CentroTecnolgico
DepartamentodeEngenhariaMecnica
CoordenadoriadeEstgiodoCursodeEngenhariaMecnica
CEP88040970FlorianpolisSCBRASIL
www.emc.ufsc.br/estagiomecanica
estagio@emc.ufsc.br
INTERNSHIPREPORT2/3
ActivitiesdevelopedintheBodyVehicledepartment
BMWMotorcycleDevelopmentCenter
03/04/2009to03/06/2009
BMWMotorradA.G.
Thisreportcontainsconfidentialinformationandprotectedfromdisclosure.
Itmustbeusedonlyforthepurposeofevaluatingthestudent.
Student:ThiagoSchimmelpfennig
BMWTutor:Dipl.Ing.HansWolfmller
UFSCTutor:Prof.Dr.Ing.LauroCsarNicolazzi
MunichGermany,June8th2009
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BMWMotorradProductDevelopmentUXEK1
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1.
Introduction
ThisreportpresentstheactivitiesdevelopedbytheacademicThiagoSchimmelpfennigduring
his period of practical training at BMWs Research and Innovation Center in Munich, Germany. The
internship takes place in the Motorcycles Development Department, in the division of Body Vehicle
EngineeringUXEK1.
In summary, the second two months of the internship involved the work with project and
development of Motorcycles Seats. The activities included studies of ergonomics, tests and
measurement of components, brainstorming of new solutions and 3D modeling of components and
surfaceswiththesoftwareCATIAV5.
Forabetterunderstandingoftheinternshipactivities,thisreportisdividedintothreemain
sections.Thefirstsectionwillprovideabackgroundabouttheimportanttopicsfortheconstructionof
seatstructures.Thesecondsectionisadetailedstudyofseatsofdifferentmotorcycles.Abriefsection
attheenddisclosesabouttheelaborationofanewconceptforamotorcycleseat.
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2.
Index
1.
Introduction................................................................................................................................2
2.
Index............................................................................................................................................3
3.
Indexofpictures.........................................................................................................................4
4.
Indexoftables.............................................................................................................................4
5.
Importanttopicsforseatsdevelopment....................................................................................5
5.1.
Vehiclepositionoftheseat...................................................................................................5
5.2.
Seatsurface............................................................................................................................6
5.2.1.
Thepressuredistributionduetothehumanbodystructure........................................6
5.2.2.
Theseatingposition.......................................................................................................7
5.2.3.
Theidealsurfaceforcomfort.........................................................................................9
5.3.
Designguidelines...................................................................................................................9
5.4.
Typesofseat........................................................................................................................10
5.5.
Seatparts.............................................................................................................................11
6.
6.1.
7.
Productsoverview....................................................................................................................13
ConclusionsregardingthedifferentSeats...........................................................................16
DevelopmentofanewSeatconcept........................................................................................18
7.1.
Boundaryconditions............................................................................................................18
7.2.
Stepsfortheseatdevelopment..........................................................................................18
7.3.
Internshipactivities.............................................................................................................19
8.
Conclusions...............................................................................................................................21
9.
References................................................................................................................................21
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3.
Indexofpictures
Picture1TriangleofergonomicswiththeHpoint(SAEJ826)...................................................................5
Picture2ShiftdirectionforthemotorcycleSeat,accordingtodifferentindividuals................................6
Picture3Analysisofthepressuredistributioninamotorcycleseat.........................................................7
Picture4Differentpositionsforthedriverwhileseatedinthemotorcycle..............................................8
Picture5Seatsurface.(a)Regionforthesupportofthelegs.(b)RegionforthePelvicsupport..............9
Picture6DifferentpositionsfortheseatofthemotorcycleBMWR1150RT.........................................10
Picture7Differentconfigurationsformotorcycleseats..........................................................................11
Picture8KTM990Adventureseatdetails...............................................................................................11
Picture9InternalseatheightadjustmentsystemforHondaPaneuropean............................................12
Picture10KTM990AdventureOverview..............................................................................................13
Picture11KTM990AdventureOverview..............................................................................................14
Picture12KTM990AdventureOverview..............................................................................................14
Picture13BMWR1200GSOverview...................................................................................................15
Picture14BMWR1200GSOverview...................................................................................................16
Picture15Referenceforthemeasurementoftheseatsurfaces............................................................17
Picture16Phasesinthedevelopmentofanewmotorcycleseat............................................................19
Picture17ExampleofaparametricsurfacemodelinthesoftwareCATIAV5........................................20
4.
