAV5.

Forabetterunderstandingoftheinternshipactivities,thisreportisdividedintothreemainsections.Thefirstsectionwillprovideabackgroundabouttheimportanttopicsfortheconstructionofseatstructures.Thesecondsectionisadetailedstudyofseatsofdifferentmotorcycles.Abriefsectionattheenddisclosesabouttheelaborationofanewconceptforamotorcycleseat.

InternshipReportThiagoSchimmelpfennigBMWMotorradProductDevelopmentUXEK1Page3of202. Index1. Introduction................................................................................................................................22. Index............................................................................................................................................33. Indexofpictures.........................................................................................................................44. Indexoftables.............................................................................................................................45. Importanttopicsforseatsdevelopment....................................................................................55.1. Vehiclepositionoftheseat...................................................................................................55.2. Seatsurface............................................................................................................................65.2.1. Thepressuredistributionduetothehumanbodystructure........................................65.2.2. Theseatingposition.......................................................................................................75.2.3. Theidealsurfaceforcomfort.........................................................................................95.3. Designguidelines...................................................................................................................95.4. Typesofseat........................................................................................................................105.5. Seatparts.............................................................................................................................116. Productsoverview....................................................................................................................136.1. ConclusionsregardingthedifferentSeats...........................................................................167. DevelopmentofanewSeatconcept........................................................................................187.1. Boundaryconditions............................................................................................................187.2. Stepsfortheseatdevelopment..........................................................................................187.3. Internshipactivities.............................................................................................................198. Conclusions...............................................................................................................................219. References................................................................................................................................21

InternshipReportThiagoSchimmelpfennigBMWMotorradProductDevelopmentUXEK1Page4of203. IndexofpicturesPicture1TriangleofergonomicswiththeHpoint(SAEJ826)...................................................................5Picture2ShiftdirectionforthemotorcycleSeat,accordingtodifferentindividuals................................6Picture3Analysisofthepressuredistributioninamotorcycleseat.........................................................7Picture4Differentpositionsforthedriverwhileseatedinthemotorcycle..............................................8Picture5Seatsurface.(a)Regionforthesupportofthelegs.(b)RegionforthePelvicsupport..............9Picture6DifferentpositionsfortheseatofthemotorcycleBMWR1150RT.........................................10Picture7Differentconfigurationsformotorcycleseats..........................................................................11Picture8KTM990Adventureseatdetails...............................................................................................11Picture9InternalseatheightadjustmentsystemforHondaPaneuropean............................................12Picture10KTM990AdventureOverview..............................................................................................13Picture11KTM990AdventureOverview..............................................................................................14Picture12KTM990AdventureOverview..............................................................................................14Picture13BMWR1200GSOverview...................................................................................................15Picture14BMWR1200GSOverview...................................................................................................16Picture15Referenceforthemeasurementoftheseatsurfaces............................................................17Picture16Phasesinthedevelopmentofanewmotorcycleseat............................................................19Picture17ExampleofaparametricsurfacemodelinthesoftwareCATIAV5........................................204. IndexoftablesTable1KTM990AdventureSeatdata...................................................................................................13Table2MotoGuzziNorgeSeatdata......................................................................................................14Table3MotoMoriniGranpassoSeatdata.............................................................................................14Table4BMWR1200GSSeatdata.........................................................................................................15Table5HondaPaneuropeanSeatdata..................................................................................................16Table6Measurementresultsforthestudiedmotorcycleseats..............................................................17

InternshipReportThiagoSchimmelpfennigBMWMotorradProductDevelopmentUXEK1Page5of205. Importanttopicsforseatsdevelopment5.1. Vehiclepositionoftheseat

As previously discussed in the last report, the motorcycle project is connected to threeimportantpointstogetherdescribedastheTriangleofErgonomics(Picture1).Anextrapointwasaddedtothestructure,accordingtothestandardSAEJ826,theHPoint.TheHPointcanbedescribedasthepoint inthemiddlesectionofthedriverwhereoccursthemovementbetweenthetorsoandthe legs.This point is constantly used for the project of vehicles and plays an important role inmotorcyclesdevelopment,whilecanbealsoconsideredthegravitycenterofthedriver.

Picture1TriangleofergonomicswiththeHpoint(SAEJ826).

The HPoint is located in different positions (x,z) for each person when seated in a

motorcycle, according to its dimensions. When seated in a comfortable position in the motorcycle,differentdrivershaveadifferentposition for theirHPoint.Amapof thosepositions is shown in thePicture2,whereispossibletoseethatsmallindividualswithsmalllegsnormallyseatmoreinthefrontofthebikeandmoreclosetotheground.Ontheotherhand,higherindividualswithlonglegsprefertoseat in an up position, further from the handling bar. The graphic represents, in case of a heightadjustmentsystem,thatthere isaspecialdirectionforthedisplacementoftheseat inthebike,beingpossibletoattendtoallthedifferentindividuals.

Thisstudy(Picture2)wasconductedaccordingtotheStandardDIN33402,consideringthatundertheminimumvalueisjust5%ofthesmallestfemaleindividualsandabovethehighestpointstays5%ofthehighermaleindividuals.

InternshipReportThiagoSchimmelpfennigBMWMotorradProductDevelopmentUXEK1Page6of20

Picture2ShiftdirectionforthemotorcycleSeat,accordingtodifferentindividuals.

5.2. Seatsurface5.2.1. Thepressuredistributionduetothehumanbodystructure

Thepelvisorpelvicgirdleistheirregularbonystructurelocatedatthecaudalend(thebase)ofthespine.Thelowestbonewhichcomposesthepelvisistheischium,alsoknownastheseatingbone.Thisregionofthebodyisresponsibleforsupportingmostoftheweightofanindividualwhenseated.Toproduceacomfortableseat,itisveryimportanttodistributethepressureovertheischiuminordernottofatiguethemusculatureinitssurrounding.

Whenanindividualisseated,about6065%ofitsbodyweightlaysovertheseatsurface.Ofthat6065%,about50%iscompressingtheischiumbones.Foranindividualwhoweightsabout85kg,itispossible toassume that inasmallareaof8 to16cm2 (eachbone) there isa forceofabout21kgf(Carsten