Lean and Green

Lean & Green | AUTO

s o l e

V n ia

C t s i hr o

Christian VELOSO

Christian Veloso is a student from RMIT University who is currently on his second year studying Industrial Design. When he isn’t trying to finish off his projects and work, Christian volunteers as a leader for a youth group called Epic under a church called Life located at North Melbourne every Friday night. He also regularly attends the church on Sundays also leading a hosting team.

He currently resides in Clayton South, Victoria. On his spare time, he does graphic design work for the youth group.

Christian was awarded with the Academic Excellence in 2013 for being the top student in Visual Communication and Design from Bentleigh Secondary College. He continues pursuing his interests in anything that is creative, from when he was younger with his background in art, and now in his new venture into the world of design as he explores the endless possibilities it offers.

Studio Context Lean & Green

Lean and Green is a design studio that aims to demonstrate the future of mobility and how SuperLightweight Cars (SLC) are going to lead the way in the transition.

The role of a concept vehicle is to demonstrate a potential future in order to gauge the public’s reaction and provide creative direction for a company to rally behind.

To successfully meet the outcome, firstly, we have to generate ideas for the next generation of automobiles.

This will involve research into benchmark vehicles, lean processes and green manufacturing.

During this studio, we will be inducted into design teams that generate and produce full scale concept cars for industry review that demonstrate the ideas of ‘Lean and Green’. Lean & Green Studios defy the prevailing Car design ideological inertia of bigger is better and adopt a position of a necessitated future for SLC. We will engage with the Lean & Green philosophy and methodology to explain our (collective) design.

Lean & Green Design Manifesto Melbourne is projected to host 7.7 million citizens in 2051 as the population densify and climate change creates more weather impacts with greater frequency, our transport systems and infrastructure will be overwhelmed. As such it is wise to consider mobility alternatives that can work in densely populated cities and engage with themes of sustainable mobility and consume resources in a much less impactive manner. With the demise of local production by Holden, Ford and Toyota in Melbourne many of the

economic impediments to alternative developments are dissipating, and local companies are looking to broader and diverse horizons.

Through this studio we will demonstrate that the future of mobility is one of smaller lightweight agile vehicles that use intelligent materials and consume energy more efficiently and radically reducing pollution and overall energy consumption. Incorporating emerging technologies in production and new ideas about light weighting, radical approaches to safety and urban mobility.

CURTAILMENT EFFICIENT RELENTLESSBENCHMARK PROMINENTENVIRONMENTAL LIVERY MODESTPRESENCE SAFE

CONSTRAINTS DESIGN APPROACH Before executing the project, there are some design approaches I have to consider:

2+x

Lean and Green

My 2+x concept proposal is to create a vehicle that will serve as an ‘ambulance emergency response vehicle’. The primary objective is design a vehicle that will occupy two occupants and meet the requirements needed for an emergency vehicle. The primary user of this vehicle will be a paramedic, an expert of their practice, who will be sent to the scene in advance before an ambulance van is available. This vehicle will require to occupy all the necessary equipment needed for a paramedic on the scene of emergency.

The vehicle will remove unnecessary equipment to maximise the seating space for both the occupants, the driver and the patient. The car will have a reduced engine capacity of only 450cc and a footprint of no more than 1200 x 2500mm. The materials used are to be lightweight to reduce the net weight of the car and the car will be fitted with a 12” rim. Having a lean process not only is carried by the design of the car, but also the manufacturing and the assembly of the car. Finding and using efficient ways of manufacturing the car is also to be considered.

The project constraints are: • Accommodate 2 people plus an x factor (2+x) • This vehicle will feature a WR450 motorcycle engine

What is Lean?

The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources .

• You will design a concept vehicle that has a footprint dimension of 1200 x 2500mm • It will be equipped with a 12” rim

&

What is Green?

‘Green’ is for sustainable design ethos and approach The 2005 World Summit on Social Development identified sustainable development goals, such as economic development , social development and environmental protection .

