Automotive Interiors
1
Index
Plastics - Consumption Consumption in Automobile Automobiles s
Future Trends In Indian Automotive Industry
Interior & Exterior Applications
Pillar Trims
Floor Consoles
Door Panels/ Door Modules
Instrument Panels/ Cockpit
Attachment Methods
Over Head Systems
Ergonomics Basics 2
Plastic Plastics s - Consumpti Consumption on in Automo Automotive tive Sector terials s Material
kg/ vehicle
tonnes
PP & Alloys
57.7
943000
PUR
18.1
296000
9.5
155000
PE
10.3
168000
PA & Alloys
15.6
255000
P VC
3.7
60000
PBT+PET
3.1
51000
UP
1.9
31000
Others (PC, PMMA, POM, PPE, SM, PF, ASA«)
13.2
216000
TOTAL
133
2173000
ABS & Alloys
This plastics consumption (2003) in European Union (27 countries) only figures the plastics parts weighed on passenger cars: production producti on scraps and spare parts are not taken into account as well as commercial vehicles. 3
Plastics Plastics use by type and weight in an aver age ca car PART
MAIN
Bumpers
PP, ABS, PC
10.0
Seats
PUR,PP,PVC,ABS,PA
13.0
Dashboard
PP,ABS,PA,PC,PE
15.0
Fuel Systems
PE,POM,PA,PP
07.0
Body (incl. body panels)
PP,PPE,UP
06.0
Under the bonnet comp.
PA,PP,PBT
09.0
Interior trim
PP,ABS,PET,POM,PVC
20.0
Electrical components
PP,PE,PBT,PA,PVC,
07.0
Exterior trim
ABS,PA,PBT,ASA,PP
04.0
Lighting
PP,PC,ABS,PMMA,UP
05.0
Upholstery
PVC,PUR,PP,PE
08.0
Other reservoirs
PP,PE,PA
01.0
Total
PLASTICS TYPE TYPES S
WEIGHT (Kgs)
105.0
4
Styreni Styrenics cs - Consumpt Consumption ion in Automobi utomobilles MAIN DATAS (per vehicle): All
Plastics
}
70 - 200 200 kg kg
(Aver age : 133 kg) GF
reinforced Plastics
Approximately
}
6 - 40 kg
24 % GF
STYRE STYRENICS (BLE (BLENDS NDS & ALLOYS LLOYS)) ± 9.5 9.5 kg kg
5
Trend Drivers
Economics
Innovation
Technical Performance and functionality 6
Technology Trend Areas
7
Future
Trends in Global Automotive Industry
1. Control on Emissions/consumptions
CO2
Other emissions : CO, NOx, Hc
Leading to a need in mass reduction 2. Increase Saf ety
Euro¶n Cap ratings
Pedestrian collisions
Leading to new designs of the f ront of the vehicle 3. More Comf ort, notably sound level Leading to noise insulation systems
8
Automobile Interiors
9
Interior Applications of Plastics in Automotive
Air Vents Fascia
Door Trim
Floor
Console
Injection Molded Bin
Blow Molded Door
Dashboard Structure
Door Module
Knee Bolsters
10
Possible Applications of Plastics in Automobile Interior Process options
Material
Injection
PA
CS
PBT
CS
POM
CS
PA
CS/Aramid
PET
CS/Aramid
GMT
PBT
Mat continuous
Ashtray
Injection
PA
CS
Air Ventilation Nozzles
Injection
PC ABS
Interiors Internal Door Handles
Options
Resin/f iller options
Typical Weight Kg's
0.40
Dashboard & Parts Air Bag Systems
Injection
Injection
PP
MF
PP
MF
ABS PC ABS MPPO
0.10
2.00
ABS
Dashboard
0.40
7.00
11
Possible Applications of Plastics in Automobile Interior Dashboard Skins
Thermo engraving
PVC Modified TPO
Central Console
Slush Moulding
Plasticised PVC
ThermoformBackfoam
ABS-PVC
Injection
PC ABS
1.5
2.00
MPPO ABS Seating Components Arm Rest
Injection
ABS
CS
0.20
Seat Back rest
S-RIM
PU
Mat continuous
6.00
GMT
PP
Mat continuous
6.00
Injection
PP
MF
Compression
UP
Roving
Door Panels
8.00 12
Possible Applications of Plastics in Automobile Interior Headliners
RIM
PU
Mat continuous
Compression
PU
Roving 2.20
Special Process
PET
Fibre cushioning and acoustic insulation
Pillar trims
Injection
PP
MF
Rear Package tr ay
Injection
PP
MF
RIM
PU
Mat continuous
Compression
UP
Roving
Injection
PA
CS
POM
CS
PA
CS
Acceler ator Pedal
Clutch Pedal
Injection
4.00
2.50
0.24
0.23 13
PILLAR TRIMS INDEX:
1.INTRODUCTION. a.What is pillar Trim? b.Nomenclature « c.Location? d.Functions. 3.PART DETAILS. 4.ASSEMBLY/ATTACHEMENTS. 5.FEATURES. 6.PERFORMANCE SPECIFICATION. 7.SAFETY REQUIREMENTS.
14
INTRODUCTION What is pillar trim ? H ard
trim which covers the Pillar, matching shape, color language and hence gives SIMILAR aesthetic as that of H ead liner and other interior.
What is pillar ?
The Structur al member that connects the roof and body. "A" PILLAR : The f oremost pillar in the upper side structure of a vehicle. Successive pillars rearward are labeled "B", "C" and, f or station wagons, "D". 15
NOMENCLATURE PILLARS
A
B C
D
PILLAR TRIMS D
A
B
C
16
LOCATION Pillar trim location in vehicle
A-PILLAR B-PILLAR
C-PILLAR
D-PILLAR
17
18
The wing doors of the concept T represent a stylistically as well as technically especially independent and fascinating body detail. They are mounted in the upper section of the A-pillars. When opened, they simultaneously swing slightly outwards and steeply upwards. The advantage: an especially comfortable entry and exit as well as comparatively little space required to the side. The rear part of the door creates the B-pillar trim above the door handle and door opener, an extremely robust solution but still sporty and elegant.
19
FUNCTIONS
1.
Connects the headliner and Body.
2.
