Test drive Toyota seats - perfectionism and long-standing traditions
117 years share simple capri pants, benches and seats with 18 types of settings and massage function
Bernd, Werner, Oliver and Marius are enthusiastic about their task of making repeated contact with the seat side supports underneath, simulating sitting and getting up, associated with constant friction in the leather upholstery. A task that requires special perseverance, a relentless attitude and full concentration on the job. Bernd, Werner, Oliver and Marius are robots from the test department of the test laboratory of the International Technology Development Center ITDC. Opel (International Center for Technical Development) in Rüsselsheim. In particular, these are removable mechanical devices with panels covered with a layer of foam rubber and upholstered in a fabric resembling denim, the movement and friction of which imitate the contact of the buttocks and thighs of a person with the seat. “For us, they are more than robots – we look at them as fully equal and qualified members of our team. They play an important role and therefore have their own names,” said Andrew Leuchtmann, senior manager at GME Interiors.
The robot team runs simulations of getting in and out of cars 50 times a week, the equivalent of a car's lifespan. Both premium ergonomic seats and other brand products require certification by Aktion Gesunder Rücken eV (AGR), an independent German organization of medical experts in the field of back orthopedics. . Of course, the standard integrated comfort seats are also subjected to this test. Once tested, engineers can determine if the seats are capable of withstanding further stress simply by checking the fabric structure. “It's normal for the color to fade and scratch on the surface, but the most important thing is that the foam layer underneath is in good condition and the fabric structure is stable,” said seating expert Leuchtmann. If not, the luxurious and ergonomic seats that Opel offers for the driver and front passenger need to be optimized - they should last a lifetime, whether installed in Mokka, Cascada, Meriva, Zafira. Tourer, Astra or Insignia.
“This is an area where we are clearly reaping the benefits of our extensive experience,” said Leuchtmann. After all, the Rüsselsheim-based automaker boasts a 117-year tradition in seat design. The successful history of highly ergonomic seating began in 2003 with the first AGR approval for the Opel Signum and continued with Opel's flagship Insignia in 2008. Thus began a real campaign for the healthy accommodation of the driver and passengers in brand cars offered at affordable prices. The impact of the new seating systems on professional drivers and people who frequently travel long distances is particularly beneficial. Numerous and varied adjustment options allow the Insignia's premium AGR-certified ergonomic seats in the Insignia to perfectly adapt to the body and requirements of each rider, so that everyone feels rested and free of symptoms even after long hours of use. Behind the wheel. Since 2003, the Opel brand has made the democratization of modern ergonomic seats one of its main objectives and today is one of the leading mass-market car manufacturers in terms of the number of ergonomic seats offered with an AGR approval certificate.
The new lightness of the Astra Sports Tourer seats
The supporting structure is the most important component of the seat. It ensures the safety of passengers and keeps the body in the correct position in the event of an impact due to a traffic accident. That being said, this design usually loses a lot of weight, but not the new Astra Sports Tourer. The weight of the seats in the new model is reduced by 10 kilograms through the use of high-strength steels. Thanks to precise computer simulations, the engineers knew exactly how much weight they could save before starting work on the first prototype. Darker colors showed dangerous areas with high stress on the structure, which could lead to breakage. “With the Astra Sports Tourer, we really took it to the limit and experimented a lot,” says Leuchtmann. Among other things, numerous tests had to be carried out on the welds. “It is impossible to weld if the material is too thin. Here I am moving along a very thin line,” said the engineer.
With the first prototypes completed and the selection of leathers and upholstery textiles finalized, Werner and his colleagues can get to work. But before that, the engineering team calculates the level of stress that the test robots should apply to the seats being tested. In addition, a team of men and women of varying weights and builds performed side-by-side tests while sitting on a layer of pressure-sensitive material to measure points and areas of maximum stress, such as areas that come into contact with the bones of the body. pelvis “We test seat prototypes on real cars,” explains Leuchtmann. “The seats of the Meriva, for example, are higher, and the seats are different from, for example, the new Astra Sports Tourer, where the seats are lower.” In addition, the test riders sit differently in the premium "ergonomic" seats. Thanks to the noticeably good lateral support of the bodywork, the side supports are higher and are therefore subjected to more stress when going up and down. The data obtained is used to calculate the average load level, which, in turn, is used to adequately program Werner and his colleagues.
In parallel, nine specially trained testers are working at the Opel Center. Their tasks include, for example, driving the new Astra Sports Tourer for hours and endless kilometers. They test items such as an electro-pneumatic lumbar support with four settings, an adjustable thigh support or a massage function, and thoroughly examine the seats and give a subjective overall rating. Serial production can only begin after the complete elimination of even the slightest weakness.
The Opel Meriva is the first vehicle to receive the AGR certification for its complete ergonomics.
