Virtual Prototyping and Analysis Ed Winkler Technical Fellow Human Systems Boeing Phantom Works

1. Virtual Prototyping and Analysis Ed Winkler Technical Fellow Human Systems Boeing Phantom Works St. Louis

2. Percentiles

3. Progression of Accommodation Expansion F-22 (1-99) JSF (JPATS) F/A-18 (3-98) Male / Female F-15 (5-95) Male only 60s 70s 80s 90s

4. BackgroundCurrentAccommodation Problems (AFI 48-123 = 64” to 77” Standing height and 34” to 40” Sitting Height.) Ref: Dr. Zehner

5. BackgroundJPATS (Joint Primary Aircraft Training System) • 1994 - Congress directed that the JPATS would accommodate 95% of female military population. • This translates to a 58” Standing Height and 31” Sitting Height minimum Ref: Dr. Zehner

6. Percentiles Are Not Additive Sum of 5th %ile Parts= 136.89 cm 5th %ile Height= 152.50 cm Difference= 15.61 cm Sum of 95th %ile Parts= 188.81 cm 95th %ile Height= 173.06 cm Difference= 15.75 cm SAMPLE SIZE=3235 *From Robinette and McConville 1982

7. Percentile Fallacy If 5th to 95th percentile limits are applied to each of the following: Remaining Percentage 95-100% 0-5% Sitting Ht. 90% Butt-Knee Lth 82% Knee Ht. Sit. 78% Shoulder Brth 71% Functional Reach 67%

8. 1 3 2 3 1 2 3 2 1 Average is Different From Everyone! x y z 2 3 1 1 2 3 3 1 2 Average 2 Subject 1 Subject 1 Subject 2 2 Subject 3 Subject 2 2 2 2 2 Average Subject 3 • Average Person? Does Not Exist (Daniels 1952) • Summary Statistics Are Not Good Data Reduction Tools for Engineering Models

10. Boundary Points and Principal Components (JPATS Cases) 3 S E C O N D C O M P O N E N T 5 2 1 6 7 8 4 FIRST COMPONENT

11. Challenge: Is a biomechanical model needed? Model actual data instead? Can Also Create Dynamic 3-D Simulations with 3-D Scans A CAESAR Subject Standing Pose Segmented and Joint Center Linked Then Repositioned to a Seated Pose A 10 segment CAESAR subject standing pose.

12. Can Use 3-D Scans to Characterize Cases Advantage • With 3-D Have a Model so Can Have Set of 3-D Cases • Can Visualize Real People As a Reference During Design Issues and Challenges • 3-D Shape or Size Statistics are Limited • To Select Cases Still Limited to Traditional Measurements

13. Distributed Cases 3 6 9 1 5 4 7 8 2 Issues: 1) How to Select Measurements 2) Where to Select Cases

14. Characterizing Populations HGU 55/P Helmet Center of Gravity Distribution Left Pupil Distribution Right Pupil Distribution Right Ear Distribution Challenge: Full Population Data is Difficult to Visualize

15. Background Small Subject ( 5’- 0”) in the T-38Inertial reels locked

16. Stature and Sitting Height Are Not Enough Eye Height Buttock-Knee Length Arm Span Sitting Height Knee Height Shoulder Height

17. Military Population Pilot Population Male Female T-1 Results: VisionMinimum Eye Height = 29.6” • Original design eye line = -10 deg. • Base of windscreen wiper • Verified through study flights as minimum for no-flap landing 91% 96% 47% 91% Percent Accommodated

18. T-38 Results: RuddersMinimum Leg Length = 43” Military Population Pilot Population Male Female Requirement: Full rudder and full brake at the same time • To recover from a blown tire on landing • Pilot tightly restrained PercentAccommodated: 95% 97% 46% 81%

19. 15.3 inch 6.3 inch Large Male 97.5 Percentile Small Female 2.5 Percentile EXPANDED ACCOMMODATION 5-95 PERCENTILE DESIGN POPULATION WITH JPATS OVERLAY COMPARISON. COMBINED ACCOMMODATION 55 50 Approx. 5-95% MALE USAF Range 45 LEG LENGTH (in.) 40 35 - JPATS Manikins 35 45 30 40 SITTING HT. (in.l)

