Analytical Method for Console Lid Latch Squeak and Rattle Risk Assessment and Validation

Squeak and Rattle (S&R) noise in automotive vehicle components is a direct measure of vehicle build quality. With the recent advances in electric propulsion technology the cabin interior has become even more quieter, but S&R remains one of the main noise issues inside the cabin. Consumer surveys such as by J D Power shows that instrument panel, floor console and glove box latch mechanism are some of the most prominent sources of vehicle interior noise. The commonly used design for console lid latch consists of latch pawl preloaded against the console bin in closed condition. The goal of design is to optimize the preload such that the latch remains in contact with the bin under all operating conditions. But inadequate design, poor manufacturing quality control and material degradation causes the loss of preload. Hence, S&R noise emerges due to friction or impact between the parts which induces undesirable vibration and noise. It is challenging to design systems free of S&R, but analytical simulation can be leveraged to identify and minimize the risk of S&R at the early stage of design before physical parts available. The current work depicts the development of an analytical simulation procedure which proposes a force-based S&R threshold to identify the S&R risk and optimize the design parameters. It encompasses the methodology to develop a high-fidelity finite element model with accurate representation of the input design parameters and modal transient dynamic analysis to predict the response. A non-linear direct transient dynamic analysis procedure was used to validate the linear analysis result to reinforce the accuracy of simulation. This simulation procedure is aimed to provide useful design suggestions and refinement to improve the S&R performance for the console latch and similar systems, to enforce stringent manufacturing quality controls and reduce cost incurred due to late design changes.