A Design Framework to Automate Task Simulation and Ergonomic Analysis in Digital Human Modeling

Using Digital human modeling (DHM) early in design brings the advantage of reducing the time and resources committed to building full-scale physical prototypes. DHM also helps in minimizing efforts put on performing human subject data collection. However, majority of the repetitive two- and three-dimensional (2D/3D) object orientations and manikin adjustments in DHM are executed manually via point-and-click based keystrokes and precision mouse control, which correspond with increased user effort and time. Additionally, such manual adjustments often fail to mimic the actual postures with high fidelity; thus, injecting further user bias into the design. Due to lack of automation, engineers follow a much conservative approach via running a limited set of ergonomics simulations on select values in contrast to performing an exhaustive search for exploring an extensive set of anthropometry and postural variations. This study introduces an early design framework to automate manikin setup, task simulation, and ergonomic evaluations in DHM to provide concept design exploration capabilities. In this research work, a cockpit packaging design problem was explored to measure the reach gap values via the automation framework. Results suggest that the automation methodology has the potential to reduce the amount of time required to perform DHM simulations and helps in minimizing user bias. The automation framework generated ergonomic evaluations with high correlation values (>0.97) and provided approximately a 97.5% reduction in time when compared to manual simulations.