20. Accommodation Limits JPATS 1-8 F-22 Requirements .5 - 99.5 %ile Male AF Pilots Case 7 Design Goal 95% of U.S College women Age 22-27 Case 1 Spec. Reqmt., 82% of U.S College Women Age 22-27 UPT Entrance Requirements 67.5 % of U.S College Women Age 22-27 USN 41 in. Sit. Ht. 39 % of U.S College Women Age 22-27 "Traditional" Design Standards, 5th - 95th %ile Air Force Pilots 5th - 95th %ile Female Pilots 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 Sitting Height - inches

21. JPATS Multivariate Cases • Case 1 -- Small • Case 2 -- Medium build, Short limbs • Case 3 -- Medium build, Long limbs • Case 4 -- Tall sitting height, Short limbs • Case 5 -- Overall large • Case 6 -- Longest limbs • Case 7 -- Overall small • Case 8 -- Largest torso Thumb tip reach Buttock knee ln Knee height Sitting height * * * * * * * * * * USAF 5-95 % 16 20 24 28 32 36 40 inches

22. EXPANDED ACCOMMODATION ANALYSIS TOOL- Variables SITTING HEIGHT EYE HEIGHT SITTING THUMBTIP REACH KNEE HEIGHT SITTING BUTTOCK KNEE LENGTH SHOULDER HEIGHT SITTING

23. Example: JPATS Cases

24. 4 Long torso/short limbs Small torso/ short limbs Longest torso 8 2 1 Overall Small Overall Large 5 7 GENERALLY AVERAGE Small torso/ Long limbs Long limbs Medium torso/long limbs 6 3

25. . . . ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. . ………… …………… ………….. ……………. ………… …………… ………….. ……………. ………… …………… ………….. ……………. . . ………… …………… ………….. ……………. . Geometry portion Statistical portion (PCA) Rapid Prototyping • New design • Re-design • Competitor evaluation • Various Populations • Combined Populations • Defined Requirements Expanded Accommodation Analysis Technique • % Accommodation • of a given design • Impact of a geometry change • on accommodation • $$ estimate impact against geometry change • vs accommodation achieved Now Allows

26. EXPANDED ACCOMMODATION ANALYSIS TOOL- Data Analysis • MULTIVARIATE ACCOMMODATION METHOD • (PRINCIPAL COMPONENT ANALYSIS) • REDUCES A LIST OF VARIABLES TO A SMALL MANAGEABLE NUMBER • ENABLES DESIGNERS TO SELECT DESIRED PERCENTAGE LEVEL OF A POPULATION TO BE ACCOMMODATED • PERCENTAGE LEVEL TAKES INTO ACCOUNT NOT ONLY SIZE DIFFERENCES BUT PROPORTIONAL VARIABILITY AS WELL • INDICATES WHICH VARIABLE PROVIDES MOST ACCOMMODATION Bottomline: Determines % population bounded by the requirements

27. Principal Component Analysis--What is it? • PCA- Statistical Multi-variate analysis approach that simultaneously converts large sets of • multi-dimension data into 2D or 3D linear principal components • How is this accomplished • Compute variance - Square of deviations • Compute Covariance - Product sums/Product of variances • - Correlation matrix between variables • Compute Eigenvalues- Similar to regression--goodness of fit • -Contribution of each data set variable (indication of percentage of • variance of data) • Compute Eigenvectors - Indicates weights of each variable in transformation • - Each eiganvalue corresponds to a set of eiganvectors • - Vectors position values • Compute Principal Component - First component corresponds to with highest eiganvalue • - Second component corresponds to the next highest value • Component is a linear combination of • original data set which accounts for • most of sample variation *Very effective in analyzing variability of human body anthropometrics (Subject representation) Component 2 …... Component 1

28. General Capabilities - Cockpit Module • PC based • User friendly, rapid response • Variable seat/cockpit geometry • Direct manikin selection (single, multiple) • Zone 1 and 2 reach to individual controls • Miss distance calculation, Interference assessment • Head clearance • Rudder pedal reach • Population percentage accommodation analysis • Male, Female or Male and Female populations

29. Direct geometry input (make new or modify any geometry) • Direct seat/motion input (standard or variable) • Instant picture re-draw • No need for complex file transfers

30. Manikin Anthropometry • 1-7 JPATS • plus #8 JSF • plus 1 additional

31. Based on JPATS Manikin Anthropometry

32. Analysis of population accommodation male Direct calculation of Percent Accommodated male/female Principal Component Analysis female

33. Additional Analysis Capabilities • 3-D Component Analysis • Subject Exclusion

34. Current Status • Completing program with Tennessee State University • Additional capabilities/modules being added • Initial validation complete • Validation appears to be well within 1 Standard Error from actual physical measurements

35. Validation

36. Now the fun is over Here is the homework Oh yea, I get to leave town

37. Problem 1. • This problem illustrates developing a design with large latitude in design options. The goal is maximum accommodation of a combined male/female population. • Eye position either 1) Get the eye up to or along the ONV line (11-18 degrees) Zone 1 or 2) in the eye box Zone 2. • Have full rudder travel for accommodation range. • Zone 2 reach, 14 inches below Design Eye Position and just forward of ejection line.