Indexoftables
Table1KTM990AdventureSeatdata...................................................................................................13
Table2MotoGuzziNorgeSeatdata......................................................................................................14
Table3MotoMoriniGranpassoSeatdata.............................................................................................14
Table4BMWR1200GSSeatdata.........................................................................................................15
Table5HondaPaneuropeanSeatdata..................................................................................................16
Table6Measurementresultsforthestudiedmotorcycleseats..............................................................17
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5.
Importanttopicsforseatsdevelopment
5.1.
Vehiclepositionoftheseat
As previously discussed in the last report, the motorcycle project is connected to three
importantpointstogetherdescribedastheTriangleofErgonomics(Picture1).Anextrapointwasadded
tothestructure,accordingtothestandardSAEJ826,theHPoint.TheHPointcanbedescribedasthe
pointinthemiddlesectionofthedriverwhereoccursthemovementbetweenthetorsoandthelegs.
This point is constantly used for the project of vehicles and plays an important role in motorcycles
development,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,
different drivers have a different position for their HPoint. A map of those positions is shown in the
Picture2,whereispossibletoseethatsmallindividualswithsmalllegsnormallyseatmoreinthefront
ofthebikeandmoreclosetotheground.Ontheotherhand,higherindividualswithlonglegspreferto
seat in an up position, further from the handling bar. The graphic represents, in case of a height
adjustmentsystem,thatthereisaspecialdirectionforthedisplacementoftheseatinthebike,being
possibletoattendtoallthedifferentindividuals.
Thisstudy(Picture2)wasconductedaccordingtotheStandardDIN33402,consideringthat
undertheminimumvalueisjust5%ofthesmallestfemaleindividualsandabovethehighestpointstays
5%ofthehighermaleindividuals.
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Picture2ShiftdirectionforthemotorcycleSeat,accordingtodifferentindividuals.
5.2.
Seatsurface
5.2.1.
Thepressuredistributionduetothehumanbodystructure
Thepelvisorpelvicgirdleistheirregularbonystructurelocatedatthecaudalend(thebase)
ofthespine.Thelowestbonewhichcomposesthepelvisistheischium,alsoknownastheseatingbone.
Thisregionofthebodyisresponsibleforsupportingmostoftheweightofanindividualwhenseated.To
produceacomfortableseat,itisveryimportanttodistributethepressureovertheischiuminordernot
tofatiguethemusculatureinitssurrounding.
Whenanindividualisseated,about6065%ofitsbodyweightlaysovertheseatsurface.Of
that6065%,about50%iscompressingtheischiumbones.Foranindividualwhoweightsabout85kg,it
is possible to assume that in a small area of 8 to 16 cm2 (each bone) there is a force of about 21 kgf
(Carstens,2004).Inordertoguaranteeacomfortabledriveforalongperiodoftime,itisimportantdo
designsurfaceswhichcandistributethispressurearoundtheseatingregion.
The Picture 3 shows exactly the pressure distribution in a seat, where the pressure
concentration on the ischium bones region is clearly visible. The measurement in the picture was
conductedinaseatsurfacewithamesharrayofabout200individualsensors,beingthiswaypossibleto
determineexactlythepressureconcentrationpoints(Ottilinger,2005).
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Picture3Analysisofthepressuredistributioninamotorcycleseat.
5.2.2.
