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Efficient methods for simulating operators performing part handling tasks in manufacturing plants are needed. The simulation of part handling motions is an important step towards the implementation of virtual manufacturing for the purpose of improving worker productivity and reducing injuries in the workplace. However, industrial assembly tasks are often complex and involve multiple interactions between workers and their environment. The purpose of this paper is to present a series of industrial simulations using the Human Motion Simulation Framework developed at the University of Michigan. Three automotive assembly operations spanning scenarios, such as small and large parts, tool use, walking, re-grasping, reaching inside a vehicle, etc. were selected.

Digital human modeling (DHM) progress worldwide will be much faster and cohesive if the diverse community now developing simulations has a global blueprint for DHM, and is able to work together efficiently. DHM developers and users can save time by building on each other's work. This paper highlights a panel discussion on DHM goals and strategic plans for the next decade to begin formulating the international blueprint. Four subjects are chosen as the starting points: (1) moving DHM into the public safety and internet arenas, (2) role of DHM in computer assisted surgery and automotive safety, (3) DHM in defense applications, and (4) DHM to improve workplace ergonomics.

This paper investigates how reaching and grasping are affected by various object properties and conditions. While previous studies have examined the effect of object attributes such as size, shape, and distance from the subject, there is a need for quantitative models of finger motions. To accomplish this, the experiment was performed with six subjects where the 3D-coordinates of the finger joints and the wrist of one hand were recorded during reaching and grasping tasks. Finger joint angles at final posture were found to depend on both object size and orientation while wrist postures were changed primarily depending on object orientation. Also, each object orientation caused alteration in relative object location with respect to the hand at final posture. In addition, analysis of temporal variables revealed that it took from 1.06 to 1.30 seconds depending on the object distance to start reaching and complete grasping of the object.

The objective of this paper is to investigate the dynamic space envelope during reaching and grasping tasks. Some amount of space is required for the hand and arm to move without interference in reach-to-grasp tasks. The required space (‘dynamic space envelope’) has not been examined in spite of its importance. In this paper, we tested the hypothesis that the dynamic space envelope is a function of object size, hand size, grip type and distance. Six subjects (5 males, 1 female) participated in an experiment, in which they reached for and grasped three differently sized cylindrical objects (D: 26 mm, 60 mm, 114 mm) placed 40 cm in front of the subjects. Twenty-three markers were attached to the dorsal side of the hand and a 3-D motion capture system recorded the positions of the markers during reaching and grasping. The total distance from start to end positions is evenly divided into 10 ranges, and the areas of the required spaces were calculated for each range.

Posture and external loads such as hand forces have a dominant effect on ergonomic analysis outcomes. Yet, current digital human modeling tools used for proactive ergonomics analysis lack validated models for predicting postures for standing hand-force exertions. To address this need, the effects of hand magnitude and direction on whole-body posture for standing static hand-force exertion tasks were quantified in a motion-capture study of 19 men and women with widely varying body size. The objective of this work was to identify postural behaviors that might be incorporated into a posture-prediction algorithm for standing hand-force tasks. Analysis of one-handed exertions indicates that, when possible, people tend to align their bodies with the direction of force application, converting potential cross-body exertions into sagittal plane exertions. With respect to the hand-force plane, pelvis position is consistent with a postural objective of reducing rotational trunk torques.

Accurate representation of working postures is critical for ergonomic assessments with digital human models because posture has a dominant effect on analysis outcomes. Most current digital human modeling tools require manual manipulation of the digital human to simulate force-exertion postures or rely on optimization procedures that have not been validated. Automated posture prediction based on human data would improve the accuracy and repeatability of analyses. The effects of hand force location, magnitude, and direction on whole-body posture for standing tasks were quantified in a motion-capture study of 20 men and women with widely varying body size. A statistical analysis demonstrated that postural variables critical for the assessment of body loads can be predicted from the characteristics of the worker and task.

This study presents a design concept for a multi-configuration modular medical evacuation fixture that can be used to retrofit standard utility vehicles for emergency medical transport. The fixture has been designed so that when installed in a vehicle and configured for litter transport, it provides mounting structure for a single patient on a North Atlantic Treaty Organisation (NATO) style litter as well as for a variety of emergency medical equipment. When installed in a vehicle and configured for ambulatory patient transport, the device provides safe seating for multiple patients as well as mounting surfaces for medical equipment. When not installed, the fixture can be collapsed for ease of shipping and warehousing. A survey of potential host vehicles was conducted to evaluate the feasibility of the proposed design. Given a preliminary concept, factors such as expected patient anthropometry, and physical data of medical equipment were used to perform basic structural analyses.

