AUTOMOTIVE

INSTRUMENT PANELS
VEHICLE STRUCTURE
VEHICLE STRUCTURE
*VEHICLE
BODY CHASSIS ELECTRICAL
TRIM
* This structure is indicative to communicate the
system wise availability of resources.
TRIM STRUCTURE
TRIM STRUCTURE
TRIM
SEATS
IP & CCB
INTERIOR
TRIM
EXTERIOR
TRIM
IP Definition
The portion of the interior extending from door to door directly in
front of the driver, and containing primary gauges and controls for
operating the vehicle.
IP holds the front-end of the passenger compartment,
Ties left and right side of the vehicle together,
Stiffens the front-end for crash,
Supports the steering column,
Holds the airbag and HVAC system.
TRIM STRUCTURE
TRIM STRUCTURE
Team structure
Design Developmetnt.
ADD, STA - APQP ,PPAP
Validation Implementaion
IP and CCB
INTRODUCTION
INTRODUCTION
An instrument panel is an assembly that consists of a structure,
substrate, and the optional assembly of the glove box, AC ducts,
Demisters (with associated ducts) and Registers
LIST OF GAUGES,METERS AND SIGNALS
standard mid range high BOM
1 Speedometer Y Y Y
analog 0-180 km/hr readings,
economy range, light,
1a Odometer Y Y Y readings--7digits, light,
1b Trip Odometer Y Y Y 4digits,digital, reset knob
1c
Turn Signal I ndicator
Light Y Y Y
1c Hazard Switch Y Y Y
1d Brake Circuit Failure Light Y Y
1e Brake pad wear indicator Y
2 Fuel Gauge Y Y Y
miles to
empty(digital)/analog
reserve indicator Y Y
2a Coolant Temperature Gauge Y Y Y
2b EPS indicator Y
3 TacoMeter Y Y
3a Engine Oil I ndicator Y Y Y
3c Hand Brake Light Y Y Y
3d Brake oil level I ndicator Y Y
3e High/ Low Beam I ndicator Light Y Y Y
3f
Battary Condition
I ndicator(alternator o/ p
indicator) Y Y Y
3g Transmission gear indication Y
4
Outside atmospheric temperature
Gauge Y
Seat Belt Reminder Light Y
Door Open I ndicator Y
Glove compartment with lock Y Y Y
Lower Console Box with Coin Case Y Y
cup holder Y Y
Cigarette Lighter Y Y
Ash Tray Y Y
A/ c control switch( tuner) Y Y
Heater Y Y
central locking system Y Y
Exterior mirrors Adjustable
(electircal) Y
Adjustable dash board illumination Y
Headlight range adjustment Y
Demisters/ Defogers Y
Deck lid release lever Y Y
Fuel lid release lever Y Y
Bonnet release lever Y Y Y
Air Bags Y
Key not removed warning buzzer Y
route map Y
Differential locks Y
mobile holder ACCESSORY ACCESSORY ACCESSORY
perfume holder ACCESSORY ACCESSORY ACCESSORY
clock ACCESSORY ACCESSORY ACCESSORY
I nterior lighting with reading light for driver
and passenger ACCESSORY ACCESSORY
front/ rear fog lights ACCESSORY ACCESSORY
AUDI O SYSTEMS ACCESSORY ACCESSORY ACCESSORY
VI DEO SYSTEM ACCESSORY
SPEAKERS, Tuters ACCESSORY ACCESSORY ACCESSORY
Requirements of IP
Performance
Aesthetics
Economics
Long term durability
Passenger air bag packaging
Segment appropriate styling
Energy management
Environmental responsibility
Occupant comfort
PACKAGING
PACKAGING
Pair of instrument switch panels
Center dash switch panel
Pair of center dash air louver panels
Passenger air louver panel
Pair front door panels
Rear side door panel
Pair front cupholder panels
Center console trim panel
Center console storage door panel
Pair overhead console trim panels
Instructions and hardware..
INSTRUMENT PANEL ASSEMBLY
STANDARD IP
MID RANGE IP
HIGH RANGE IP
Good example of low end IP
Tata Ace
Mahindra Max
Three wheelers
INPUTS REQUIRED FOR IP DESIGN
The instrument panel of an automobile is a good representation
of the complexity of the materials used in the entire vehicle.
1. TYPE OF CATEGORY:
Standard
Mid range
High range
2. CAB AREA AND DIMENSIONS:
Length: Length available outer panel and driver seating area
Width : Width available between two side panels
Height : Height available lower panel to IP mounting area
3. STEERING POSITIONS:
Steering positions, dimensions and if it is adjustable steering how much
movement required.
