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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.

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.

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.

This study investigates occupant containment characteristics of tempered and laminated automotive moveable side glass in rollover collisions. FMVSS 216 test protocols were used to induce roof damage or sheet metal damage around the window opening in Lincoln Navigators equipped with tempered and laminated side glass. Dummy-drop tests were then performed to investigate relative containment. The results demonstrate that, for rollovers in which the window structure is compromised, tempered side glass and laminated side glass perform comparably relative to occupant containment. Also discussed are the general strength characteristics of different types of glass construction, the availability of laminated side glass in recent model U.S. vehicles, and anecdotal data supporting the conclusions of testing.

Accident data from the Fatal Accident Reporting System show that over 300 people each year are killed or injured while riding in the bed of a pickup truck. The number of individuals involved varies from year to year with no discernable trend. The number of people involved has lead to requests for the application of additional warnings to the bodies of pickup trucks, beyond those already found in the owner's manuals advising against the use of the bed of the truck to carry passengers. The question addressed in this study is whether the occupants of the bed of a pickup truck are aware of the risk of increased injury if the truck is involved in an accident while they occupy the bed and as a result whether they require additional information in the form of warnings.

During the past 20 years, computer databases containing systematically recorded descriptions of on-road vehicle accidents have become an established resource for vehicle safety engineers. Until recently, however, use of these data sources for crashworthiness analysis has been limited to those engineers who have both ready access to large computer systems and sufficient skill in computer programming methods. In the following paper, the authors describe a robust data analysis software application they have jointly developed. This program runs on a personal computer and summarizes data residing in specially-prepared subsets of the NCSS, NASS and FARS databases.

Head injury is a serious threat to lives of people working around farm machinery. The consequence of head injuries are costly, paralytic, and often fatal. Clinical and biomechanical data on head injuries are reviewed and their application in the analysis of head injury risk associated with farm tractor discussed. A significant proportion of tractor-related injuries and deaths to adults, as well as children, is due directly or indirectly to head injury. An improved injury reporting program and biomechanical studies of human response to tractor rollover, runover, and falls, are needed to understand mechanisms of the associated head injury.

The objective of the study was to investigate the biomechanical response of the intact cranium. Unembalmed human cadavers were used in the study. The specimens were transected at the base of the skull leaving the intracranial contents intact; x-ray and computed tomography (CT) scans were obtained. They were fixed in a specially designed frame at the auditory meatus level and placed on the platform of an electrohydraulic testing device via a six-axis load cell. Following radiography, quasistatic loading to failure was applied to one of the following sites: frontal, vertex, parietal, temporal, or occipital. Retroreflective targets were placed in two mutually orthogonal planes to record the localized temporal kinematics. Applied load and piston displacement, and the output generalized force (and moment) histories were recorded using a modular digital data acquisition system. After the test, x-ray and CT images were obtained, and defleshing was done.

This paper has utilized a specially created subset of the data contained within the National Accident Sampling Study (NASS) for an updated and expanded analysis of the relationship between Delta V and injury. The data presented embrace over 20,000 accidents of passenger cars, light trucks and utility vehicles involved in accidents between 1980 and 1991. These unique accidents have been extracted from the massive amount of available information contained within the NASS data in order that the variables which have the greatest information content for our subject can be studied and analyzed. Some of the variables which were extracted and studied include Delta V, Principle Direction of Force, restraint system type and use, injuries, vehicle weight and type as well as the occupant variables of age and sex which are believed to influence human tolerance to injury.

In a crash, impact against the steering assembly can be a major cause of serious and fatal injury to drivers. But the interrelationship between injury protection and factors of surface area, configuration, padding, relative position of the spokes, and number and stiffness of spokes and rim is not clear. This paper reports a series of high-G sled tests conducted with anesthetized animal subjects in 30 mph impacts at 30 G peaks. A total of eight tests were conducted, five utilizing pig subjects, one a female chimpanzee, one an anthropomorphic dummy, and one test with no subject. Instrumentation included closed circuit TV, a tri-axial load cell mounted between the steering wheel and column, seat belt load measurement, six Photo-Sonics 1000 fps motion picture cameras, and poloroid photography. Medical monitoring pre, during and post-impact was followed by gross and microscopic tissue examination.

Past research has shown that although occupants often survive crash impacts of business jet aircraft, they are often injured either in the course of egress or because they are unable to evacuate. A physical task analysis was performed to evaluate procedures for emergency egress from a typical business jet to demonstrate how possible human factors problems can be identified. First, the tasks required for the flight crew to evacuate via all possible routes were determined. Second, each task was divided into a series of physical elements, such as reach and grasp, corresponding to each movement or exertion. Third, physical aspects of the aircraft affecting performance of each element such as location and force, were measured. The physical requirements of each element were compared with available human factors data, to rate its difficulty. Selected aspects of the analysis are discussed.