Cover the sheet metal and give the same ³LOOK´ as that of head liner/other interior.
3.
Acts as energy absorber.
4.
Provide space for the subassemblies such as air bag, crush pad, seat belt retractor, etc.
20
PART DETAIL A-PILLAR TRIM
H/L SIDE
AIR BAG DISPLAY COVER.
TRIM
PUSH NUTS
IP SIDE
CARTRIDGE 21
PART DETAILS B-PILLAR TRIM
ATTACHES TO UPPER TRIM
AIR BAG DISPLAY COVER
UPPER TRIM
ATTACHES TO LOWER TRIM
LOWER TRIM
ATTACHES TO DOOR SCUFF
22
PART DETAILS B-PILLAR TRIM SLOT FOR BELT HEIGHTADJUSTMENT
HEAT STAKE
FOUR WAY LOCATOR 23
PART DETAILS B-PILLAR WITH CARTRIDGE
B-PILLAR WITH BELT SLIDER
CARTRIDGE
BELT SLIDER
24
PART DE DETAILS C-P C-PILLAR TRIM H/L SIDE
FITS TO BODY
25
PART DE DETAILS C-P C-PILLAR TRIM
SEAT BELT SLOT
WHAT WHA T ARE THESE FEA FEATURE TURE?? 26
PART DE DETAIL D-P D-PILLAR TRIM SEAT BELT SLOT
27
C / D - PILLAR C-D COMBINED AS SINGLE TRIM
28
ASSE ASSEMBLY / ATTACHMENTS B-PILLAR LOWER WITH DOOR
PILLAR TRIMS WITH BIW
29
ASSEMBLY / ATTACH MENTS A-PILLAR
INSTRUMENT PANEL 30
ASSEMBLY / ATTACH MENTS A-PILLAR TO BIW
PUSH NUT
31
ASSEMBLY / ATTACH MENTS B-PILLAR UPPER TO LOWER
B-PILLAR LOWER TO BIW (DOOR SCUFF)
WHAT FOR THESE FEATURE
32
B-PILLAR LOWER TO BIW
B-PILLAR LOWER B-PILLAR LOWER
DOOR SCUFF
DOOR SCUFF
33
ASSEMBLY / ATTACH MENTS C/D-PILLAR TO BIW
WHY THIS FEATURE AND HOW IT WORKS? 34
ASSEMBLY / ATTACH MENTS PILLAR TO HEAD LINER
1. Headliner and weather strips should overlap consistently for system proveout. (H/L and B, C-pillar trim to weather stripping - 12 mm) . 2. Pillar trims and weather-strips should overlap consistently for system prove out. (A-pillar to weather-weather stripping -5-8 mm). 35
ASSEMBLY / ATTACH MENTS A-PILLAR TO H/L
B-PILLAR TO H/L
A-PILLAR TRIM
HEAD LINER
HEAD LINER A-PILLAR TRIM C-PILLAR TO H/L HEAD LINER
NOTE : The overlap b/w head liner and pillar trims will be 10 to 15mm.
C-PILLAR TRIM
36
FEATURES
1.SEAT BELT
2.AIR BAG
3.CRUSH PAD
4.GRAB HANDLE
5.GAUGES
37
FEATURES SEAT BELT ASSY
D-RING
BELT MODULE
B-PILLAR TRIM SEAT BELT HOW THE SEAT BELT SYSTEM GET ASSEMBLED 38
FEATURES AIR BAG
AIR BAG DISPLAY COVER WHERE DOES THE AIR BAG GET PLACED?
39
FEATURES CRUSH PAD
RIB CARTRIDGE
CRUSH PAD
B-PILLAR TRIM
40
FEATURES
GRAB HANDLE
Model: U322 Customer: CHRYSLER
GRAB HANDLE
41
GAUGES The meter gauges to monitor: ·Boost ·EGT (Exhaust Gas Temp) ·CDT (Compressor Discharge Temp) ·Fuel Pressure ·Oil Pressure ·Volts ·Water Temp ·Oil Temp ·Transmission Temp
·Air/Fuel Ratio 42
GAUGES
43
PERFORMANCE SPECIFICATION Performance Specification for Hard trim and Garnish Environment Cycle Heat Age Infrared Heat Exposure Adhesion Safety
1.
FMVSS 302 : Parameters Requirements
2.
: - Determine the burn resistance within ½ inch of the occupant airspace. : - The individual components and composites shall not burn or transmit a flame front across its surface at a rate more than 101.6 mm/min.
FMVSS 201 : Parameters Test method Requirements
: - Vehicle level test. : - FMVSS 201 : - HIC d value should be 1000 or less.
44
Floor
Consoles
45
Center ConsoleConsole- Exploded view 11
1 FRAMEWORK FRT T/C 2 INS TOP PANEL HARD
28
10
4 TOPPANEL
9
12
3 INS TOP PANEL SOFT
27
5 HS
C/H TOP PNL
6 C/H LOWER
13
8
7 RUBR LIP C/H A/ R
26
8 C/H UPR
25
7
9 K LID C/H ALUMINIUM 10 PNL
14
24
6
EAR LEVER PLA
11 RUBBER MAT
EAR LEVER
12 LID A/T FRT
15
23
1 3 HS
5
A/T FRT
14 HOUSIN
16
22
ASHTRAY REAR
15 ASHTRAY REAR 16 I-CUP STR TRAY
4
17 LID A/T STDRIM
36
18 LID A/T ALU 19 FRAWORK C/H LWR
3
2 0 HS
21
35
2
STORA E TRAY
21 RUIBBER MAT TUN BKT 22 FRA TUN BKT FRT OPT
20
34
23 SHAFT HIN E ARMREST 2 4 HN
LWR
25 LID INNR UPPR
1
19
33 31
26 FRAMEWORK ARMREST 27 CARR FOIL 28 SURFACE COVERIN 29 LOC HAN-T CON FLOOR OPT
32
37
30 RUBBER CAP RH 31 RUBBER CUP LH 32 BOT TUN BRKT FRT
30
18 17
33 CONTACT ELEM BKT 34 CVR PLT RR
29
46
35 BKT TUN CON FRT AU 36 BEARIN
ARMREST
37 IK CARPET
Floor
Console Exploded View 37780 5
37778 6 115246 3
37780 6
377799
37779 4 162
120 or 249
37779 1 37778 5
377798
115825 8
115788 1 37779 0 37778 9
37778 4
47
A B C of DOOR TRIMS/MODULES
48
DOOR TRIM /DOOR MODULE Door Trims : Flat Hard Board with Vinyl , Fabric and Foam lamination Formed hard Board with Vinyl , Fabric and Foam lamination Formed or Flat Hard board with Foam, Fabric lamination with Plastic Door top, arm rest and Magazine pocket Complete Plastic Door trim with Hard board/wood stock fabric insert.