2+x Scenarios of Use

Scenario

CONCEPT 2 + x Graduate with a paramedic or a paramedicine degree

+

Become a qualified paramedic with driver’s licence

Develop skill and confidence

Join a hospital and become a paramedic

Learn how to drive an ambulance

Have field experience and go through the process as a trainee

EMERGENCY RESPONSE VEHICLE My concept is proposing a vehicle that will accommodate two occupants and an x factor. The x factor in this proposition is a vehicle that will deliver as an emergency response vehicle for paramedics.

This vehicle’s primary use it to allow paramedics to aid at the scene of emergency before an ambulance van is available. It will occupy only one driver, that will be the paramedic,

and the possibility of carrying one passenger, the patient. This vehicle will need to meet the requirements of an emergency response vehicle.

It will have to be able to have the necessary medical equipment installed and/or stored within the vehicle. It will need a seat that has enough leg space for the patient, potentially able to recline.

Become a Single Response Unit (SRU)

Assist to place the patient into the ambulance

Receive an emergency call

Wait till an ambulance is available on scene

Drive to the scene of emergency

Aid person on the scene

FEATURES The features in the car would be: • Medical kit • Oxygen • Airway management set

• Cardiac monitor • Collapsible wheelchair • Siren/ lights No ambulance is available and patient needs immediate hospital attention

Aid patient into the vehicle and drive to the hospital

Assist the patient into the emergency room

CAR

DIET EXTERIOR

FEATURES

The exterior of the vehicle is effectively reduced in size with a much smaller footprint of 1250 x 2500mm; which is one of the constraints on the brief.

Given that ambulance are generally large vehicles in order to accomodate a patient, there is nothing much I can reduce from the exterior of this concept.

There is the possibility of removing the doors in order for the emergency response officer to exit the car as soon as possible on arrival. But then on the other hand, Melbourne has cold and hot temperatures and often rains which leaves the patient vulnerable to the weather conditions in Melbourne.

The car will need to feature all necessities of an emergency response ambulance, but will be reduced for the use of the smaller sized vehicle. It will feature the standards of an emergency vehicle with sirens and blue and red lights. In this micro ambulance, it will feature a dashboard or centre console monitor that shows the patient’s condition on a the screen. It will have a small storage space in the rear that will be occupied by medical equipment needed for a paramedic. It will need to store a medical kit, oxygen, cardiac monitor, airway management kit and possibly a collapsible wheelchair.

I will also be looking at removing the siren lights on top of the ambulance and possibly integrate the lights, with the use of LEDs, on the roof of the car. The lights will need to be able to cover a 360˚ angle to alert pedestrians and other drivers of the car’s presence, without causing any diversion on the driver’s visibility of the road.

There will be a seat that is able to recline to allow the patient to rest, but due to the dimensions of the car the patient won’t be able to fully recline to a laying down position. Ideally in an ambulance, the patient is laying down and facing the opposite direction of the vehicle’s travel, but for the saftey of the occupant in case of an accident, the patient’s seating position is forwardfacing.

INTERIOR The interior of the car will be reduced by removing the stereo, centre console island and upholstery seats that is replaced with a lighter composition such as fibreglass. The seat will have to be covered with a cloth for hygiene purposes that can be either disposed of or washed.

Sun visors are not installed in the car as it is tinted from the outside to allow privacy for the patient within the car. The carpet is removed and replaced with a thin metal flooring that can be easily cleant and sanitised.

OPTIONS ˚ Manual Windows (greener option) ˚ Electric Windows ˚ Central Locking ˚ Air Conditioning ˚ Centre Console - Medical Monitor - Bluetooth Calling - Stalk/ Gear Stick

PERSONA

BOARD

John 33

Luke 12

Caroline 25

Jane 68

John is an experienced paramedic who enjoys helping people out who are in need. He has seen many different cases and has become confident in his skill.

John is an outgoing person and knows how to connect well with others, he often socialises during his nights off work with some friends and colleagues.

