Car Body Design and

Aerodynamics
Automotive Engineering

Prof. Andrea Tonoli

Politecnico di Torino,
Dipartimento di Ingegneria Meccanica e
Aerospaziale
andrea.tonoli@polito.it
 Aim of the course
Introduction of the main aspects that influence the car body
design taking the mutual constraints into account.
Packaging ergonomics
Ergonomics
Visibility (direct and indirect)
Structural aspects
Structure configurations
Structural analysis
Noise and vibration
Passive Safety
Restraint system
Crash and energy dissipation
 Course organization
Classroom lectures exercice
Keynote presentations Case study:
(industrial practice) Packaging of a vehicle
Visits Visual requirements
verification
Structural analysis (FEM) of a
car body (static parameters)
Case study results
Technical reports and
drawings to illustrate the
Exam: obtained results
Oral and/or written discussion
(the exercice reports are integral part of
the exam and of the evaluation)
 Packaging
Establishing the required interior
space, and arranging interior and
structural components (seats,
controls displays, ...) to guarantee
driver and passenger safety,
comfort, convenience and
accomodation.

Comfort
Controls accessibility
Cabin and trunk accessibility
Powertrain, suspension and
structure positioning
Requirements (standards)
Front side Back side

Cervical

Thoracic

Lumbar

Sacrum

2.2 -1
2.2 - 2
 Anthropometric data

Anthropometric measurements are statistically distributed

( approx. Gaussian distribution). The distribution can be defined
from the average and standard deviation.

Percentile: if 100 people are ordered from the least to the

greatest for any given measurement, the 1st percentile is that
exceeded by 99% of the group, the 70th percentile is that exceeded
by 30% of the group....

Different databases (and percentiles) can be gathered for male and

female population. To reduce complexity dimensions used for
automotive anthropometry are based on 50% male 50% female
population.
The anthropometric data change with time !
2.3 - 3
2.3 - 4
 Manikin percentile models
SAE J826 manikin (H-point machine)
EU manikin for R point definition

Percentile 10th 50th 90th 95th 99th

A [in] 15.37 16.40 17.46 18.10 18.74

B [in] 16.05 16.99 17.94 17.99 18.69

Task oriented models
Task oriented: head contours
Task oriented: eyellipse
Task oriented: control reach
Body base grid for vehicle measurement

USA
EU
 Basic postures

seated reclined cramped

+ longitudinal size + vertical size

+ vertical size
+ control reach + load on backbone
+ longitudinal size
+ visibility + vibration and fatigue

- vertical load on backbone
- vibration and fatigue
- vertical size
- control reach
- longitudinal size
- vibration and fatigue
- in/out of the cabin
- in/out of the cabin
- visibility
- visibility
 Angles for automotive postures

() SAE Wisner Wyse RENAULT

Alfa 85-95 85-95 90-110 90-110

Beta 105-115 95-120 95-135 90-135

Gamma 95-105 85-100 87-103 95-120

Delta 15-28 15-25 20-30 25-30

 Packaging procedure

1. Pedals setup and operation

2. Mechanical constraints
3. Definition of heel point (HP)
4. R point definition (driver)
5. Check Interference with steering column and dashboard
6. H point definition (second and third row)
7. Head contours
a1) a2)

HP HP

b)

c1) c2)
 T
SR

P
GB

FW
SA

TR
3035
 25 27-30

95th 95th

R G

330-400
20-30

HP

150-200
1000 800-850
2.6 - 3
148 9 Ergonomics and Packaging

Fig. 9.11. SAE J1100 dimensions relative to drivers posture.

The backbone is the structure that transmits the vertical load of the upper
2.6 - 4verte-
body to the legs. The transmitted force increases from the cervical
brae to the lumbar ones that, in comparison, are the most heavily loaded
as indicated by their larger size 9.1.
2.6 - 5
 SAE J1100 Package dimensions

elbow
hip
Package definition
 9.4 Pedals Functionality and Positioning 155

Fig. 9.14. Test bench to investigate the postural seating comfort (seating buck ).
The bench is representative of the position of the driver and the main cockpit ele-
ments: pedals, seat, steering wheel and allows to measure the angles between the body
segments.
Factors influencing seat comfort
Subjective and
psycological
Physical attributes
10% Of the seat
Pressure
9%
distribution
9% Backbone support
54%
9% Thermal behavior

9% Vibration isolation

2.7 - 1
 Seat comfort
Factors influencing comfort for still vehicle
Body support
Perceived contact stiffness;
Lateral support
Possibility to adjust the posture
Tactile perception
Aestetics

Factors influencing comfort for moving vehicle

Vibration isolation
Avoid limitations to the drivers motion
Reduce the dynamic loading of backbone and contact regions

2.7 - 2
 Pressure distribution
(comfort index for still vehicle)

cushion Seat back

rear

front

Seat back

Upper
y = 56,1 RA + 11,25 RD 16,16
Lower
Comfort index

2.7 - 2
2.7 - 3
 Vibration insulation of the seat
(comfort index for moving vehicle)

Power spectral density of the

transmitted acceleration
1
Wi ( f )

G SS ( f )Wi 2 ( f )df
SEAT % =
100
G ff ( f )Wi 2 ( f )df

Weight function

Power spectral density of the vehicle

structure (seat connections to the veh.
Body)

0.5 Hz < f < 80 Hz

a b

2.7 4
 Automotive climate
Tester
Front view
Thermal Shield
Control system
Automotive climate
Pump Tester
Back view
Sweating patch

Temperature and
humidity sensor

2.7 - 5
2.8 - 1
2.8 - 2
2.8 - 5
2.8 - 6
2.9 - 4
2.10 - 1
Eye structure
Fig. 2.11-1
Limits of visual fields, obstruction
 Fig. 2.11-2

Min transparency = 70%

 source

p = 0 A( )

A0 n 2 sin 2


A( ) = 1
n 1 cos


eye
0 1.5'

= 60 = 1.5'2.85 = 4.3'
A(60) = 2.85

Fig. 2.11-3
 source

d
c = B( )
r
eye d = 4.6 mm
4.6
r = 3000 mm = 3.57 = 5.46'
3000
B(60) = 3.57

Fig. 2.11-4
 source

eye

Fig. 2.11-5
Fig. 2.11-6
Fig. 2.11-7
Fig. 2.11-8
Fig. 2.11-9
Fig. 2.11-10
Fig. 2.11-11
Fig. 2.11-12
Fig. 2.11-13
Fig. 2.11-14
Fig. 2.11-15
Fig. 2.11-16
Fig. 2.11-17
Fig. 2.11-18
Fig. 2.11-19
Inside mirror
h > 4 cm
1
a = 15cm
1000
1+
r
rmin + rmax
r= > 1200 mm
Outside mirror 2

h > 4 cm
1
a = 13cm
1000
1+
r
Fig. 2.11-19