Door Module : Door Module carrier with window regulator, latch, inner release handle etc High Integrated Door trim Module without carrier , with all the module components fitted directly on the Door trim 49
FLAT
DOOR PADS Flat Hard board with vinyl and foamed backed fabric lamination
Tata Motors Sumo Door
Ford Endevour Door Pad 50
FORMED
DOOR PADS Formed Hard board with vinyl and foamed backed fabric lamination
Ford Ikon
Fiat Siena 51
PLASTIC DOOR TRIMS Plastic and Hard Board combination
Ford Endevour 52
Manual Window Lifting Mechanism
53
Manual Window Lifting Mechanism
54
Manual Window Lifting Mechanism
55
Power
Window
56
Power
Window
57
Power
Window
58
Power
Window
59
Power
Window
Electric Motor Worm Gear Spur Gear Linkage
60
Electric
Motor
Normal DC motor used to actuate the lif ting
61
62
63
Worm and Spur Gear Normal DC motor used to actuate the lif ting
64
Linkage Rod The Rod on which glass is lif ted.
65
Cup
Holder
Accessory to hold your Cup .
66
Magazine
Pocket
67
Audio
Speakers
68
69
Reflectors
70
Reflectors
71
72
Air
Bag
73
New
Trends in Door Panel
Web Enabled Door Locks Keyless Go! with Smart Cards Blue Tooth Power sliding doors
74
Web
Enabled
Door Locks
Users can access doors and control security devices by sending commands to the module by Cell Phone 2-way Pager E-Mail Directly f rom the Web Site
75
Blue Tooth : Voice
Commands
The module allows user to make and receive calls, this also enables voice commands to open and close the doors.
76
Keyless
Go!
Just
take a Smart Card with you and Touch the door to open it. Enables you to start ignition by a button. Allows Passive Exit.
77
78
FRONT DOOR MAP POCKET IS ATTACHED WITH SCREWS TO REDUCE THE HEAT STEAK M/C COST (AS A LOW VOLUME PRODUCTION) RIBS IN THE MAP POCKET TO AVOID WARPAGE
FRONT DOOR TRIM ASSY
79
Exploded Front Door
SWITCH BEZEL ANB40012 (LH) ANB40023 (RH)
COVER ANB40002 (LH) ANB50023 (RH) SCREWS 11509231 (QTY- 61)
HANDLE 10396621 (LH) 10396622 (RH)
UPPER SUBSTRATE ANB50021 (LH) ANB40014 (RH)
CLIPS 16754704 (QTY- 05) SWITCH 10386129 (LH) 10386130 (RH)
WINDOW SWITCH 10377668 (LH) 10377669 (RH)
CLIPS 16754704 (QTY- 04)
COVER ANB40004 (LH) ANB40019 (RH)
ALUM. BEZEL ANB40009(LH) ANB40016(RH)
FOAM ANB40012(LH) ANB40023(RH) S CLIPS ANB40006 (QTY- 04)
HANGER BKT ANB40008 (LH) ANB40017 (RH)
LOCK BEZEL LOWER 90560166 (QTY- 02)
LOCK BEZEL UPPER 13104077 (QTY- 02)
SUBSTRATE ANB40003 (LH) ANB40021 (RH) SCREWS ANB40010 (QTY- 16)
NUTS 11519497 (QTY- 04) G ASKET ANB50007 (QTY- 04)
LOGO ANB50020 (QTY- 02)
RETAINER 11519031 (QTY- 21)
SPK. GRILL 10370444 (LH) 10370406 (RH) BOLTS 1158901074 (QTY- 04)
MAP POCKET ANB40001 (LH) ANB40018 (RH)
PANEL LOWER ANB40000 (LH) ANB40013 (RH)
COVER 10393132 (QTY- 02) LAMP 15021517 (LH) 15021518 (RH)
80
DOOR SHEET METAL
81
LOCATERS WITH GASKETS TO AVOID BSR
THESE RIBS TO AVOID RATTLING SOUND DUE TO SPEAKER VIBRATION
SCREW BOSSES FOR MAP POCKET
LOWER DOOR SUBSTRATE
82
ARMREST SUBSTRATE Material ± PP+20%GF
83
SKIN Material - PVC
UPPER SUBSTRATE
FOAM BUN (ARMREST)
SUBSTRATE Material - ABS
84
ARMREST SUB-ASSEMBLY
HANGER ASSY
85
SWITCH BEZEL
WINDOW SWITCH
86
ALLUMINIUM FOIL
HANDEL BEZEL
PLASTIC
REMOTE HANDEL
87
SPEAKER GRILL Material ± Expanded metal, Powder coated
SEAT HEATTING SWITCH
88
89
Locaters with gasket H2 REAR DOOR
90
SWITCH BEZEL ANB43002 (LH) ANB43003 (RH)
Exploded Rear door
COVER ANB43200 (LH) ANB43300 (RH)
CLIPS 11609760 (QTY -04) HANDLE 10396621 (LH) 10396622 (RH)
G ARNISH
TRIM ANB52496 (LH) ANB52526 (RH)
SUBSTRATE ANB40029 (LH) ANB43005 (RH)
FOAM ANB50002 (LH) ANB50003 (RH)
COVER ANB40026 (LH) ANB43004 (RH)
CLIPS ANB40006 (QTY -04)
ALUM BEZEL ANB43008 (LH) ANB43009 (RH)
SCREWS 11509231 (QTY -36)
CLIPS 16754704 (QTY -04)
SUBSTRATE ANB50000 (LH) ANB50001(RH)
G ASKET ANB50007 (QTY ± 04)
LOCK BEZEL LOWER 90560166 (QTY ± 02)
BOLT 11589010 (QTY ± 04)
SCREWS ANB40010 (QTY -19)
