Conceptual design of motor cycle helmet to meet the requirement of thermal comfort, ergonomics and safety

In recent times, due to rapidly growing population, traffic congestion and lack of parking space, two wheelers are the most popular mode of transportation. As per Indian traffic rules, it is mandatory to wear the helmet for safety while riding two wheeler. To provide safety for the rider, helmets are incorporated with lightweight plastic exterior, protective polystyrene layer and urethane comfort padding. It is very difficult to wear helmets for the longer duration in summer due to high temperature rise and lack of ventilation which increases the stress level of the humans. Since helmet designs are available in standard sizes and standard interior forms, it is difficult to fit for riders with different head shapes. There is a need for helmet which meets the requirement of thermal comfort, adjustable interior, better visibility and pleasing aesthetics.

In this project work an attempt has been made to conceptually design a motorcycle helmet for improved thermal comfort, visibility, safety with adjustable interior form considering rider's ergonomics. Initially, GEMBA study has been carried out on existing helmets to understand the design requirements, ergonomics and thermal comfort. Based on the user survey, QFD and PDS were generated and the product specifications were obtained to meet the requirement. Concept sketches were generated incorporating features like adjustable head form, air vents and exhaust fans for thermal comfort. Detailed design for the selected helmet concept and geometric model for the same has been created incorporating all the features as per the concept. A full scale working model of the helmet is built with all features, tested and demonstrated for its functionality.

Motor cycle helmet is conceptually designed, modelled and built incorporating features for improved thermal comfort, visibility and with adjustable interior form considering rider's ergonomics. Steady state airflow simulation on the helmet interior was carried out with a head form of rider (95 percentile male) to assess the air flow pattern and temperature distribution. It is found that exhaust fan provided on the rear end of the helmet along with air vents turned out to be a better possible configuration to extract the heat from the helmet.