Cyclical stepping (gait) has been studied extensively. Some of these results are reflected in the straight and curved path step-following algorithms in commercial digital human modeling (DHM) implementations. With the aid of these algorithms, DHM users define start, intermediate, and end path points and the software generates a walking-like motion along the path. Most of these algorithms have substantial limitations, among them that the figures exhibit “foot skate,” meaning that the kinematic constraint of foot contact with the ground is not respected. Turning is accomplished by pivoting the entire figure, rather than through realistic lower-extremity motions. The simulation of the non-cyclical stepping motions accompanying manual material handling pickup and delivery tasks requires manual manikin manipulation. This paper proposes a paradigm for the simulation of stepping behavior in digital human models based on a model of foot placements and motions.

A 3-dimensional kinematic model for predicting grip posture was developed. The finger joints are all rotated at a constant rate until contact is detected between the fingers and the work object. By comparing the model’s predicted hand postures with experimental data, it was shown that the model gave reasonable predictions (R2=0.72). The model predicts MCP (Metacarpophalangeal) and PIP (Proximal Interphalangeal) joint angles better than it predicts DIP (Distal Interphalangeal) joint angles. A sensitivity study using this model was performed. The hand length, hand breadth, object size and skin deformation level were changed and the effects of these factors on hand posture was examined. The hand length, hand breadth and skin deformation level do not seem to affect hand posture much. But the change in object size affects hand posture much more than other factors.

For many industrial tasks (push, pull, lift, carry, etc.), restrictions on grip locations and visibility constrain the hand and head positions and help to define feasible postures. In contrast, foot locations are often minimally constrained and an ergonomics analyst can choose several different stances in selecting a posture to analyze. Also, because stance can be a critical determinant of a biomechanical assessment of the work posture, the lack of a valid method for placing the feet of a manikin with respect to the task compromises the accuracy of the analysis. To address this issue, foot locations and orientations were captured in a laboratory study of sagittal plane and asymmetric manual load transfers. A pilot study with four volunteers of varying anthropometry approached a load located on one of three shelves and transferred the load to one of six shelves.

Occupational populations have become increasingly diverse, requiring novel accommodation technologies for inclusive design. Hence, further attention is required to identify potential differences in work perception between workers with varying physical limitations. The major aim of this study was to identify differences in shoulder loading and perception of effort between a control population (C) and populations affected by chronic back pain (LBP) and spinal cord injury (SCI) in one-handed seated transfer tasks to targets. The effects of the injuries, and associated pain, are likely to produce variations in movement patterns, muscle loading and perceived effort.

In many task analyses using digital human figure models, only the terminal or apparently most stressful posture is analyzed. For reaches from a seated position, this is generally the posture with the hand or hands at the target. However, depending on the characteristics of the tasks and the people performing them, analyzing only the terminal posture could be misleading. This possibility was examined using data from a study of the reaching behavior of people with spinal cord injury. Participants performed two-handed forward reaching tasks. These reaches were to three targets located in the sagittal plane. The terminal postures did not differ significantly between those with spinal cord injury and those without. However, motion analysis demonstrated that they employed distinct strategies, particularly in the initial phase of motion.

The reach capability of drivers is currently represented in vehicle design practice in two ways. The SAE Recommended Practice J287 presents maximum reach capability surfaces for selected percentiles of a generic driving population. Driver reach is also simulated using digital human figure models. In typical applications, a family of figure models that span a large range of the target driver population with respect to body dimensions is positioned within a digital mockup of the driver's workstation. The articulated segments of the figure model are exercised to simulate reaching motions and driver capabilities are calculated from the constraints of the kinematic model. Both of these current methods for representing driver reach are substantially limited. The J287 surfaces are not configurable for population characteristics, do not provide the user with the ability to adjust accommodation percentiles, and do not provide any guidance on the difficulty of reaches that are attainable.