Luke is a young boy and enjoys being outdoor. He enjoys the playground and playing sports and anything that makes him active. He is also curious about new things and likes to put himself in unique situations.

Caroline is a student who generally stays indoors rather than going out. She enjoys watching television series and listening to music. She sometimes go to concerts with her friends to see her favourite artists perform live. Most of her day consists of her staying in at home and studying.

Jane is well advance in years and has only started enjoying her retirement stage of her life. She no longer has her husband in her life and lives by herself in the home she raised her children in. She enjoys in her spare time doing the garden on bright sunny days and occasionally drives down to the local market to buy her weekly groceries. Jane looks forward to every Sunday once a month when she gets to see her grandchildren and her own children.

John has taken up the role as a Single Response Unit (SRU) paramedic, where he is first to arrive on the scene of emergency by himself. It is required for him to act calmly and able to aid the person in need. His job is to look after the person until an ambulance van is available to take the patient to the hospital. There are often times where John is able to bring his patient in his car to the hospital in less major cases.

There are times where Luke will end up in unusual situations that usually ends up with him injuring himself. Often it is an injury while playing sports, but there are times where he gets badly injured climbing trees and playground structures.

Luke lives with his family in a household in the Eastern suburbs of Melbourne, which is also a 30 minute drive from the school he attends.

She lives in an apartment within the city with two other university students who she became friends with, they are all within the same age. On weekends she takes a break from studying to release some stress by going to the local coffee shop socializing with friends. She goes to church on Sunday mornings via public transportation.

There was one incident where Jane experienced one minor heart attack and was admitted to the local hospital located one-hour and 20 minute drive. She now has an emergency wristband that allows her to press a button to send a distress signal to the hospital which will relay to the closest emergency response vehicle near her area.

RESEARCH

BOARD

EQUIPMENT

Cardiac Monitor

Collapsible Wheelchair

Medical Kits

Oxygen

Airway Management Set

Paramedics Uniform

BENCHMARK RESEARCH (1959)

CC Tango (2005) • Slightly Wider • Longer in Length • Mini Car • Front Engine

• One Seater • Narrow (990mm) • Similar Length (2565mm) • Micro Car • Front Engine

HISTORIC PRECEDENTS Post World War II, micro cars became really popular and during that period it was often referred to as a cycle car; mainly because it was built around the frame of a motorcycle.

A new breed of micro cars came out during the 1990’s with bubble cars, city cars and smart cars which experienced price drops. Recently an Indian company manufactured the Tata Nano which was titled as the world’s cheapest micro car.

Smart Fortwo W450 (1998) • Slightly Wider • Same Length • Micro Car • Rear Engine

From the book, H.point: The fundamentals of car design & packaging by Stuart Macey and Geoff Wardle, I was able to use it as reference for the technical design stage of my car. This guided me

through the technical aspects and as well as influence my design, like the improvement of ingress and egress using gullwing doors.

MATERIALS &

PROCESSES

STEEL

Steel is mainly used within the underlying chassis or cage beneath the body of a car. This forms the so called skeleton of the vehicle. Parts of the car such as the beams on the door, roofs and even body panels are made of steel. Other forms of steel such as stainless steel is used in the making of the exhaust. Steel is also used in the making of the engine.

ALUMINIUM

Aluminium is a tough and lightweight material which is used on body panels of the car. It is also used for creating the rims of the car. Pure aluminium is not as durable and is usually mixed with other metals to create an alloy.

Aluminium can be engineered for specific purposes with alloying.

POLYMERS

Polymers are used in many parts of cars today. It is found in bumpers, seating, dashboard, fuel systems, body (incl. panels), electrical components, lighting, upholstery, interior and exterior trims and more. Although there are up to 13 different polymers or more used in a single car, there are mainly three types of polymer that makes up 66% of plastics (approx.):

FIBREGLASS

Fibreglass is commonly used in automotive as an insulation material in cars. It can also be used in making seats instead of using heavywighted upholstery.