SPEKER 25725733 (QTY ± 02)
LOCK BEZEL UPPER 13104077 (QTY ± 02) NUT 11519497 (QTY ± 04) HANGER BKT ANB43010 (LH) ANB43012 (RH)
ALUM BEZEL ANB43008 (LH) ANB43009 (RH) RETAINER 11519031 (QTY ± 18)
MAP POCKET 10370371 (LH) 10370399 (RH) PANEL LOWER ANB40027 (LH) ANB43007 (RH)
LAMP ASM 15021517 (LH) 15021518 (RH)
91 SPK. GRILL 10370897 (LH) 10370898 (RH)
Locaters
HEAT STEAKS FOR MAP POCKET
LOWER SUBSTRATE Material - ABS
92
UPPER SUBSTRATE Material ± ABS with PVC skin
C- PILLER
LOCK BEZEL
UPPER SUBSTRATE ASSY
93
HANDEL BEZEL
HANDLE ASSY
REINFORCEMENT FOR SIDE CRASH TEST AS PER FMVSS-202 C ± PILLER Material - ABS
94
ARMREST ASSY
ARMREST ATTACHMENT POINTS
95
ARMREST ATTACHMENT POINTS
ARMREST SUBSTARTE
FOAM BUN
ARMREST TRIM
96
DOOR LOADING TESTING FOR MISSUSE (FMVSS ± 214)
97
Door Module Experience
Sealing
Latch
Exterior
Handle Loudspeaker
Side Impact Bolster Window Regulator
98
Door Module Experience Sealing
Latch Loudspeaker Exterior
Handle
Window regulator 99
DOOR MODULE Double Arm Window Lifter Door trim panel + Mechanisms
100
DOOR MODULE Double Rail Window Regulator Door trim panel + Mechanisms
101
DOOR MODULE Single Rail Window Lifter Door trim panel + Mechanisms
102
DOOR MODULE Single Rail Window Lifter Door trim panel + Mechanisms
103
Level of Modularity
Level 1 Components
Components - Latches - Trim - Regulators - Hinges - Handles - Wiring - Switches
Level 2 Functional
Level 3
Integr ation
Systems Integr ation
Function Improvement
Full
- Steel HW Module
____________________ Up-Integr ation - Super Plug Door Module - Door Trim Module - µX¶ Frame / Hybrid HW Mod.
Modular
Door
Level 4 Full
Door Integr ation Total Modular Door
- Door HW Module
- Outer Skin
- Door Trim Module
- DH Subsystems
- Door Structure
- Door E/E Arch.
- Glass, Seals, etc.
- Door Structure - Inner Trim, etc.
104
Door Module Market Evolution
Door Module - Fr ame Concept
105
Components Carrier
Door Module Market Evolution
Structur al
Metal
Module
Door of the vehicle³Smart´
Carrier
Door Trim Module Trim Panel as components carrier Plastic Carrier
106
Door Module Market Evolution
+ Door Trim Module
Door Structure
Outer panel
New Door Concept
107
Door Module Market Evolution Conventional
door
- 4 planes - Dry and wet areas
Metallic (or Plastic) carrier (AGT)
- 3 planes - Dry and wet areas
Door Trim Module (DTM)
- 2 planes - Localized dry areas 108
Door Module Market Evolution Conventional
door
Metallic (or Plastic) carrier (AGT)
Door Trim Module (DTM)
- Inner sheet metal with - Door inner sheet metal - Openings in the inner openings to assembly completely open (door sheet metal to assembly the components stiffness reduced) the door module (same - Reinforcements in the - More reinforced door stiffness than traditional critical areas (hinges, due to the big opening door) latch, upper area, etc) in the inner sheet metal - Same reinforcements 109 door than in a traditional
Door Module Description
Door trim support: Integrated fixing system for the door trim
Fixation for the window lifter motor
Plastic
padding Door sheet 110 metal
Door Module Description
Door trim support:
Integrated clips for the harnesses
Loudspeaker
WR support
111
Door Module Description
Door trim support:
Latch support
112
Door Module Description
Door trim support: - Trim panel attachment to the door inner sheet metal
113
Door Module Description
Medallion: - Low pressure injection technology. - Cover with fabric. - Integration of the clip·s in the medallion part.
114
Door Module Description
Door trim support: - Housing for the medallion clip·s. - Support for rails of the window lifter.
Medallion clip·s
Support for window lifter rail 115
Door Module Description
Sealing system: - Sealing joint all around the door trim panel. - Every mobile piece has a seal joint. - The sealing concept is validated and in the market.
