Ανάπτυξη μεθοδολογίας μοντελοποίησης ανθρώπινης κίνησης για τη βελτίωση του εργονομικού σχεδιασμού προϊόντων και σταθμών εργασίας : εφαρμογή στην αυτοκινητοβιομηχανία

Abstract

The efficient and reliable human-centred design of products and processes is a major goal of the manufacturing industry. Thus, numerous aspects related to performance, safety and ergonomics, need to be verified using Simulation and Virtual Reality techniques, in the context of the product development procedure. The realistic and accurate representation of human motion in Virtual Environment is crucial for the reliability of the simulation results. In this context, this dissertation focuses on the design and development of a novel methodology for human motion modelling, based on the adaptation of a given motion of a digital human model to new anthropometrics and environment’s constraints (related to virtual prototype or workspace). The proposed approach aims at the generation of realistic and reliable digital human motions in order to drive computer manikins into a Virtual Environment, so as to obtain reliable evaluation results during ergonomic design of a product or a production line’s workspace. The introductory chapter presents both the importance and the limitations of the ergonomic design using computer manikins, which consisted the major motivation of this research work. State-of-the-art is presented next, concerning other approaches related to human motion modeling using computer manikins, as well as software tools for digital human modeling and ergonomic design. Next chapter presents an extensive analysis, which focuses on the better understanding of the human motion. This analysis is based on a Statistical Design Of Experiments (SDoE) and makes use of experimental motion captured data. Analysis of Variance (ANOVA) was performed for the determination of the impact factor of the anthropometric parameters influencing the human motion path. Semi-empirical additive models was developed next, based on the results of this analysis, which connects the effect of anthropometrics with the trajectories of the markers that are attached on the human body during the motion capture procedure. The composing of the proposed motion modelling methodology is following. Given that human motion is analysed by a set of sequential motion frames, the modelling methodology aims at the generation of digital human’s postures for each frame of the desirable motion scenario. Motion scenario is each possible combination of “task – computer manikin – environment”. For the creation of a new motion’s frame, the algorithm of the methodology generates alternative postures, ensuring the rejection of non-realistic and constraint-violating postures. The basic concept of the modelling methodology is based on the multi-criteria decision making, which is used for the alternatives’ evaluation and the selection of the best-ranked human postures that constitute the new human motion. The criteria concern both the extensionality of the new motion and the satisfaction of the new constraints, related to the geometric modifications of the working environment. The description of the primary and secondary components of the implemented system, as well as their detailed design are presented next. The developed system consists of the following primary components: i)the data base, which includes reference motions, computer manikins, virtual environments and tasks , ii)the alternative generation mechanism, which takes into account the new constraints, iii)the evaluation criteria of alternatives, which are related to joint angles’ and end-effector’s similarity, iv)the decision matrix, which calculates the evaluation score of each alternative posture, based on the criteria, v)the aggregation mechanism, which calculates the utility score of each alternative, based on the evaluation scores and the weights of the criteria, vi)the ranking mechanism, which sorts the alternatives based on the utility score and selects the best-ranked alternative for each motion frame. The developed system enables the creation of adapted motions for digital humans that satisfies the new conditions and constraints. The new conditions and constraints come from the modification of the anthropometrics of the digital human model that realize the motion and/or the modification of the shape/geometry of the working environment. The evaluation of the proposed methodology’s efficiency is illustrated through a set of experiments through the pilot application coming from the automotive industry. The pilot application aims at the ergonomic evaluation of the interior design of a passenger car, focusing mainly on the position optimization for the driver’s seat and the door’s handle. The evaluation demonstrates the prediction capabilities of the algorithm, when both anthropometrics and environment parameters are modified. The algorithm generates accurate and realistic human motions that can be efficiently used in order to improve the computer-aided ergonomic design of manufacturing products and processes.