CARBON FIBRE

Carbon Fibre is a durable and lightweight material that can be used as an alternative material for manufacturing body panels, rims and even complex parts such as engine parts like Koenigsegg.

They are also used to reinforce materials such as ceramic brakes into carbon ceramic brakes.

• Polypropylene (32%) • Polyurethane (17%) • Poly-vinyl-chloride (16%)

Steel can be engineered to be more rigid or be able to crumple to absorb impacts in specific areas of the vehicle.

RUBBER

GLASS

Rubber is mainly used in the making of tyres for cars. In addition to the all-important tyres, there are also various parts of the car that is made of this material, such as: • Wiper Blades • Engine Mounts•

• Belts Seals

Glass is primarily used to create windows and windscreens for visibility outside the car. It is also applied to create mirrors that are used to make side mirrors, rear view mirrors. With the advancement of technology, glass is also used to create lenses for reverse cameras and navigation screens, like HUD or centre consoles.

MATERIALS &

PROCESSES The Press Shop

Bodyshop

The press shop is where the roll of sheet metal is rolled through a belt where it is the cast over a die form and pressed into shape.

Other cases, like in super cars that use carbon fibre technology, it is layered in a die mould that is then superheated to form a unibody. Fibreglass will also be similar to this process.

Paint Shop

After the bodyshop, the car is ready to be washed and degreased then coated with a layer of zinc phosphate. It then has 3-4 layers of paint that will protect the car from environmental influences.

AssemblyF

In this stage the car is fitted with all the wiring and connections that controls the communication in the car.

The floor, dash and seats are installed inside along with the glass being glued for the windows and windscreens.

The construction of the chassis is assembled in this stage with all the pressed metal parts joined together. The parts are either welded, glued or bolted together.

inal Assembly

The final production stage reaches the stage called a ‘wedding’ where the engine, drive and chassis come together and bolted with precision.

Cadillac El Mirage

Welch Allyn Connex Vital Signs Monitor UI Prototype

REFERENCE

DASHBOARD

Chevrolet Corvette 1984

KIA K900 2015

Volvo V40

Ford 012C 1999 Concept by Marc Newson Audi Quattro 2014 Concept

BMW Dashboard design by Denys Nevozhai

DASHBOARD

CONCEPTS

60

40

ABS

80

20

100

N 1 m

BP

68

mm

45

SpO2

97%

6.8 km

2

3

ABS

100

6

140

120

104

80 60

5

4

2

40 20

Left in 200m

0

St. Kilda Road

012 4811 km

000 1 m

0

4

1

3

6.8 km

1N 2

bpm

NIBP

SpO2

120/80

98%

SYS/DIA mm Hg

Body Temp.

RESP.

37.3

14

3 45

78 KPH

BP

mm

45

SpO2

012 4811 km

0

Telestra

2.7 x1000/min

Unknown ABS

012 4811 km 6.8 km

80

100

120

60

Distance

mm

17.2km

+63 412 345 678

20

Est. Time

4.27pm

0 km/h

Time

4.04pm Cabrini

68 BP 45 SpO2 97% m

40

Destination

97%

Left in 200m

6.8 km

1

81

68

8 87

4

2

PULSE

5 m

Left in 200m

St. Kilda Road

Left in 200m

3 012 4811 km 6.8 km

5

012 4811 km

Unknown +63 412 345 678

4

INSPIRATION

BOARD INTERIOR SPACE

INSPIRATION

BOARD INTERIOR

INSPIRATION

BOARD EXTERIOR

Lean & Green Concept Proposal

I have decided to combine some features from these two sketches, as a result I have designed the concept car I will start to develop on, seen on the right-hand side of the page.

This concept utilises a gullwing door which improves the ingress and egress of the car. It has air vents that allows air to flow into the engine compartment. The siren lights that are installed above are designed in a way to imitate a spoiler, it is rear mounted to allow space for the doors to fully open without interference.