Sealing joint all around the door trim
116
Door Module Description
Sealing system: Section AA Door trim
A Sealing profile
A Door sheet metal
117
INTRODUCTION TO INSTRUMENT PANELS
118
AIM ³ ON COMPLETION OF THE TRAINING THE PARTICIPANT WILL BE ABLE TO DESCRIBE DIFFERENT INSTRUMENT PANELS. ´
AGENDA INTRODUCTION TO INSTRUMENT PANEL
EXPLAIN SIGNIFICANCE OF IP - SAFETY - COMFORT
DIFFERENT PARTS OF IP - IDENTIFICATION - FUNCTIONS
SUMMARY
EVALUATION
119
Instrument Panel Development
Engineering Requirements Styling Requirements
Architectural Options
Design Options
Platform Needs and Requirements
IP Assembly Process
Material Options
Vehicle GA Process 120
Consumer Trends in Instrument Panels
Comfort and Safety
Function
± C limate control
± C up holders
± Spacious
± Electronics
± Ergonomics - ease of controls, buttons, features
± Electronic integration
± Quiet
± Heads-up display features
± Airbags
± Storage
± Easy to read instrumentation
± Long lasting - durable
Styling ± ³Interior Designed´ ± Sleek, modern, coordinated colors and textures ± Luxurious look and feel
Vehicle
Affordability
± T otal cost ± C ost-performance-feature ratio 121
Instrument Panel Requirements
Static Steering Column Stiffness and NVH ± ±
Static stiffness upon vertical and transverse loads Frequency response of column and column/support subsystems
Instrument Panel NVH ± Frequency response of IP system
FMVSS 208 Crashworthiness ± K nee intrusion and knee load management capability ± Occupant deceleration management ± Energy absorption capability of IP system
FMVSS 214 Crashworthiness ± Maximum load carrying capability and collapse load ± C ross-vehicle load path continuity
FMVSS 201/ECE 21/ADR 21 Head Impact Protection ± Local structural stiffness ± Local energy absorption and load carrying capability
Offset Deformable Barrier Impact ± Load management capability ± Steering column movement
and NCAP 122
Functional
Frequency
Per f ormance Requirements
Steering column static stiffness upon vertical and transverse loads
Steering column frequency response
Steering column and column support system frequency response
oC
response of IP
system
IP
system durability
Long-term structural performance
Aging behavior
Environmental response
Road Surfaces
E ngine
123
Functional
Per f ormance Requirements
FMVSS 208 Crashworthiness
Upper
Occupant
Knee and lower leg energy and load management
Knee intrusion
Load transfer capability
ODB
torso load management deceleration 30 mph
/ 48kmh Vehicle Pulse
Impact
Driver front end crash behavior
Localized IP deflection behavior
Front-of-Dash
Load path between steering column, IP and vehicle body124
intrusion and steering column deflection
Functional
Per f ormance Requirements
FMVSS 201, ECE 21, ADR 21 Head Impact Protection T op Excluded Area
View Instrument Panel
W indshield
Steering W heel Headform Impact Fixture Headform
Instrument Panel
5 "
Vertical Plane
Steering W heel
W indshield
Headform Vertical Plane
Right Side View
Excluded Area Instrument Panel
Left Side View
125
INSTRUMENT PANEL THE MOST IMPORTANT AND CRUCIAL SUBSYSTEM FOR A CAR
? HOW¶S THAT????????????????????
126
SIGNIFICANCE OF INSTRUMENT PANEL
The Instrument Panel (IP), IP Structure, and Console are key to customer perception of the vehicle. Safety
performance
Aesthetic Human
appearance
interfaces
127
FUNCTIONS OF IP The
IP & Console locate most driver controls, vehicle subsystems and feedback devices.
The
IP Reinforcement provides structural mounting .
Support
components of vehicle subsystems for the comfort, convenience, and protection of the occupants.
128
MAJOR COMPONENTS OF IP: Instrument Panel Assembly (Console as and when needed)
Storage Bins, Cup holders, Coin holders
IP Structure (cross car beam and brackets)
Transmission Shifter, Knob, Boot
HVAC Module
Harness, Control Head
Gear Shifter Assembly
Air Outlets, Side window Defoggers, Lap Coolers
Glove box Bin, Door Latch, Striker, Lock
Air Ducts, Defroster Ducts and Grills
Ashtray assembly Parking Brake Handle/Actuator Steering Column Covers
129
INSTRUMENT PANEL ASSY
130
PANEL-ASM INST UPPER Spray Skin
Carrier
NOZZLE-W/S DEFR
DUCT-AIR INL
131
PANEL ASM-INST LWR
PANEL-INST LWR
REINFORCEMENT ASM-I/P
132
PANEL ASM-INST ASM-I NST KLEMMUTTER 2,5x8,5
KLEMMUTTER 3,5x8,5 PANEL ASM-INST UPR
BLIND RIVET 4-K12 4x10 Pos. 9 DUCT-I/P AIR OTLT BLIND RIVET 4-K12 4x16 PANEL ASM-INST LWR
TUBULAR RIVET
RETAINER-DRVR INFO DISPLAY TUBULAR RIVET
BLIND RIVET
133
GLOVEBOX ASM
134
COMPARTMENT COMPAR TMENT ASM-I/P ( W/DOOR )
DAMPENER ASM-I/P COMPT DR
SPRING CLIP
PAN HEAD SCREW ADAPTER
ADAPTER
COMPTARTMENT ASM-I/P
DOOR ASM-I/P COMPT
135
DOOR ASM-I/P COMPT HINGE-I/P COMPT
FASTENER-PEG, FASTENER-PEG, GLOVE BOX
ROD-I/P COMPT DR LAT REL
HINGE-I/P COMPT
PANEL-I/P COMPT DR INR
LEVER-I/P COMPT DR LAT
ROD-I/P COMPT DR LAT REL SPRINGACTUATOR LEVER-I/P COMPT DR LAT
PANEL-I/P COMPT DR OTR
LOCK-ASM I/P COMPT DR
136
INSTALLATION-I INSTALLA TION-I/P /P MLDG
MOLDING ASM-I/P CTR
CARRIAGE BOLD 20x12
137
MOLDING ASM-I/P CTR
HOUSING ASM-I/P CTR AIR OTLT DFL
SPRING CLIP 34723-EM
MOLDING-I/P CTR
SPRING-HTR & A/C CONT MODE
138
COVER STEERING COLUMN
139
INST. COV. STEERING LHD
COVER ASM-STEERING COL TR
COUNTERSUNK SCREW
CAP-COUNTERSUNK SCREW PAN HEAD SCREW
COVER ASM-STRG COL TR
140
COVER ASM-STEERING COL TR
MOUNTING RAIL
COVERING STEERING
COVER STRG COL HSG UPPER
141
COVER ASM-STRG COL TR