Theseatingposition
Duetothedifferentproportionsofthehumanbodyandtoitsstructureintheseatingregion,
a long time or travel in the same seating position can conduct to the muscular fatigue in the seating
area. This way, the drivers always look for alternative positions in order to relax the musculature.
Therefore,therearetwodifferentpositionsinwhichthedrivercanstay,asshowninPicture4.Those
positions change the angle of the pelvic and the curvature of the column, giving different pressure
distributionsforeachcase.
The possibility of changing the seating position in a motorcycle can be achieved by two
differentstrategies,whichcanbealsocombined:
Seatwithinclinationadjustment:Theangle/inclinationismeasuredwiththehorizontalline
and if it is positive, the driver is going to be pushed forward on the bike, achieving more
pressureintheregionofthelegsandseatingmorestraight.Iftheangleisnegativethedriver
isgoingtobepushedbackwardsandtheseatingpositionisgoingtobemoresimilartothe
Picture4(b),wherethecolumnpresentsaslightlycurvature.
Seatwithbigsurface:Withabigsurfacefortheseat,thedrivercanchooseinwhichposition
heisgoingtoseat.Whenheseatstothefrontofthebike,heisinthestraightconfiguration.
SeatingmoreinthebackisgoingtobringthedrivertotheconfigurationasinthePicture4
(b).
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A motorcycle can eventually dispose of a seat kit which can provide both inclination
adjustment and big seat surface. These actions embrace a wide range of individuals and, if combined
withaheightadjustmentcanleadtoafullcustomizedandergonomicseatkit.
Picture4Differentpositionsforthedriverwhileseatedinthemotorcycle.
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5.2.3.
Theidealsurfaceforcomfort
Asexplainedintheprevioussection,havingalongerseatsurfaceisagoodwaytopromote
different driver positions and therefore more comfortable seats. The shape of the surface, however,
requires some specific construction techniques that allow a better pressure distribution rather than a
flatsurface.
As a consequence of the different driving positions the seat can be divided in two main
regions,asshowninthePicture5.TheregioninthebackoftheseatPicture5(b)canbelongerandis
goingtobeusedmainlyfortallerindividualsorthosewhoprefertoseatatthebackofthebike,havinga
drivingpositionsimilartothePicture4(b).Thefrontoftheseatistheregionwhichsupportsthelegsof
thedriverPicture5(a).Inthisregiontheseatmusthaveacurvaturewhichfollowstheopenlegsofthe
driver,pushinghimmoreincontactwiththefrontofthebikeinapositionwhichisstraighter,suchas
describedinPicture4(a).
Picture5Seatsurface.(a)Regionforthesupportofthelegs.(b)RegionforthePelvicsupport.
5.3.
Designguidelines
Mainlyintheautomotivesector,wherethecompetitionisextremelyhighandallthedetails
are considered by the costumers, the design plays a very important role for the costumers first
impressionandneedtobeanimportantvariableintheprojectphase.
Tomatchtheprojectrequirements,thefunctionalityoftheparts,thecomfortandasmooth
andcontinuousdesignisanextremelyhardtaskfortheengineersandrequiresadetailedstudyofthe
geometries.
Formotorcycleseatstherearesomerulesinwhichtheengineersmustpayattention.
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Smoothlines:Thecornersandedgesoftheseatmustalwaysbeinagreementwiththelines
andjoininggapsofthebike.Incaseofaseatwhichhasaninterchangeableposition,forall
theconfigurationsitisimportanttokeepthoseparametersinagreement.
Coverage of internal parts: This topic is very important in seats with interchangeable
position.Evenforthehigherposition,itmustnotbepossibletoseetheinternalsideofthe
motorcycle, where the support parts stays, such as tools, electronics and lockers. This rule
limits many times the highest point of the seat, whereas it reduces the thickness of the
availablefoamoftheseat.