I have decided to remove the side mirrors as I found it unnecessary for an emergency vehicle, and creates a more lean car by removing excess material and weight. Also, by removing the side mirrors, I was able to maximise the width of the car to the full 1200mm from the constraints of the design brief. Thus allowing me to create more space within the interior.

Lean & Green CAD Development

The design approach was to make a minimalistic form so it has a friendly profile and approach towards people.

The designed is inspired by vans, which are the primary vehicles used for ambulances. By utilising the form of vans, it maximises space for the interior allowing to create room for the patient to recline and store medical equipment necessary for paramedics to perform first aid.

The CAD development process used extruded shapes and extrude cuts to create the form and fillets to give is some shape. This resulted in a model car of a box-shaped form like vans. Working on one half of the car maximises time as it can be mirrored at the end of the process; mainly because cars are generally symmetrical.

This was my experimental stage of using CAD as the model did not turn out quite the way I’ve intended it to look as I just developed it from scratch without referencing it with my own sketches. As a result I have a car that has very little finesse.

HUMAN

FACTORS INGRESS

HUMAN

FACTORS INGRESS

INTERIOR

SHOT

TECHNICAL ELEMENT

ARRANGMENTS

= Space to store equipment = Engine = Fuel Tank

100 14˚

11˚

Back Angle 21˚

H. Point 625

TECHNICAL ELEMENT

ARRANGMENTS

= Space to store equipment = Engine = Fuel Tank

Lean and Green | Simon Curlis

Christian Veloso

HERO

SHOT FRONT

HERO

SHOT REAR

Here, I start to explore more curved surfaces to give the vehicle more form and road presence. Also, I have sketched different side mirror designs, that was an integral part that I was not able to put on my first CAD model. I’ve decided to build a new model from scratch based on this sketch.

Developing the interior plays an integral role into the design of the Entity. Creating as much space for both occupants and to have all the necessary functional parts of the car, such as a dashboard and steering wheel. Looking at half a dash, allows more space for the passenger side, thus allowing the patient to have more leg room when reclining.

In this redeveloped CAD model I used surfacing to create more form and shape with the design.

Using the Victorian ambulance livery on the vehicle, it gives the car more road presence and authority and creates a sense of familiarity that it is an emergency vehicle.

There are still a few things to fix up here:

• Discontinuous surface from the hood to the A-pillar • Thickness of A-pillar is too narrow • Increase the size of the side-view mirrors

• Front bumper needs to protrude out more to give it more form • Redesign the front grill • Develop headlights • Redesign the interior

1

2

3

4

5

6

D

2600

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C

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B 1600

C

Title: 1380

A

1

2

Part No.

3

EA-01

4

Size:

Rev:

Date: 8/06/2015

A3

A

THIRD ANGLE PROJECTION

Qty:

Units:

1

MMGS

Entity Description: Orthogonal View Scale:

5

A

1:20

Sheet: 6

11 of

Lean & Green Exterior

The inverted ‘Ambulance’ word is intentionally designed that way for when other road users view at their side mirrors or rear-view mirrors, they are able to read it back to front.

The Entity is equipped with LED siren lights that are encased in a transparent acrylic housing installed on the roof-top. At the rear-bumper, there are vent that proved air flow through the engine compartment,

that enters through the rear-wheel envelope and the underpass then out through the vents. The Entity features a door opens with a gullwing feature that improves ingress and egress. It is also equipped with keyless door entry for when the paramedic has their hands full from assisting their patient into the vehicle.

The design of the car features reflective livery during night time and days that are lower in visibility.

This enhances the Entity’s road presence and creates awareness of other road users and pedestrians.

The front bumper is equipped with siren lights that provide directional light source which can be seen in a rear view mirror or side mirrors. The side mirrors have indicators installed to alert other road users and pedestrians the direction the driver is heading towards.

Lean & Green Interior

With the interior of the Entity, the passenger half of the car has no dash to create more space for the patient’s leg room. This maximises the comfort for the passenger as they are able to recline from the limited volume of the interior and personal space.

