“One challenge we would frequently face in the design of the simulation model was the lack of attention to some dummy positions, such as sitting in the back or children riding as passengers,” explains Philipp. “Even tiny adjustments to the seat belt would often mean that we had to start the whole process again.”
Philipp therefore wanted a modular design for the simulation model by all accounts so that the new process is as time-efficient as possible and can be used in a variety of ways. So he set about automating the steps involved in the process of seating the dummy in the rear using Robotic Process Automation in ANSA and adapted the finite element models generated in this way using Python scripts. “Getting to grips with the FE software and all its tools was really time-consuming,” adds Philipp. “The subject is very complex because of the wide variety of dummy types, child seats and vehicle models. But my team at PSW was always there with expert help in answer to any questions I had about the models used.”
And the results are impressive, with scope to adjust dummies and booster seats, even allowing for the shape of the seat foam, and to produce or adjust seat belts. Philipp’s modular process also offers the option of processing models directly with graphic feedback and the possibility of making subsequent changes – such as moving the seat belt without having to repeat the seating process.
The new approach already offers time savings of up to 50% compared to previous solutions. Philipp is now studying for a master’s degree in mechanical engineering with a focus on automotive technology and is supervising the further development of the seating process at PSW as a student employee. “I demonstrated the feasibility with my bachelor’s thesis. Now the task is to improve and develop the process further. There is scope for additional tools, for example, and for the first and third row of seats but also for other vehicles and dummy types. And, of course, we also want to increase the level of automation,” explains Philipp.