4. AIR DUCTS AND LOUVERS:
Air ducts and louver locations, sizes and how many numbers required
5. AUDIO AND VIDEO SYSTEMS:
Audio and video system locations, dimensions and type of fitment
method
6. AIR BAGS:
Air bag locations and number of bags .
7. GLOVE BOX OR UTILITY BOX:
Type of document boxes, sizes, locations and closing and locking
conditions
8. ASSEMBLY FITMENTS METHODS:
Nut and bolt fitment
Screws type fitment
Press or Hook type fitment
9. ASSEMBLE AND DISASSEMBLE OF IP:
The process use for assembling and dismantling.
10. GAUGES AND FUEL METERS:
Fuel gauges
Speedo meters
Temperature control Gauges
All types of keys etc
11. ACCESSORIES:
Ash box, Cup holders, Mobile holder, Perfume holder, Clock holding
space, Cigarette lighter etc
TILT AND TELESCOPIC STEERING COLUMN
Main features required for IP
material selection
Recyclable
Superior strength-to-weight ratio
Excellent weather resistance
Abrasion resistance
Enhanced corrosion and chemical resistance
Temperature-resistant, non-reflective
Excellent printability
Superior dimensional stability
High optical clarity
DESIGN FOR THE ENVIRONMENT
There are three major elements of design for the
environment:
Design for environmental manufacturing
Design for environmental packaging and
Design for disposal and recycleability
Design for environmental manufacturing
involves the following considerations
Non-toxic processes & production materials
Minimum energy utilization
Minimize emissions
Minimize waste, scrap & by-products
Design for environmental packaging involves
the following considerations
Minimum of packaging materials
Recyclable packaging materials
Bio-degradable packaging materials
Design for disposal & recycleability
involves the following considerations
Re-use / refurbishment of components & assemblies
Material selection to enable re-use and minimize toxicity
Avoids filler material in plastics such as fiberglass and graphite
Material identification to facilitate re-use
Design to enable materials to be easily separated
Design for disassembly (e.g., fracture points, fastening vs. bonding)
Avoid use of adhesives
Limit contaminants - additives, coatings, metal plating of plastics, etc.
Maximize use of recycled or ground material with virgin material
Design for serviceability to minimize disposal of non-working products
VALIDASTION AND TESTING
VALIDASTION AND TESTING
Instrument panel must be strong enough to support the systems, but flexible
enough to properly absorb crash energy in the event of an accident.
Additionally, instrument panel must be made of materials sturdy enough to
withstand normal use but flexible enough to absorb the occupant impact
energy during an accident.
So the IP carrier must pass rigorous testing, since, it must withstand high
loading during impact. The indirect accelerated glass weathering method is
used to determine the durability, colorfastness and gloss measurements of
any material used for automobile IP.
Dimensions:
Length: 73.0 in.
Width: 37.0 in.
Height: 26.25 in.
Instrument Panel Temperature Limiting:
Microprocessor-controlled linear axial fan circulates the air evenly in the test
fixture to help keep the box from exceeding the temperature limit.
GM specified temperature limits - 77C, 85C, 93C, 102C or 110C -
depend on the type of materials being tested and their location in the vehicle
Temperature is measured by a thermocouple on the back surface of a GM-
specified reference black panel, with an adjacent thermocouple for
monitoring purposes.
Fan comes on only when the control temperature reaches the set point and
turns off 3C below the set point.
Automatic curtain shields samples from irradiance when black panel
temperature cannot be maintained at or below the specified limit with the use
of the linear axial fan.
Temperatures can be programmed in Centigrade or Fahrenheit.
Data logging system continuously monitors black panel temperature and can
optionally monitor sample temperature.
Thermocouples can be fitted to samples to evaluate interior temperatures of
materials or components.
Redundant back-up systems ensure sample protection.
Latest Trends In Assembling IP
Instrument panels can experience surface temperatures ranging from 140
to 221 F. These large variations in temperature can change the physical
properties of thermoplastics.
Temperature changes lead to expansions and contractions, depending on
the materials coefficient of thermal expansion. With a subsequent
reduction in the storage modulus, this condition ultimately results in loose
fitting joints. In addition, if there are excessive hoop stresses on a boss
undergoing thermal expansion and contraction, a high stress field will
result. A crack will form to relieve the stress, and failure of the
attachment is the end product.
Latest Trends In Assembling IP
Automotive engineers now consider pressure-sensitive adhesives (PSAs) to
be cost-effective assembly solutions that improve process speeds while
significantly reducing NVH problems. Ideal for high-performance
applications, PSAs are easy to apply, lighter than most mechanical
fasteners and offer better stress distribution over a wider surface area.