Removing half of the dash allows room for potential equipment to be installed, such as a monitor. The seat is covered with a cotton cover that can be removed and be replaced when necessary. This feature allows hygiene and sanitary issues that come with sick patients.

The driver’s half of the interior features a dashboard that almost consumes the area. This allows the driver to see the dashboard clearly and minimise the time looking down and more time looking at the road.

The seats are adjustable to suit the needs of different people, it can move longitudinally and recline.

Behind the two occupants, there is space for storing medical equipment and gadgets that are required for the paramedic to perform first aid. Under the surface ,the engine is housed with all the mechanical aspects of the car. Under the passenger’s seat would be space for the fuel stored in a tank installed underneath.

This half-dash features an 18� screen where it displays a full LED-LCD display. It also houses the vehicles intrumentations such as the indicator stick, the wiper stick and the steering wheel. The steering wheel features a finger clutch at the rear-side that triggers the gear shifts while driving.

The indicator stick houses the siren lights and pushing the button at the end of the stick toggles the siren on and off.

The dashboard features a sat nav to allow the driver to navigate to the desired location. There are cases where some people, particularly aged citizens, have a PRU Medical Alert pendant or wristband. When this is activated it will route the emergency alert to the Entity where it is displayed on the dashboard as it alerts the paramedic. It will then automatically set the navigation to the beaconing location, thus allowing the paramedic to drive to the scene of emergency.

1:1 Scale Model Team Project Development My main responsibility was the building of the trunk space of the concept car. But before I could start creating the boot-space, the seats and outer body needed to be placed.

This was so in order to get the dimensions of the trunk’s surface, I needed to measure the distance between the body to the rear of the seats and the width between the walls in the interior. So I was left to create the CAD model for the seats and help cutting it out and fix the

seats up together. But before all this happened. I contributed to the base foundation of the car model. I bought four casters from a local hardware store that has lockable hinges.

The base was not straight once it was finished, so I took the initiative along with two team members to fix it straight away, since we wanted a stable base as it will support everything else and a person on it.

1:1 Model result

Reflection

This studio was definitely a challenge as I am still inexperienced with the use of CAD. I had to overcome the challenge by reminding myself how to use Solidworks from last year.

The major obstacle I faced was time.

Having a busy schedule on weekends, having a full day on Fridays and church on a Sunday, I found time to do work crammed also trying to do my other class work. I had to overcome it by delegating time to which work required my attention as to how much work load is needed before the submission. There would be nothing I could change to change to situation if I were to start this semester again.

What I’ve gained from this studio, is that the automotive design industry is a difficult scene, especially when you are one person trying to make a complete concept car instead of a team. By doing so, I have gained some time management skills and learnt to pick up a few more tricks with Solidworks and how to render images. Being in a team creating a full scale model of a car was daunting at first, but fortunately the team I was a part of were dedicated people. We were able to go ahead and build a car to which we are all proud of. I’ve also learnt how to try to take initiative in a design studio. I’m a person who usually takes initiative, but in a learning environment I’d always rely on the lecturer/teacher to delegate task and tell us what to do. I’ve learnt from Simon Curlis if we were in the industry and have not

taken initiative we would definitely be sacked. From this experience I have learnt to be more aware of what can be done in the studio instead of sitting and waiting for the lecturer to come in. I’ve also learnt that creating a full scale model creates a different scenario to what sketches and CAD models portray. Full scale models allow the user to interact with the object as if it were a market product.

This approach allows the designer, like myself, to observe and decide any changes that can be made and what adjustments could be done.

From the Lean and Green studio, my design practice still needs major development. Discovering that to be industry ready requires initiative and doing more than just the minimum. I know I’m a hard worker, but I struggle at times with my busy weekly schedules due to commitments. Each semester presents itself with different timetables and schedules making me having to adjust my work habits.

I learnt that my design practice lacks a bit more imagination and ambitious work ethics. I need to maximise my time during train rides back and forth from home to the city.