CRASHPAD ASM STEERING
COVER STRG COL HSG LOWER
142
PANEL ASM-I/P TR
CARRIAGE BOLD 20x12
PANEL ASM-I/P TR
143
PANEL ASM-I/P TR
SPRING
PANEL IN
PANEL OTR
144
DECOR MOLDING DR/PS
MOLDING-I/P DRIVER SIDE
SPRING FEDER
DECOR MOLD PASSENGER SIDE
145
ENVIRONMENT COMPONENTS
CROSS CAR BEAM HVAC
NAVIGATION DISPLAY
146
Abbreviations Abbrevations HLU
Hand Lay UP
RIM
Reaction Injection Moulding
GMT
Stampable Thermoplastics
IM/BMC
Injection moulding ( Bulk moulding Compound)
RTM
Resin Transfer Moulding
UP
Unsaturated Polyester
VE
Vinyl Ester
PU
Poly urethane
EP
Epoxy
MF
Mineral Filled
CSM
Chopped strand Mat ( Glass)
SMC
Sheet Moulding Compound
CS
Chopped Strands ( Glass )
LCP
Liquid Crystaline Polymers
PI
Polyimides
PTE
Polyester Thermoplastic Elastomer
PPE
Poly phenyelene ether
MPPO
Modified Poly Phenylene Oxide
147
Assembly & Attachment Methods of IP
148
Assembly Techniques f or Plastic parts
149
Assembly Techniques ±Snap Fits
Snap f it cantilever beam type
Snap f it cylindrical Type 150
Assembly Techniques ±Snap Fits
Factors
f or calculating cantilever beam f or Snap f it
151
Assembly Techniques ±Snap Fits
Mold
Design For Snap Fits
152
Assembly Techniques ±Spin Welding
153
Assembly Techniques ±Ultr asonic Welding
154
Assembly Techniques ±Hot Plate Welding
155
Assembly Techniques ±Adhesive Bonding
156
Assembly Techniques ±Ultr asonic Insertion
157
Assembly Techniques ±Screw and Bosses
158
Assembly Techniques f or Plastic parts
159
INDEX
ATTACHMENT METHODS USED IN IP GMX-211 ASSEMBLY ASSEMBLY LINE ± JEEP LIBERTY GENERAL PROCEES FLOW DIAGRAM
160
VARIOUS ATTACHMENT AIDE :
Screws & Nuts
Self Retaining Speed Nuts
Rivets Clips
Cable Clips
Plastic Fasteners Pour In Place Gluing Snap Fixing Welding
Vibration Welding Ultrasonic
Insert Molding
161
SCREWS & NUTS : Screws & Nuts:
High Bonding Strength Resistance to Vibration Standardized part Availability Low Cost Low Assembly Time
162
SCREWS & NUTS : Self Retaining Speed Nuts: A unique dual locking action. Ease of application and reduced assembly time. Resistance to loosening from vibration. Maximum holding power with minimal installation torque required.
163
GMX-211
BENEFITS:
Plug a Temporarily Unused Hole Provide Vibration-resisting Fasten in Wood, Heavy Gauge Metal Odd-shaped Panel Holes Reduced Cycle Time Lower Cost
ROBOTICS NUT Expansion-Type Fasteners
164
GMX-211
NO ACCESS TO THIS AREA
SEATING LOCATION
165
GMX-211
SECTIONAL VIEW 166
ASSEMBLED VIEW
GMX-211
167
CENTER STAKE AREA
GMX-211
168
EXPANSION NUT Expansion-Type Fasteners
169
SEATING LOCATION
170
ASSEMBLED VIEW
171
SECTIONAL VIEW 172
BLIND RIVETS:
Types:
ECONOMICAL
Dome Head Most widely available and commonly used head style.
VERSATILE EASY-TO-USE SPEED OF ASSEMBLY, CONSISTENT MECHANICAL PERFORMANCE AND EXCELLENT INSTALLED APPEARANCE
Countersunk Head -120° The Countersunk Head Blind Rivet is used in applications requiring a flush surface.
,
Multi-Grip Blind Rivets Plastic Blind Rivets Olympic Mega-Grip Rivets
Very High strength
173
The graph illustrates the mechanical function of a blind break-mandrel rivet during installation.
BLIND RIVET 174
GMX-211
Dome Head Rivet 175
ASSEMBLED VIEW
GMX-211
176
TUBULAR RIVET
BEFORE PROCESSING
AFTER PROCESSING
177
Clips :
A low cost replacement for screws and rivets. Can be used for metal, plastic, and a variety of materials. Ideal for assembling gaskets, nameplates, and lightweight panels to other panels and components
178
GMX-211
BENEFITS:
Designed for Use Over Rectangular Studs Reduced Cycle Time Lower Cost Most Suitable where Removability is Criterion GENERALLY USED FOR LIGHTWEIGHT APPLICATION.
TRIM CLIPS
179
GMX-211
ASCRY PLATE
KNEE BOLSTER
SEATING LOCATION 180
GMX-211
ASSEMBLED VIEW
RETAINER & TRIM PLATE 181
ASSEMBLED VIEW
182
Cable Clips : Provide strong, reliable retention. Maintain dimensional stability. Work with a wide range of diameters. Reduce parts handling and speed the assembly process. Be conveniently removed and reused as needed
183
GMX-211
CABLE ROUTING CLIPS
184
GMX-211
SEATING LOCATION
185
ASSEMBLED VIEW
GMX-211
186
GMX-211
SECTIONAL VIEW 187
GMX-211
ADJUSTABLE CABLE CLAMP
188
ASSEMBLED VIEW
GMX-211
189
PLASTIC FASTENERS :
Lightweight, yet durable. Provide corrosion resistance. Offer thermal and electrical insulation. Can be easily removed and reused. Are an attractive fastening alternative, that is reliable and long-lasting.
190
POUR IN PLACE : Benefits of Insert Molding
Reduces Assembly Time Can be used on Irregular surfaces Consistent quality Durable surface Design and decoration flexibility Choice of textures Touch N Feel No adhesive IT REQUIRES SECONDARY TRIMMING OPERATION
191
POUR IN PLACE : STEP - I
192
POUR IN PLACE : STEP - II
193
POUR IN PLACE : STEP - III
194
FINISHING ACHIEVED USING POUR N PLACE
Dylark
195
GLUEING
196
SNAP FIXING : Reduces Part Count
TYPES
Eliminate Screws, Clips, Adhesives,
ANNULAR
Or Other Joining Methods
CANTILEVER
Faster
TORSIONAL
Cheaper Flexibility Of One Time Assembly/ Service Assembly TOOL BECOMES COMPLEX
197
SNAP FIXING : ANNULAR
Figure 1: A pen sometimes retain the cap
utilizes
an annular snap fit to
.
Figure 3: A ball and socket joint is a kind of annular snap fit.
Figure 2: This bottle cap uses an annular snap fit.
198
Snap Fixing : CANTILEVER
Figure 4: These four snap fit designs allow different types of disassembly.
Figure 5: The stages of a
U
shaped cantilever snap fit.
