Development of an Adjustable Physical Mockup Used for Design Validation of Passenger Car Ergonomics and Interiors

摘要

Ergonomics and interior geometry are important validation contents in vehicle product development. In this paper, a fully adjustable physical mockup with the flexibility to install various interiors was developed, which can be used to validate the ergonomics and interiors for any target population and various passenger cars. By requirements analysis, target vehicle types and contents needed to be validated using this equipment were identified. Based on statistical analysis of the sizes of different passenger cars, the dimensions of basic structure and the adjustments ranges of main components were determined, as well as the main functions and structural requirements. Based on above analysis, reference fiducially marks system, and the positions and travels of adjustment devices were calculated. According to the validated concept design, considering the standards of section bars and machines, the main structure and adjustment devices of every component were designed and analyzed of their strength, stiffness and kinematics. Together with the manufacturer, the sub-systems of the mockup were produced, assembled and tested. The acceptance test showed that this mockup could simulate and present different passenger cars well as the design target, and could evaluate, modify and reevaluate various ergonomic problems and interior designs.