BEWHUWCIi U*& OSiLt REPORT NO. FRA/0R&D-76/275.I % „ LOCOMOTIVE CAB DESIGN DEVELOPMENT Volume I: Analysis of Locomotive Cab Environment & Development of Cab Design Alternatives Jl J. Robinson D. Piccione G. Lamers Boeing Vertol Company P.O. Box 16858 Philadelphia PA 19142 ^A .ususa&j S'A1H O* OCTOBER 1976 INTERIM REPORT DOCUMENT IS AVAILABLE TO THE U.S. PUBLIC THROUGH THE NATIONAL TECHNICAL INFORMATION SERVICE. SPRiNOFIELO, VIRGINIA 22161 Prepared for U.S. DEPARTMENT OF TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION J Office of Research and Development Washington DC 20590 A NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Govern ment assumes no liability for its contents or use thereof. 'C NOTICE The United States Government does not endorse pro ducts or manufacturers. Trade or manufacturers' names appear herein solely because they are con sidered essential to the object of this report. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient** Cafolog No. FRA/ORSD-76/275.I 4. Title and Subtitle S. Report Dole LOCOMOTIVE CAB DESIGN DEVELOPMENT October 1976 Volume I: Analysis of Locomotive Cab 6. Performing Orgonnotien Code Environment § Development of Cab Design Alternatives 8. Performing Orgonisotton Report No. Author's) Robinson, D. Piccione, G. Lamers DOT-TSC-FRA-76-22,I 9. Performing Orgcniiotion Nome and Address 10. Work Unit No. (TRAIS) Boeing Vertol Company* RR628T/R7341 11. Contract or Grant No. P.O. Box 16858 Philadelphia PA 19142 DOT-TSC-913-1 13. Type of Report ond Period Covered 12. Sponsoring Agency Nemo and Address Interim Report U.S. Department of Transportation October 1974-April 1976 Federal Railroad Administration Office of Research and Development Id. Sponsoring Ageney Code Washington DC 20590 FRA-RRD-33 15. Supplementary Notes U.S. Department of Transportation Transportation Systems Center *Under contract to: Kendall Square Cambridge MA 02142 16. Abstract This report presents an analysis of the line haul freight engineer's working and living environment, the resultant locomotive cab design and design alternatives. The analysis is based on a delineation of functional requirements found in current line haul operations together with those additional requirements which could arise during the next 10-15 years. The recommended design is the result of a detailed human factors engineering analysis of these requirements according to state-of-the-art criteria and system design practices. Substantial engineering analysis was devoted to the recommended design; this included disciplines of cost, occupant protection, component and subsystem reliability, and system safety analysis. 17. Keywords Human Factors Engineering 18. Distribution Statement Crew Station Design, System DOCUMENT IS AVAILABLE TO THE U.S. PUBLIC Analysis, Locomotive Crew, Cab THROUGH THE NATIONAL TECHNICAL Design, Function Analysis, Line INFORMATION SERVICE, SPRINGFIELD, Haul, Locomotive Cab, Cab Safety, VIRGINIA 22161 Crashworthiness 19. Security Clossif. (of this report) 20, Security Classif. (of this page) 21. No. of Pages 22. Price UNCLASSIFIED UNCLASSIFIED 206 Form DOT F 1700.7 (B-72) Reproduction of completed page authorized .* Jt> PREFACE The locomotive cab designs described in this report were developed by Boeing Vertol under the sponsorship of the Transportation Systems Center (TSC) for the Department of Transportation, Federal Railroad Administration (FRA). The objective of this work is to develop a locomotive cab design through a human factors systems analysis of the functional requirements of train handling leading to specifications suitable for the development of a cab which is in concert with all operational and safety concerns. The authors would like to acknowledge the contributions of Dr. John Jankovich, the. contract technical monitor, and Dr. Donald Devoe of the Transportation Systems Center; Mr. William McLean, Boeing Vertol Company Surface Transportation Systems Manager of Research and Development; and Mr. Norman Macdonald of the Electro-Motive Division of General Motors, principal subcontractor during the study. iii METRIC CONVERSION FACTORS Apptorinttt CoavantOM to Metric Mtttsitt Approximate Convtrtions Iron Mttrie Mutartt Srnbsl Wise Yes Isn Metttfrf by Te Hat Srabtl Ssabsl WW* Tea **>*» MinJ*t> by Te Red Spsasl LENGTH LENGTH 0.04 0.4 M ft M 1.1 •0 JO ft 04 yd AHEA _ar§a_ c*r* in1 cr»» tr» 0.08 3 squsrs miles 2.1 ke)> 0.4 MASS (wtiabt) MASS (swiibl) » 2t « 2J 0.