199
SNAP IN GLOVE BOX 200
SNAP IN AIR DUCTS
201
Welding :
VIBRATION WELDING ULTRASONIC WELDING FUSION WELDING
Advantages of Welding Speed Strong Joints Tolerance of Contaminated Surfaces. Joins Difficult Substrates, Such As Polyolefins Improved Recyclability
DECKEL INNER FUSION WELDED TO DECKEL OUTER 202
Welding : Ultrasonic welding
Most Commonly Used Thermoplastic Welding Very Fast (Fractions to a Few Seconds) Free of Flash. Easy to Automate Suitable for High Volume Production.
Ultrasonic Welding Mechanism 203
Welding : Vibration welding
Suitable for Most Thermoplastics, (Amorphous and Semi crystalline) More Tolerant of Moisture in the Polymer, Nylons Best Results When the Joints Are Planar
Vibration Welding Mechanism
204
Insert Molding :
205
Over Head Systems
206
207
TOPICS
Why headliners are used?
Types of headliners
What mean by A,B,C sur faces
Terminologies used in headliners
Major Subsystems
Additional Subsystems
Design Consider ation
Headliner Manufacturing Process
Assembly Sequence
Vehicle environment f or headliners
208
WHY HEADLINERS ARE USED?
The function of the headliner over the past years has evolved from merely a "liner³ to that of a vital player in both structur al and acoustical soundness and silence respectively. The headliners today are a sandwich of many different materials that are combined in order to enhance these properties Enhances
appearance Conceals roof structure Promotes interior harmony Feels good (soft) Avoids odor Avoids fogging
209
TYPES OF HEADLINERS
Standard
Sunroof
Moon roof
210
STANDARD HEADLINER GRAB
HANDLE CUTOUT
CUTOUT FOR `A¶ PILLAR
CUTOUT FOR `C¶ PILLAR
CUTOUT FOR `B¶ PILLAR
CUTOUT FOR ?
CUTOUT FOR VIOSR
CUTOUT FOR RECEPTACLE CUTOUT FOR BEZEL
CUTOUT FOR MAP LAMP
211
SUNROOF /
MOONROOF
HEADLINER
SUNROOF / MOONROOF OPENING
212
MAJOR
TYPES OF SUNROOF /MOONROOF H/L
Top Slider Pop-up Electric Spoiler Folding Type
213
TOP SLIDER
214
POP-UP
215
ELECTRIC SPOILER
216
FOLDING
TYPE
217
WHAT MEAN BY A, B, C, SUR FACE From the design point of view, only 3 surfaces are considered; A-Sur face The fabric side or Interior show surface. B-Sur face Surface from the back side of the fabric to the laminated blank outer surface. C-sur face Top most surface which is closest to the sheet metal (Roof) and is opposite the A surface Closing Sur face The side wall of boundary and internal cutouts. This surface is part of A or C surface from CAD file point of view `C¶ CLOSING SURFACE
µA¶ SURFACE
SURFACE
`B¶ SURFACE
218
TERMINOLOGY -
MATERIAL
COVER GOODS
Polyurethane core: The main component for binding other materials to itself. known as the high strength board under the basic construction of chop ped glass, adhesive, and PET scrim. Cover Goods: The material which makes up the outermost aesthetics (fabric) and is mated with the laminated blank on the 2nd surface. This material is usually made up of fabric +foam +adhesive (tri-laminate). 219
TERMINOLOGY -
MATERIAL
COVER GOODS
bric: Face Fabric: Comes in many types with base thread of either ei ther Polyester or Nylon. Scrim: A material normally found on the C surface of the formed substrate which can assist in the ability to attach components and provides provi des protection from human contact against the fiber glass. Adhesive: Material which bonds the substrate to the fiberglass fi berglass to the scrim to the cover goods. goo ds. 220
TERMINOLOGY - PE PER RFORMANC ANCE E Sag: The deviation from initial installed position to the f inal position after complete environmental cycling. Peel eel Strength: Strength: The ability of the fabric to withstand a 180 1 80 degree pull from the formed fo rmed substrate. Acoustic Abil Ability: Ability to absorb sound from varying varying sources such as roof panel noise, road noise, engine noise, and BSR¶s. Fogging:
The ability to not have materials gas out and leave deposits on the interior glass. lamma abil bility: Flamm Must comply with government regulations for flame propagation.
221
MAJOR
SUB-SYSTEM SUB-SYSTE
FOLLOWING ARE THE SUB-SYSTEMS WHICH W HICH FORM PART OF OVERHEAD SYSTEM:
OVERHEAD CONSOLES
VISOR ASSEMBLIES
GRAB
MAP, DOME AND COURTESY LAMPS
HEAD IMPACT MANA GEMENT (HIC)
HANDLES
ADDITIONAL SUB-SYSTEM:
SIDE IMPACT AIRBA GS
HVAC
CONVENIENCE ELECTRONICS INCLUDIN G:
INTRUSION SENSOR
REAR PARKING ASSIST MODULES
VIDEO ENTERTAINMENT SYSTEMS
222
MAJOR
SUBSYSTEM SUBSYSTE
223
OVE OV ERH RHE EAD CONSOLE CONSOLES
224
VISOR ASSEMBLIES
225
GRAB HANDLES
226
MAP,
DOME AND COURTESY LAMPS
227
WORM TRACKS Worm
tracks are groove/channels running on the c-surface of a headliner.
Worm
tracks hold the wire harness routing in place
The
wire harness is glued on these tracks
Worm
tracks are beneficial for allowing clearance to the roof steel, by taking some depth from wires Worm
tracks are used as locators also for Foam pads
228
HEAD IMPACT MANAGEMENT HIC
stands for Head Injury Criteria. The HIC number is a relative measure of experimental data to a critical head injury threshold for blunt impact. HIC is a numerical value dervied from the following formula; The formula for HIC of the FMH (free motion headform) is
but the spec. is for HIC(d) or the dummy equivalent of HICfmh
HIC
value should not exceed 1000 as per safety regulations.
HIC
pads are protective padding between the headliner and vehicle roof, which provide a cushioning effect for occupants head, in the event of a crash.