38. Problem 2. • This problem looks at a range of fixed designs (do not change any geometry numbers). The goal is to rank each design for the best accommodation and estimate accommodation for 1) all male and 2) male/female populations. • Reach points given are Zone 2 (do not change locations)

39. Problem 3. • This problem looks at a design problem that has many restrictions for possibly a specialty design. • Manikin 4, 5, 6 and 8 must be shown to be accommodated as well as maximizing overall male/female percentage. • Optimize and develop a design for maximum accommodation, male/female plus 4, 5, 6 and 8. • Seat contact (8 inches) below SRP to floor and floor to canopy is 50 inches. • Rudder travel from any horizontal SRP is 30-50 inches. • Range of seat or ejection angle is 11-25 degrees. • Top of head in Zone 1 is minimum of 3 inches to canopy. • Reach point Zone 2 is now 2 inches forward of ejection line and 14 inches down from DEP.

40. Problem 4. • This problem is a specialized design with constraints associated with moving devices (rudder and seat). • Maximum linear rudder travel plus (+) maximum linear seat travel totals 12 inches or less. • Must reach in Zone 2 a point 14 inches down from DEP and forward of ejection line • SRP to floor under seat is 8 inches minimum. • Goal is maximum accommodation.

41. Notes: All reaches for the model in Zone 1 and Zone 2 are a “Functional reach”, i.e., pinch. Canopy clearance is 3 inches minimum from Zone 1 posture (top of head to inside mold line). SRP to Floor is a minimum of 8 inches (estimates kit/seat thickness). Ejection clearance is 28 inches or greater. For eye position either 1) Get the eye to the ONV line (11-18 degrees) Zone 1 or 2) in the eye box Zone 2. Rudder accommodation (manikin foot just touching rudder circle). Do not exceed 5 degree delta between back angle and ejection angle. Shin contact radius min. 2 inches. Model notes You have to change manikin sizes from geometry screen, then select them from Boundaries/Others/browse menu When you change manikin do it proportionally …torso (eye ht, sit ht, shl ht), same for butt knee and knee ht. Might crash if too many manikins on screen and you change zone 1 or 2 Only edit the MODE 1, 2, 3 manikins for problems Up and forward seat adjust is for 30 deg is 330, back 15 is 15 DO NOT…DO NOT edit or change any link equations Help screen gives general methods for making everything run If it locks up or manikin positions itself funny….close and re-open it.

42. Demo Teams Questions

43. Problem 1. This problem illustrates developing a design with large latitude in design options. The goal is maximum accommodation of a combined male/female population. Eye position either 1) Get the eye up to or along the ONV line (11-18 degrees) Zone 1 or 2) in the eye box Zone 2. Have full rudder travel for accommodation range. Zone 2 reach, 14 inches below Design Eye Position and just forward of ejection line. • Problem 3. • This problem looks at a design problem that has many restrictions for possibly a specialty design. • Manikin 4, 5, 6 and 8 must be shown to be accommodated as well as maximizing overall male/female percentage. • Optimize and develop a design for maximum accommodation, male/female plus 4, 5, 6 and 8. • Seat contact (8 inches) below SRP to floor and floor to canopy is 50 inches. • Rudder travel from any horizontal SRP is 30-50 inches. • Range of seat or ejection angle is 11-25 degrees. • Top of head in Zone 1 is minimum of 3 inches to canopy. • Reach point Zone 2 is now 2 inches forward of ejection line and 14 inches down from DEP. • Problem 2. • This problem looks at a range of fixed designs (do not change any geometry numbers). The goal is to rank each design for the best accommodation and estimate accommodation for 1) all male and 2) male/female populations. • Reach points given are Zone 2 (do not change locations) • Problem 4. • This problem is a specialized design with constraints associated with moving devices (rudder and seat). • Maximum linear rudder travel plus (+) maximum linear seat travel totals 12 inches or less. • Must reach in Zone 2 a point 14 inches down from DEP and forward of ejection line • SRP to floor under seat is 8 inches minimum. • Goal is maximum accommodation.