«5 hikosraRi Itacsko) 1.1 sberitoiis O.J (2000 IM VOLUME VOIUME 0.03 not » alllillters Ailijlitsr* liters 2.1 p> Ibsp It aiiiiliien \M Hoi 90 atllilHsrs liters 0.20 c cups 0.24 liters cubic netars 3S ft* P< pkns 0.47 Hnrs 1J «i evens 0.95 tilers (slices M ••ten cubic ten 0.03 cubic mew* TEMPERATURE (tittt) I cubic vents 0,7t TEMPERATURE lotitt, t/Siaiet add 32) SVtlSttSf •c sabB •t HI n -40 0 1*0 10 I l«0 100 tOOJ I • f .,,.,. J• . •,. i,t l.i h • I 'i' 'i* '•• V i -j i -40 -20 6 20 140 »0 to J« TABLE OF CONTENTS Page LIST OF ILLUSTRATIONS 2 LIST OF TABLES 3 1. INTRODUCTION 5 2. SYSTEM ANALYSIS 9 3. DETAILED DESIGN 49 4. ALTERNATE CONCEPTS 127 5. PRIMARY CONTROL DISPLAY DEVELOPMENT 137 6. SUMMARY 137 7. RECOMMENDATIONS 1*1 SELECTED BIBLIOGRAPHY 1*3 APPENDIX A... 1*5 APPENDIX B 171 APPENDIX C 2°1 LIST OF ILLUSTRATIONS Figure Page 2-1 Locomotive Cab Requirements 10 2-2 Baseline Cab Functional Analysis . 14 2-3 Second Level Train Functions 16 2-4 Typical Level 3 Crew Functions 18 2-5 Typical Level 3 Crew Functions 19 2-6 Engineer Functional/System Variable Matrix 22 2-7 Typical Information and Action Requirements Analysis .... 28 3-1 Locomotive Cab Design Functional Analysis Through Recommended Cab Design 50 3-2a Recommended Cab Design Layout 56 3-2b Recommended Cab Interior Arrangement . 57 3-3 Locomotive Engineman Vision Requirements 62 3-4 Monocular Vision Plot 64 3-5 Binocular Vision Plot 65 3-6 Binocular Vision Plot with Head Movement 66 3-7 Crew Seat Design Requirements 69 3-8 Functional Reach Envelope-Minimum Percentile 70 3-9 Primary Design Display Panel 74 3-10 Primary Control Panel 82 3-11 Repeater Control Panel 90 3-12 Secondary Display Panel 94 3-13 Overhead Auxiliary Control Panel .... 99 3-14 Brakeman's Crew Station 114 3-15 Occupant Protection Criteria 120 3-16 Occupant Protection Criteria (continued) 121 3-17 Occupant Protection Criteria (continued) 122 3-18 Possible Structural Layout for Baseline Crashworthy Cab ... 124 3-19 Possible Structural Layout for Baseline Crashworthy Cab (Con.)125 4-1 Idler Car Concept 128 4-2a Rotating Crew Station 130 4-2b Revolving Platform 131 4-2c Three-Quarter View Revolving Platform 132 4-3 Armrest Controls, Chair Controller 134 A-l Level 3 Crew Functions 146 B-l Information and Action Requirements Analysis 172 LIST OF TABLES TABLE PAGE 2-1 Ordered Mission Requirements 23 2-2 Locomotive Subsystem/Engineer Task Frequencies 24 2-3 Locomotive Subsystem Function Analysis 26 2-4 Preliminary Display Criteria 30 2-5 Display Requirements Analysis 35 2-6 Control Requirements Analysis 39 3-1 Locomotive Engineman Forward Vision Requirements Selected Visual Targets 61 3-2 Engineering Warning Annunciator Legend Listing 92 3-3 Internal Vision and Reach Analysis - Main Control Panel 109 3-3a Internal Vision and Reach Analysis - Main Display Panel 110 3-4 Internal Vision and Reach Analysis - Secondary Display Panel 110 3-5 Internal Vision and Reach Analysis - Overhead Auxiliary Control Panel Ill 5-1 Primary Control/Display Comparison 138 3/4 •i? INTRODUCTION The purpose of contract DOT/TSC-913 is to develop a locomotive cab design based on the operator's functional requirements in train operation. The design is predicated on human engineering and other engineering disciplines leading to specifications which are suitable for the design, development, test and evaluation of a cab that is in concert with all operational and safety conditions. The locomotive cab design is based on the most complex set of functional requirements, which are, as anticipated, based on line- haul operational needs. This report presents an analysis of the line-haul freight engineer's working and living environment and the resultant locomotive cab design and design alternatives. The analysis is based on a delineation of functional requirements inherent in contemporary line-haul operations together with those additional situations which might conceivably arise during the next 10-15 years. The recommended design is the result of a detailed human factors engineering analysis of these requirements in accordance with state-of-the-art criteria in railroad operations and system design practices. The technical content is presented in the following sections and a summary is presented below. First, however, it is appropriate to offer a brief description of the freight engineer's working environment to place the analysis in perspective. Today's locomotive engineers are, and will, at least in the foreseeable future, continue to be exposed to a wide variety of assignments. Each task has its own peculiar set of train handling requirements. The economics of train makeup and manpower utilization may dictate, on the one hand, the employment of longer and heavier trains traveling at slower speeds, while on the other hand, short, fast trains which run at frequent intervals ap pear to hold some promise for the economical movement of produce and merchandise. Locomotive consists are getting longer because trains are heavier and need more tractive effort. Locomotives may be inserted in the train at critical points as helper units, operating either remotely from the front of the train or manned. The trains themselves are usually made up of a mix of loads and mass diatribution in combinations of old and new cars as the result of destination blocking.