Accurate data on the body dimensions of truck drivers are needed and such data are not presently available. This paper provides basic source data and an anthropometrical overview of the usefulness and limitations of existing data bases; discusses the influence of population factors, including age, sex, and demographic variables; and reviews population sampling problems. Heavy truck drivers as a whole appear to represent a physically different population from that of either the U.S. general population or other professional groups. Future anthropometric surveys must provide information for improved accommodation for the increasing range of physical size of users, and for obtaining data more useful to engineers involved in heavy truck interior cab design.

This paper presents an analysis of 67 neck injuries incurred in diving and sliding accidents in swimming pools. The accidents were investigated to establish the appropriate medical and mechanical factors involved. A mathematical model was developed to allow the prediction of the trajectory and velocity of the subjects prior to their injury. Nine of the accidents were selected for real life simulation. The simulation included the selection of test subjects of similar physical build to the accident victims who then performed the maneuvers leading to the injury, but in deeper water. High speed movies (200 frames per second) were taken, above and below the water, to measure the motion. A frame by frame analysis provided data to determine the trajectory and velocity profiles of the test subject. The maneuvers studied included diving from the pool edge, diving from various board types and sliding down various sliding board configurations.

Business and executive aviation represent a combined total of over 40% of the general aviation fleet, but (1977) accounted for only 8.37% of all general aviation accidents recorded. During the period 1964-1977 some 7,351 aircraft engaged in business flying, and 883 in corporate/executive operations, were involved in accidents reported by the NTSB. These accidents were reviewed utilizing the University of Michigan Computerized Accident Files to provide an overall view of the incidence and nature of business/executive aircraft accidents relative to occupant crash injuries. In addition more detailed case studies of selected accidents investigated including a Lear Jet 25B, Cessna 421, Beech Volpar Model 18, and Ted Smith Aerostar 601, are provided to illustrate specific types of crashworthiness, occupant protection, or post-crash emergency egress findings applicable to business/executive operations. Post-crash fire was reported in 29 cases (16.3%) during the 3-year period (1975-1977).

Statistics indicate that during the past decade (1967-1976) the number of general aviation aircraft involved in an accident is equivalent to at least 38% of the total U.S. production during that period. Estimates that an aircraft will be involved in an accident over a 20 year life range are as high as 60-70%. Recognition of this probability has led to crashworthiness and occupant survivability “packaging” design concepts as offering the most realistic approach to reduction of serious and fatal injuries when an accident occurs. This paper reviews and illustrates current general aviation aircraft accident experience relative to occupant impact injury and damage indexes, and provides new data relative to current-generation aircraft.

A study of free-fall accidents and resulting injuries was conducted to determine how useful these types of data could be in establishing human injury tolerance limits. “Tolerance” was examined primarily for children at two levels - reversible injury and threat to survival. The specific objectives were to investigate specific free-falls in sufficient depth to permit biomedical or mathematical reconstruction of the fall, simulate selected free-falls to estimate impact response, and compare predicted responses with observed injuries as a means of estimating human tolerance levels. From more than 2100 reported free-falls, 110 were investigated on-site. Seven head-first and three feet-first falls were then simulated using the MVMA 2-D Crash Victim Simulator. Newspaper reports of free-falls showed that males fell six times as often as females and most often while at work. Children fell from windows and balconies more often than from any other hazard.

The importance of crashworthiness and the role of restraint systems in occupant impact protection in U.S. civil aircraft design is being increasingly recognized. Current estimates of the number of fatalities which could be prevented annually in survivable accidents range from 33 to 94%. This study reviews the development of existing Federal Aviation Administration restraint system standards from the first requirement for safety belts in the Air Commerce Regulations of 1926 to present 14 CFR 1.1. The FAA and industry standards are critically evaluated for Parts 23 (small airplanes), 25 (air transports), 27 (rotorcraft), and 29 (transport category rotorcraft). State-of-the-art developments, including an overview of previous accident experience, results of experimental studies, comparison with other standards, and primary data sources are provided.

General aviation accident investigations can provide valuable data to the design engineer concerning the crash performance of current models and can indicate needed improvements for occupant protection in future aircraft. Current statistics and the historical background of major investigations during the past 65 years are provided. A five-year study of general aviation accidents occurring in the State of Michigan is used as a basis to illustrate recent findings relative to occupant injury mechanisms, relative crash protection, and crashworthiness performance of current models of aircraft. Results indicate that the degree of structural damage may not relate to the degree of occupant injury when the cabin area remains relatively intact. A primary requirement is documented for adequate upper-torso restraint for all occupants, and the excellent crash performance of such a system is described.

Properties of the human neck which may influence a person's susceptibility to “whiplash” injury during lateral impact have been studied in 96 normal subjects. Subjects were chosen on the basis of age, sex, and stature and data were grouped into six primary categories based on sex (F, M) and age (18-24, 35-44, 62-74). The data include: measures of head, neck and body anthropometry in standing and simulated automotive seating positions, three-dimensional range of motion of the head and neck, head/neck response to low-level acceleration, and both stretch reflex time and voluntary isometric muscle force in the lateral direction. Reflex times are found to vary from about 30 to 70 ms with young and middle aged persons having faster times than older persons, and females having faster times than males. Muscle strength decreases with age and males are, on the average, stronger than females.