229
HEAD IMPACT LOCATIONS IN CAR
230
HEAT VENTILATION AND AIR CONDITION
231
VIDEO ENTERTAINMENT SYSTEMS
232
TOPICS
There are three major process f or manufacturing headliners :
ACOUSTICOR POLYBOND THERMOBOND
233
ACOUSTICOR
234
POLYBOND
235
THERMOBOND
236
ASSEMBLY SEQUENCE
237
STATION 1: HIC FOAM (FSD)
238
STATION 1: HIC FOAM (FSD)
239
STATION 2: CO MPONENTS (FSU)
240
STATION 2: CO MPONENTS (FSU)
241
STATION 2: CO MPONENTS (FSU)
Components are attached to clips and retainers by skilled oper ator
242
STATION 3: OHC AND WIRE HARNESS (FSD)
243
STATION 3: OHC AND WIRE HARNESS (FSD)
Overhead Consoles (OHC) is nested into f ixture prior to Headliner arrival
244
STATION STA TION 3: OHC AND WIR WIRE E HARN HARNE ESS (FSD)
Hea Headliner is pla p laced ced FSD over Consol Consoles and wire ha h arness is pla placed ced Tempor aril rily on the ba b ack of of the the H/L
245
STATION STA TION 3: OHC AND WIR WIRE E HARN HARNE ESS (FSD) Wire connections are ma made to the consol conso le, Loosel Loosely routed and reta retainer is positioned
246
STATION STA TION 3: OHC AND WIR WIRE E HARN HARNE ESS (FSD)
247
STATION STA TION 3: OHC AND WIR WIRE E HARN HARNE ESS (FSD) Skill Skilled ed oper ator a tor appl pplies gl glue bea bead and adheres wire ha harness to it
248
STATION 4: QUALITY CHE CHECK (FSU)
Wire Ha Harness is pl plugged into ta table and el electrical ectrical check is per f formed ormed and resul results are stored in computer.
249
VEHICLE ENVIRONMENT
250
HEADLINER ATTACHMENT
251
SLIDER MECHANISM
252
VEHICLE STRUCTURE
ROOF RAIL REAR
ROOF BOW
ROOF RAIL FRONT A PILLAR
RAIL SIDE ROOF
B PILLAR
REAR INNER PANEL
253
VEHICLE STRUCTURE FOR S/R & M /R
ROOF RAIL REAR
ROOF RAIL FRONT
REAR INNER PANEL
254
255
Vehicle classifications as per ECE
256
Three-Dimensional Ref erence System
X ±Axis runs vertically through the vehicle front to back Positive X coordinate is to the rear of the vehicle Negative X coordinate is to the front of the vehicle
Y - Axis coordinate is a point left or right of the centerline
Positive Y coordinate is left of the centerline Negative Y coordinate is right of the centerline
Z ± Axis Runs perpendicular to both X and Y planes along the height of the vehicle
Positive Z coordinate is closer the roof of the vehicle Negative Z coordinate is nearer the floor of the vehicle 257
Point of Origin
Intersection of all three planes 0X, 0Y, 0Z coordinate
OEMs locate point of origin in different places Center of front bumper Center of the firewall Point where the middle of the wheel and rocker panel meet
Know the point of origin to ensure proper use of coordinates
258
Two Dimensional Views
Prints and drawings are two-dimensional, so different views must be used to properly show a point X-Z shows location along length and height X-Y shows location along length and width Y-Z shows location along width and height
All three are necessary
259
Grid Lines and Work Lines
Grid
lines are formed by intersection of planes
Grid
lines are at 100 millimeter increments
Grid lines help package and locate objects and spaces Work lines are located on individual parts Used to lay out parts and project views of parts at different angles 260
Body Position and Design Position
Body position is where a part is located with respect to the body X and Y coordinates in two dimensions X, Y and Z coordinates in three dimensions Commonly called ³in body´ or ³in vehicle´ position
Design position is point of view you draw the part from 261
Location Terminology Right Hand Outboard
Fore
Inboard Inboard
Af t
Outboard Lef t Hand
Other terms used to describe locations
Centerline Left Hand and Right Hand Inboard and Outboard Fore and Aft
262
Locating Points Within the Vehicle
Many locating points are used to define occupant¶s location in a vehicle
Eyellipse Seating Reference Point H-Point D-Point Accelerator Heel Point Hand Reach Envelope
Critical for developing safe, comfortable seat systems 263
Eyellipse
Statistical representation of the driver¶s eye location in the vehicle Eye range is an ellipse
Eyellipse must allow for clear view inside and outside the vehicle Starting point for vehicle design If the driver can¶t see properly, vehicle is not safe 264
Seating Ref erence Point
Based on eyellipse location so occupant is properly positioned in vehicle Measured from intersection of line down from mid-eye centroid and projected back and hip angles Referred to as SgRP
Becomes the origin for defining design H-Point
265
Importance of SgRP
Establishes the rearmost normal design driving or riding position for each designated seat Considers all modes of adjustment Horizontal, vertical and tilt
OEM provides SgRP and
Foot angle Knee angle Heel point Hip angle Back angle 266
SgRP Helps Def ine...
SgRP, torso angle and hip point, define Location of eyellipse in vehicle Wiper pattern Defrost pattern Seat belt zones Airbags and knee blockers Hand reach envelope
267
Oscar and H-Point
Oscar is used to measure seating accommodations
Oscar template is two-dimensional
Oscar machine is three-dimensional
Shows designers how occupant will sit in seat
Helps determine design H-Point, the pivot point of thigh and torso
Design H-Point should match SgRP
268
D-Point and Acceler ator Heel Point
D-Point
Lowest point on the buttocks contour on Oscar Measures how far the occupant sinks into the seat Used to avoid hard point sin the seat that may make the occupant uncomfortable
Helps determine foam thickness and suspension type
Accelerator Heel Point 87o minimum
Refers to Oscar¶s heel point with shoe on un-depressed accelerator Altering heel point affects comfort and safe operation of foot controls 269
Hand Reach Envelope
Reaching distances for specific driving populations define and envelope´ into which primary and secondary controls should be located Reaching distance depends on elevation of the control from H-Point 270 and type of vehicle
Position and Comf ort
Driver position is defined by several measures ± Eyellipse represents field of vision ± Eyellipse helps define seating reference point, or SgRP ± SgRP becomes basis for defining design HPoint ± Design and actual H-Point are measured using two- and three-dimensional Oscar templates and manikins
271
Measuring H-Point
272