They are able to adhere strongly to difficult-to-bond substrates, offer both
high- and low-temperature resistance, and are available in both
permanent and repositionable form. PSAs can also be specially formulated
to exhibit sound damping properties. Their ability to help suppress sound
make these PSAs ideal choices for use in conjunction with a variety of
substrates for NVH and anti-squeak and rattle applications.
Key PSA applications include mirror bonding, weather stripping, trim and
emblem attachment, surface protection, NVH/anti-squeak and rattle
applications, instrument panel and air bag assembly, occupant restraint
systems, flooring and headliner attachment, and wire harness wrapping
Adhesive transfer and double-coated films are often used in the assembly
of instrument panel components. Ultra high molecular weight films may be
used in steering wheel assemblies for anti-abrasion applications.
PSA Materials:
Cloth tapes provide the most economical anti-squeak and -rattle
protection, and are used for clip retention and harness wraps inside
instrument panels.
Adhesive coated low-density polyethylene (LDPE) films cover through-
holes in the dashboard that may occur during model changeovers and
redesigns. By covering these holes, reduces wind noise and the
hissing of air squeezing through open spaces.
FREQUENTLY USING MATERIALS
T P O (Thermoplastic Poly Olefin)
A B S (Acrylonitrile-butadiene-Styrene)
T P U (Thermoplastic Poly Uthen)
P V C (Poly Vinyl Chloride)
P C (Poly Carbonate)
Polymeric
HDPE (High density Poly Ethylene)
Manufacturing Methods
The main technologies used for instrument panel carriers are:
Injection Molding (Used for Hard Panels with Consistent grain and
gloss; Typically lowest cost process for panels)
Mold in color (Hard Panels with Consistent color, grain and gloss; Cost-
effective)
Vacuum form (Soft surface with Lower gloss)
Powder Slush Molding (Excellent grain quality and touch perception)
Positive Thermoforming (Lower cost alternative to other foam in-
place processes)
Negative Thermoforming (High durability, Weight reduction )
Laminate Insert Molding (High durability, 100 percent recyclable)
Step-by-step manufacturing and assembly
process of instrument panels
1. Create plastic instrument panel housing through injection-molding:
The injection-molding process involves state-of-the-art equipment to produce
high quality instrument panel housing that has minimal defects like sink-marks
or inconsistent bumps.
2. Paint and dry instrument panel housing:
After the instrument panel housing has cooled, it is sent to be painted and
dried.
The original color of the panel after injection molding is black. The painting
process is completely automated. Each instrument panel is individually
brought into a painting room.
sprays paint onto the instrument panel quickly, rotating around the panel
in rapid, serpentine -like motions to ensure a consistent and thorough paint-
job.
The painted panels are then moved to an oven where they are dried
Painted Instrument Panel housing
3. Insert wiring and other small subassemblies into
instrument panel:
The painted instrument panel housing is taken onto an
assembly line where workers manually install wiring and basic
subassemblies onto the shell. Wiring subassemblies, which may
have a complex configuration of wires meshed together, arrive
ready-to-install to ensure quick and accurate assembly.
Wiring harness installation station.
4. Insert radio, air vents, climate control panel, and other
large subassemblies into instrument panel:
Larger subassemblies like the car radio, air vents, climate
control panels, ash-tray and CD-storage panels are next
assembled. In some cases, the larger subassemblies are attached
onto the wire harnesses already mounted in place. Much of the
assembly process involves snap-on as opposed to screw-in
parts to facilitate insertion.
5. Place instrument panel into vehicle
The completed instrument panel exits the instrument panel
assembly line and is inserted into the vehicle. The instrument
panel requires the use of heavy equipment to securely fasten/bolt
it into the vehicle.
6. Insert steering wheel and final subassemblies onto
instrument panel
Major subassemblies like the steering wheel are finally
assembled onto the instrument panel. In some cases, larger
subassemblies may require screws, bolts or special heavy equipment
to ensure a tight fit with the vehicle.
Fishbone Assembly Sequence for IP
Failure Modes and Effects Analysis (FMEA)
This analysis provide information on which parts may fail
more easily, and therefore be replaced more frequently.
