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Copyright © ESI Group, 2009. All rights reserved. Copyright © ESI Group, 2009. All rights reserved. Virtual Seat Prototyping : to build it right the first time 1

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  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    Virtual Seat Prototyping :to build it right the first time

    1

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    Massage

    Customers comfort requests Support

    2

    How to bring revolutionary innovative changes to seats, while cutting the development costs drastically?

    Safety regulations

    Regulatory / Third party Multiple markets

    Environment regulations

    Recycling

    Weight reduction

    Customers anthropometries

    Population getting larger Interior space reduction

    Heating, air conditioningCustomer requests

    Seat design

    Structural foams for frame

    Soy, coconut for foam Innovative seat adjustments

    Innovative mechanisms

    Innovative lumbar support

    Active componentsIntegrated systems

    Imbedded heating pads Imbedded fans

    NVH and Durability Vibration absorption

    No wrinkles, no bridging gaps

    Innovative damping systems

    Innovative cover materials

    SEAT PROTOTYPINGTHE CHALLENGE

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved. 3

    1st Proto

    Classical Seat Development ProcessStart of production

    Trial-and-error loops on physical prototypesCostly design changesDifficult tuning of new materialsWeak synergies

    Certainly not with the standard classical development process based on trial-and-error loop on physical prototypes Too slow, too expensive to leave space to innovation

    SEAT PROTOTYPINGTHE DIAGNOSIS

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved. 4

    1st Proto

    Virtual Seat PrototypingStart of productionStart of production

    Trial-and-error loops on virtual prototypesBest practice integrationEasy and fast design changes (ex. materials)Anticipation of the impact of new materialsEasier evaluation and optimizationImproved synergies: the bigger picture with a single model

    Including virtual seat prototyping is one answer.

    SEAT PROTOTYPINGTHE OBJECTIVE

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    With virtual seat prototyping

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    References

    l BMW: Virtual Seat Comfort Assessment, C. Amann, T. Klisch, A. Huschenbeth, BMW Group, N. Montmayeur, C. Marca, ESI Group, VDI Congress, Nov. 2005, Braunschweig.

    Virtual Assessment of Occupied Seat Vibration Transmissibiltiy, C. Amann, A. Huschenbeth, R. Zenk, BMW Group, N. Montmayeur, C. Marca, C. Michel, ESI Group, SAE DHM conference, June 2008, Pittsburgh, PA.

    p RENAULT Group: Virtual Seat Comfort Design, J. Makala, A. Savary, Renault Group, N. Montmayeur, C. Marca, ESI Group, IQPC Conference, Feb. 2007, Frankfurt

    Virtual Seat Comfort Assessment for Low-Frequency Ride Comfort, A. Savary, J.P. Leclerc, J. Makala, Renault Group,, 5th Symposium on Automobile and Railroad Comfort, Nov. 2008, Le Mans, France.

    a FORD Group: Virtual Seat Manufacturing and Testing for FMVSS 202a Backset prediction, N. Montmayeur, C. Marca, D. Dwarampudi, ESI Group, M. Kolich, S. Nunez, Ford Motor Company, SAE DHM conference, June 2007, Seattle, WA.

    Virtual Seat Comfort Engineering through Hardness and Initial Softness Prediction, N. Montmayeur, C. Marca, C. Cabane, D. Dwarampudi, ESI Group, M. Kolich, S. Nunez, Ford Motor Company, SAE DHM conference, June 2007, Seattle, WA.

    Virtual Seat Comfort Assessment through Affective Fore-Aft Lumbar Travel Prediction with a HPM-II Dummy Model, N. Montmayeur, C. Marca, C. Cabane, D. Dwarampudi, ESI Group, M. Kolich, S. Nunez, Ford Motor Company, 7th CTI Forum, June 2007, Munich.

    a HYUNDAI Motor Company / DYMOS New Anthropometry of Human Body Models for Riding Comfort Simulation, S.-H. Kim, S.-H. Hwang, K.N.Lee, Hyundai Motor Company, H.-Y. Choi, K.M.Kim, S. Sah, Hong-Ik University, N. Montmayeur, ESI Group, SAE DHM conference, June 2007, Seattle, WA.

    . GENERAL MOTORS, TOYOTA BOSHOKU, GRUPO ANTOLIN, MAZDA, HONDA,

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    Conclusion

    Thissimulationinputcanreallybeconsideredasan"ultrarealistic"model,sinceitallowsthesimulationofthewholecomplexmechanicalphenomenaoftheseat,thenon-linearityofthematerials,thelargedisplacementsofthecushionfoamandsprings,aswellastheeffectofthecovertrimming.

    Thedevelopedmodelsandmethodologyallowthecomputationof

    predictiveresults,usingonly physicalparametersandwithoutanytuningorfiltering.Thisgoodcorrelationbetweensimulationsandtestsconfirmstheabilitytoassesstheridingseatcomfortinafull virtualprocess.

    Virtual Seat Comfort Assessment for Low-Frequency Ride Comfort, A. Savary, J.P. Leclerc, J. Makala, Renault Group, 5th Symposium on Automobile and Railroad Comfort, Nov. 2008, Le Mans, France.

  • Copyright ESI Group, 2009. All rights reserved.Copyright ESI Group, 2009. All rights reserved.

    THANK YOU !

    Virtual Seat Prototyping :the bigger pictureto build it right the first time

  • Copyright ESI Group, 2009. All rights reserved.

    Virtual Seat Prototyping : to build it right the first timeSlide 2Slide 3Slide 4With virtual seat prototypingSlide 6Slide 7ReferencesConclusionSlide 10Slide 11