ThePicture6illustratesamotorcycleseatwithpositionadjustment.Atthehighestpositionis
already possible to see the beginning of the discontinuity between the seat lines and the motorcycle
lines.Itisalsopossibletoobservethenecessityofagapinthebodyinordertohidetheinternalpartsof
themotorcycle.
Picture6DifferentpositionsfortheseatofthemotorcycleBMWR1150RT.
5.4.
Typesofseat
Normallythemotorcyclesuse3differentconfigurationsforitsseats,accordingtothedriving
styleandthemarket(seefirsinternshipreport).ThoseconfigurationscanbeobservedinthePicture7,
whichare:
Twopartseat:Thisseatisnormallyusedinbikeswhichcomewithseatheightadjustment.In
those cases, most of the times just the driver seat can be adjusted, while the pillion seat
remainsinitsoriginalposition.Thepillionseatcanbeinsomecasesremovedanditsbase
usedasluggagesupport.
Integer seat with step: This configuration is more used for sport motorcycles without seat
adjustment.Thestepbetweenthedriverandpillionseatgivesamoreaggressivestyletothe
motorcycle.
Integerseatwithoutstep:Thisconfigurationisalsoaintegerpartbutwithoutthestep.Itis
moresuitableforenduremotorcycles.
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Picture7Differentconfigurationsformotorcycleseats.
5.5.
Seatparts
Motorcycleseatsareusuallycomposedofsimilarcomponents,independentofthebrandof
thevehicle.Inordertomakeabetterexplanationaboutitscomponents,themotorcycleKTMAdventure
990willbeusedaccordingtothePicture8.
Picture8KTM990Adventureseatdetails
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Themotorcycleseatitselfiscomposedbasicallyofthreecomponents:thecovering,thefoam
andtheseattray.Thecoverandthefoamarebasiccomponents,ontheothersidetheseattrayisthe
mostexpensivepartandpresentsmostofthefunctionalityoftheset.InthePicture8(a)itispossibleto
seetheunderareaoftheseat.Theredcirclesrepresentthefixingpointsoftheseatontheframe,as
longastheyellowlinespointtothedampingelementsoftheseat.Thedampingelementsareusedto
helpinthereductionofthevibrationwhichcomesfromtheengineandfromtheroad.Itcanbelocated
eitherintheseattrayorintheframeofthebike.
The Picture 8 (b) shows the motorcycle region where the seat is fixed. The red circles
representthepointswheretheseatisproperlyfixed,howeverthosepointsarejustnecessarytoavoid
the removal of the seat from the bike. All the force propagation from the driver to the bike and the
oppositearegoingthroughthedampingelements.
ThePicture8(c)and(d)showsthedetailsofthefixingcomponents.InthePicture8(d)itis
shownthelockersystemforthisbike,whichisconnectedtothesidelockerandopenedwiththekey.
For different motorcycles however this configuration can completely change, mainly if the
motorcycle presents height adjustment systems, such as the BMW R 1200 GS and the Honda
Paneuropean. The Picture 9 illustrates the interior of the height adjustment system for the Honda
Paneuropean, where it is easy to perceive that such systems require more expensive and detailed
componentsforthebike.
Picture9InternalseatheightadjustmentsystemforHondaPaneuropean
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6.
Productsoverview
Inordertohaveabetterunderstandingaboutsomedifferentbikesnowadaysinthemarket,
as a part of the internship activities a specific study was conducted with several bikes, detailing
characteristicssuchas:
Presenceofdriverheightadjustmentsystem;
Measurementoftheseatusablesurface;
Directionoftheheightadjustmentsystem;
Principleofworkofthesystems.
The analysis was conducted with 5 different motorcycles and the tables 15 shows the
significantaspectsforeachbike.Amethodologyfortheevaluationoftheseatssurfacewasadoptedand
isdescribedinthesection4.7.