THE MAJ OR MANUFACTURERS
Calsonic kansi (Nissan, Honda, Hyundai, BMW, Misthubishi )
Collins & Aikmam(DaimlerChrysler, GM and Ford )
Delphi (Mercedes-Benz M Class and GM )
Faurecia (BMW, Mercedes, Ford, Opel, SeatPeugeot,
Skoda, Toyota, Volkswagen, DaimlerChrysler, GM, Volvo)
Lear (Volvo, OPEL, Toyota, Suzuki, Hyundai, Fiat,
Mahindra)
Machino Plastics. Ltd (Maruti, Eicher Motors Ltd.)
Magna (BMW, J AGUAR, ROVER, DaimlerChrysler, Ford,
GM, Volkswagen)
Visteon (Mazda, Ford, Hyundai, DaimlerChrysler, Fiat,
Nissan and Renault)
Siemens (Audi, BMW, DaimlerChrysler, Ford, Opel, Seat,
MG Rover, Peugeot, Skoda and Volkswagen. )
Mirajker Design (TATA MOTORS, HM, Nissan )
MKL (Nissan)
Peguform(Audi)
J ohnson Controls
PO (LANCIA, RENAULT)
Magnetic marelli Spa
Bayer
Bright Brothers. Ltd
Borealis
Denso
(Sai Automotive)
IP design & development at OEM and Tier
IP design & development at OEM and Tier
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1
1
System Design Specification- material, process, features
DVP ( Design Verification Plan ) who will do what ?
Design Reviews- features Vs cost, quality
DFMEA/PFMEA ( Design Failure Mode Effective Analysis)
Part supply consistency
IP and CCB Design how can you play
a role
Exposure and experience in tape drawings, clay to validate the concepts
and digitization.
Surfacing with Icem surf. Translation of surfaces to CATIA
Engineering and surfaces in CATIA.
Adaptation of the HVAC and to meet the ergonomic requirements.
Iterations of IP packaging to accommodate other systems.
Ability to negotiate with various systems at minimum cost and
schedule impact .
Relationships defined with other environments. ( other systems )
Manufacturability focus - Split in to parts, definition of interfaces.
Definition of mounting points and schemes.
Design of CCB and IP mounting structure and integrating the two.
Inputs for CCB design - Steering column , IP, Audio system wiring
harness.
IP and CCB Design how can you play a
role
IP design- Defining the tool draw.
Cost and BOM developed.
Feasibility run for assembly. - Process design,validation - FMEA.
Design protection for LHD with minimum modifications.
Low cost variants to be accommodated.
Development of SDS and DVP devt with Vendor.
Protection of LHD and RHD, High series and standard series
Packaging, surfacing of ducts.
Interaction on development of vents - Desired flow, Ensure adequate cross
section for vents for HVAC
Providing stiffeners, mold flow through external sources,
CCB Back bone of IP
Design and Development-
how much should you know
CCB design
Inputs for CCB design - BIW,Steering column , IP, Audio system, wiring
harness and HVAC.
Load conditions considered- Steering column loads - torsion, lateral, IP -
Vertical.,
Mounting points CCB on BIW.- Facilitated the transfer of loads though
box structure through Plenum , A pillar and finally to floor.
Ensure uniform distribution of CCB loads.
Optimization of CCB structure to achieve NVH targets.
Design protection for LHD and RHD with minimum modifications.
Reduction of part count by commonisation of the brackets.
CCB design and Development
CCB design contd.
Feasibility run for assembly. - Process design,validation - FMEA.
Selection for appropriate section for ease of manufacturing ,low cost,
low tooling , availability.
Provide flexibility to accommodate stack-up tolerances by providing
appropriate hardware and ensuring right location.
Optimization of tube - Section Dia, Thickness, Local change of sections
to achieve the modal targets in the given packaging constraints.
Interaction on development of vents - Desired flow, Ensure adequate
cross section for vents for HVAC
Providing stiffeners, mold flow through external sources,
Cost and BOM developed.
IP & CCB
IP & CCB
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CHALLENGES IN VALIDATION
CHALLENGES IN VALIDATION
Some important tests
Some important tests
Aesthetics.- appearance, Texture.
Functional.
NVH - Squeak and rattle,vibrations
Flammability
Durability.
Odour.
Environmental.-Heat , wear, aging, climatic
Regulations -Surface reflection
Screw hold strength and grab handle loading.
Serviceability. etc
IP & CCB
IP & CCB
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CHALLENGES IN DESIGN
CHALLENGES IN DESIGN
Major challenges faced in CCB
Benchmarking
Fixture design and development.
Stack up tolerances.
Shipment fixtures.
Consistent tooled up parts.
Minimizing the part count.- Sections, hardware.
Commnisation over variants.
Process refinements.
Optimization of sections,
Structured Costing - By material, tooling,processes, transport etc.