Vehicle motions can adversely affect the ability of a driver or occupant to quickly and accurately push control buttons located in many advanced vehicle control, navigation and communications systems. A pilot study was conducted using the U.S. Army Tank Automotive and Armaments Command (TACOM) Ride Motion Simulator (RMS) to assess the effects of vertical ride motion on the kinematics of reaching. The RMS was programmed to produce 0.5 g and 0.8 g peak-to-peak sinusoidal inputs at the seat-sitter interface over a range of frequencies. Two participants performed seated reaching tasks to locations typical of in-vehicle controls under static conditions and with single-frequency inputs between 0 and 10 Hz. The participants also held terminal reach postures during 0.5 to 32 Hz sine sweeps. Reach kinematics were recorded using a 10-camera VICON motion capture system. The effects of vertical ride motion on movement time, accuracy, and subjective responses were assessed.

Significantly, more fatalities and serious injuries occur due to ejection in roll over accidents. The present study was conducted to determine the occupant retention and head-neck injury potential aspects of laminated glass in roll over accidents. The head injury and neck parameters were obtained from Hybrid III 50% male dummy test device impacting on various types of side windows with laminated glass. Results indicated that the glass contained the dummy assembly and the head neck biomechanical parameters were below the critical value injury tolerance limits in simulated rollover accidents.

This study begins the exploration of the relationship between shoulder external moments and perceived exertion levels for submaximal delivery tasks. Twenty subjects were recorded while performing hand load movement tasks to specified targets. After each exertion, subjects were asked to rate the effort required to perform the task. The recorded motion profiles were processed using a biomechanical upper extremity model, from which resultant external shoulder moments were calculated. Average resultant shoulder moments, stratified by exertion level, were also calculated. Several individual subject moment/exertion profiles showed identifiable trends. It was demonstrated that while no strong relationships exist for individual task exertion effort prediction based on resultant shoulder moments, there is a general trend in the overall data sample, as is shown by a high correlation between mean integrated resultant shoulder moment by exertion level and exertion levels.

Although biomechanics models can predict the stress on the musculoskeletal system, they cannot predict how the muscle load associated with exertion is perceived. The short-term goal of the present study was to model the perception of effort in lifting and reaching tasks. The long-term goal is to determine the correlation between objective and subjective measures of effort and use this information to predict fatigue or the risk of injury. Lifting and reaching tasks were performed in seated and standing situations. A cylindrical object and a box were moved with one hand and two hands, respectively, from a home location to shelves distributed in the space around the subject. The shoulder and torso effort required to perform these tasks were rated on a ten point visual analog scale.

Interference between physical objects in the workspace and the moving human body may cause serious problems, including errors in manual operation, physical damage and trauma from the collision, and increased biomechanical stresses due to movement reorganization for avoiding the obstacles. Therefore, a computer algorithm to detect possible collisions and simulate human motions to avoid obstacles will be an important tool for computer-aided ergonomics and optimization of system design in the early stage of a design process. In the present study, we present a method of modifying motions for obstacle avoidance when the object intrudes near the center of the planned motion. We take the motion modification approach, as we believe that for a certain class of obstacle avoidance problems, a person would modify a pre-planned motion that would result in a collision to a new one that is collision-free, as opposed to organizing a totally unique motion pattern.

Phase I, Phase II, Caterpillar, Allis-Chalmers, Clark, Hyster, Toyota, and Entwistle fork lift upset studies have been conducted with Hybrid II dummies, Side Impact Dummies, and stunt men. The investigations concluded that the dummy lacks the ability to brace itself, hold on, and does not have adequate biofidelity to represent the human in a fork lift upset. Crushing injuries and death typically occur when the operator is thrown or jumps from the overturning forklift and is pinned by the overhead guard or canopy. The dummy studies demonstrated a wide range of Head Injury Criteria (HIC) values that were not reproducible. Furthermore, other injury producing variables such as angular acceleration, angular velocity or induced brain stress were not investigated. The injury level of 1000 for the HIC for the mid-sized male, small female, and 6 year-old has been recommended by the National Highway Transportation Safety Administration (NHTSA).

Determination of human tolerance to injury is difficult because of the physical differences between humans and animals, dummies and cadaver tissue. Certain human volunteer testing has been done but at subinjurious levels [STAP 86] [EWIN 72] Considerable biomechanical engineering injury studies exist for the adult human cadaver however little is available for the pediatric population [SANC 99] [KLEI 98b]. Studies have been made of pediatric skull bone modulus, fetal tendon and early pediatric studies of the newborn during delivery, however, a paucity of information still exists in these areas. A number of dummies have recently been made available principally for airbag testing to bridge the gap between the 50 percentile Hybrid III male dummy and the 95 percentile male dummy.