Datasheet
SeatAdjustmentSystem
KTM990Adventure
Class:Endure
Year:2008
Picture10KTM990AdventureOverview
Heightoftheseat:
860mm
(uniqueseat)
Typeoftheseat:
[X]Onepiece[]Twopieces(DriverandPillion)
Heightadjustmentsystem:
[]Yes[X]No
Table1KTM990AdventureSeatdata
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Datasheet
SeatAdjustmentSystem
MotoGuzziNorge
Class:Tourer
Year:2007
Picture11KTM990AdventureOverview
Heightoftheseat:
Typeoftheseat:
Heightadjustmentsystem:
800mm(uniqueseat)
[X]Onepiece[]Twopieces(DriverandPillion)
[]Yes[X]No
Table2MotoGuzziNorgeSeatdata
Datasheet
SeatAdjustmentSystem
MotoMoriniGranpasso
Class:Endure
Year:2008
Picture12KTM990AdventureOverview
Heightoftheseat:
Typeoftheseat:
Heightadjustmentsystem:
870mm(uniqueseat)
[X]Onepiece[]Twopieces(DriverandPillion)
[]Yes[X]No
Table3MotoMoriniGranpassoSeatdata
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BMWR1200GS
Datasheet
Class:Enduro
Year:2006
SeatAdjustmentSystem
Picture13BMWR1200GSOverview
Heightoftheseat:
810mm
(lowseat)
840mm
860mm
(normalseat)
860mm
880mm
(highseat)
Typeoftheseat:
[]Onepiece[X]Twopieces(DriverandPillion)
Typeoftheadjustmentmechanism:
[]Electrical[X]Mechanical
Totalheightadjustment:
20mm
Angleofheightadjustment:
90withhorizontalline
Needoftools:
[]Yes[X]No
Seatangleadjustment:
[]Yes[X]No
Table4BMWR1200GSSeatdata
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HondaPaneuropean
Datasheet
Class:Tourer
Year:2006
SeatAdjustmentSystem
Picture14BMWR1200GSOverview
Heightoftheseat:
775mm
(lowposition)
790mm
(middleposition)
805mm
(highposition)
Typeoftheseat:
[]Onepiece[X]Twopieces(DriverandPillion)
Typeoftheadjustmentmechanism:
[]Electrical[X]Mechanical
Totalheightadjustment:
30mm
Angleofheightadjustment:
50withhorizontallinebackdirection
Needoftools:
[]Yes[X]No
Seatangleadjustment:
[]Yes[X]No
Table5HondaPaneuropeanSeatdata
6.1.
ConclusionsregardingthedifferentSeats
The seats presented in the tables 15 were all measured according to a special standard,
assuming some constants for the evaluation of the main dimensions of the seat. This procedure was
done according to the Picture 15 both for the driver and pillion seat. The Table 6 presents the
measurementresultswhichwereafterusedfortheevaluationofthenewprojecttargets.
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Picture15Referenceforthemeasurementoftheseatsurfaces
Pillion
Driver
A
B
C
D
E
F
G
H
I
KTMAdv.
MotoMorini
Granpasso
HondaPan
European
MotoGuzzi
Norge
BMWR1200
GS
150
250
5
320
580
210
240
280
8
150
270
11,5
250
480
260
280
310
6,7
200
310
6
330
370
270
300
310
0,5
170
310
5
290
360
280
310
300
1
170
310
1,5
335
390
230
280
300
4
Table6Measurementresultsforthestudiedmotorcycleseats
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7.
DevelopmentofanewSeatconcept
7.1.
Boundaryconditions
7.2.
Stepsfortheseatdevelopment
The starting point in the development of the seat is the analysis of the space between the
seat surface (which has a height target) and the frame of the bike. If this space is too reduced, it
becomesimpossibletoprojectasupportstructurethatmustbebetweentheframeandthesurface.In
addition,thethicknessofthefoamintheseatingregioncannotbesmallerasastandardvalue,inorder
toaccomplishthebasiccomforttargets.
Secondly,itisimportanttocheckthedimensionsofthedesignedseatsurface,asshownin
the Picture 15. Those dimensions play an important role in the comfort of the seat and must be
followed.