The process of developing a new chair takes about five years. Two of them the investment team invests in the implementation of new concepts. That's exactly the case with Opel's cabin versatility champion Meriva. It is the first and so far the only vehicle to receive an AGR approval certificate for its complete ergonomic system. It includes ergonomic seating and 84-degree FlexDoors, a flexible FlexSpace rear seat movement concept and an optional FlexFix foldable bike rack. An example is the new Astra Sports Tourer. Thanks to a state-of-the-art development process, also taking into account customer feedback as well as their opinions published on the forums and blogs, the optional FlexFold rear seat system was created with the possibility of a 40:20:40 split at the touch of a button. In addition, heated external heating is available for the first time on request – an increased level of comfort ensures that the next trip with family and friends will be even more enjoyable.
To ensure that Opel continues to play a leading role in car seat development, engineers are now working in complete secrecy to develop the third generation of high-quality, premium ergonomic seats. “Maintaining the advantage of our know-how compared to competitors on the market and its consistent development is of decisive importance,” emphasizes Leuchtmann. “This is the main reason why we strive to support as much development as possible within the company – some components are even produced in our Kaiserslautern plant.” The supporting structure of the front seats is made entirely in Kaiserslautern. The proximity of the plant to the head office in Rüsselsheim also has a number of logistical advantages. The goal is clearly defined – the car seats of the future will be even better ergonomically, even lighter, more sophisticated in style and more secure. “We still have many new ideas on how to make the shape and contours of the seats even more effective in terms of individual adaptation to the body of different passengers,” explains the expert. "And there's a lot more to come in the area of massage functions." There is no doubt that in the future we can expect many new Opel models with high-end ergonomic seats, as the democratization of comfort in this area is one of the company's main goals.
Historical overview of Opel seat development and design
1899 hour - capra. The entire patented Opel Lutzmann automotive system looks like a horse-drawn carriage, and the seats are no exception. There is no way to regulate them.
1929 hour - lower position. 30 years later, the Opel 4/20, nicknamed the "Moonlight Roadster", still only offers a fixed, upholstered bench. However, its position is now much lower, and passengers have the opportunity to stretch their legs.
1950 hour – more comfort. Opel Olympia seats are mounted on a metal frame and are adjustable in the longitudinal direction. The front seatbacks can be folded forward to make it easier for second-row passengers to get in and out.
1956 hour – stepless longitudinal adjustment. Another cornerstone is the conventional front seat with continuously adjustable fore/aft and backrest adjustment in the Opel Kapitän. The seatbacks are comfortably and naturally placed in the optimal position by pulling out the special lever and at the same time exerting pressure on the backrest.
1968 hour - Sports seats. The legendary Opel GT received anatomically shaped sports seats with integrated headrests. The elongated buttocks and improvements in the shoulder area show the direction of development.
1970-ies - head restraints. Opel offers additional head restraints for some of its models such as the Monza, Kapitän / Admiral / Diplomat as well as the Rekord C and D. The Opel Diplomat B is available with height-adjustable comfortable head restraints that you can even use. change your forward lean.
1978 hour – The first height-adjustable seat. Drivers of the Opel Monza can easily adjust the height of their seat using the telescopic lever.
1994 hour - Security with a capital letter. The seats of the Opel Omega B are extremely comfortable and electrically adjustable. Reinforced rear seat backs and side impact airbags make an important contribution to passive safety, and for the first time crash tests are carried out with a load in the trunk. All three seats in the second row of seats are equipped with three-point seat belts and head restraints.
2003 hour – the first AGR approval certificate. Aktion Gesunder Rücken eV (Initiative for Better Back Health), an independent German organization of medical experts in the field of back orthopedics, recognizes the multi-contour driver's seat with 18 types of electrical settings in the Opel Vectra / Opel Signum models with its prestigious approval certificate. Opel is the first car manufacturer to offer health-friendly rear seats in the middle class.
2008 hour - comfortable seats. The standard comfort seats in the Opel Insignia offer a wide range of adjustment options - the height can be adjusted in the range of 65 millimeters (using the electric mechanism), and the longitudinal adjustments allow adjustment in the range of 270 millimeters. These are excellent numbers, and the premium driver's seat has the AGR seal of approval.
2012 hour – overall ergonomic concept. 84-degree FlexDoors, AGR-certified ergonomic seats, and the FlexFix foldable bike carrier are compelling benefits for the AGR experts, who awarded Meriva with a certificate of approval. This is the first and so far the only production car to receive such an award for overall ergonomics.
2015 hour – Superior comfort in a compact class. For the first time, AGR-certified premium ergonomic seats in the new generation Astra not only have 18 types of settings, including lateral support adjustment, but also have the added comfort benefits of a storage massage function. various individual settings for ventilation.