Athirdstepinthedevelopmentisthedefinitionoftheheightadjustmentdirection.Thisis
strategicfortheconceptoftheseatsupports,toitsattachmenttotheframeandtothedesign.Inthe
touringbikesthisinclinationusestostayaround45degrees.Forendurebikeshoweverthisnumbercan
beincreasedupto90degrees.
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Oncethosedefinitionsareready,itispossibletostartwiththeproperlydesignoftheseat
supportparts.Thegeometryandfunctionalityofthosepartsdependsonitsapplicationandduringthe
projectisalsoveryimportanttotrytoaggregatethehighestnumberoffunctionsforthesameparts.
Followedbythedesignofthesupportsisthedesignoftheseattraysandlockers.Actually,
boththedesignsmustbedonealmosttogethersincethosepartsmustbetogetherassembled.Theseat
trayisoneofthemostexpensivecomponentsofthemotorcyclebody,sinceitssizerequiresbigmolds
andmachinesforitsproduction.Theseatlockersarethecomponentswhichwillmaintaintheseatonits
positiontohidetheinternalcomponentsandthetoolsofthebike.
Oneofthefinalstepsforthedevelopmentoftheseatisitssurroundingarea.Assoonasthe
conceptisready,thecomponentswhichstayattheborderoftheseatmustbechangedduetocollisions
in the parts. Those parts are, for instance, the fuel tank, the body of the tank and other plastic parts
whichstaysundertheseat.ThePicture16resumestheentiredevelopmentphaseoftheseats.
Picture16Phasesinthedevelopmentofanewmotorcycleseat.
7.3.
Internshipactivities
Based on the presented concepts for the development of a seat and the study of another
motorcycles on the market, the activities in the last 2 months of internship involved basically the
conceptandmodelingofanewmotorcycleseat.Thetaskswerebasically:
Adequationofthedesignedsurfacetothecomforttargets;
Conceptofacheapandefficientheightadjustmentsystemforfixingtheseatontheframe;
ModelingoftheseattrayandsurfaceonCATIAV5;
Conceptandmodelingofseatlockers;
Analysisandcorrectionoftheboundaryparts(tankandvehiclebody).
Unfortunately,duetotheconfidentialityoftheprojectitisnotpossibletolistanddescribe
allthedetailsoftheconcept.ThePicture17howevergivesanoverviewoftheparametricsurfaceofone
motorcycledevelopedbytheinterninthesoftwareCATIAV5.
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Picture17ExampleofaparametricsurfacemodelinthesoftwareCATIAV5
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8.
Conclusions
The second third of the internship fortunately leaded to good results in the field of the
activities.Theknowledgeacquiredinthefirsttwomonthswasveryimportanttogetmoreresponsibility
inthepredevelopmentphaseoftheproject.
Theseatinamotorcyclerepresentsaverycomplexcomponent,bothinitsgeometryandin
thecomfortrequirements.Thepossibilityofworkingwiththeseatwasverygoodtoimproveboththe
projectconceptskills(solidmechanics,constructiontechniques)asthesurfacemodelingtechnique.Itis
importanttoenhancethatbeforethemodelingofthecomponentstheideasmustbepreciselystudied
andevaluated,inordertonotrepresentfutureconceptfailswhichcancostmuchtimeandmoneyfor
thecompany.
The internship goes, however, more to a practical area of the engineering, where the
scientificknowledgeisnotusuallydirectlyapplied.Ontheotherhand,theprojectdevelopmentrequires
alotofcreativityandstudyofcomponents,marketandcustomerpreferences.
The progress with the German language played also an important role in the last two
months, making possible to the intern to integrate different project teams and to work together with
engineersresponsibleforothermotorcyclecomponents.
9.
References
Pheasant,S.(1986).Bodyspace:anthropometry,ergonomics,anddesign.London:Taylor&Francis.