Simulation Driven Optimization of Automotive Floor Console Mounting Brackets – An Overview

Floor consoles or Center consoles are an indispensable part of Automotive Cockpit systems in modern passenger vehicles. It occupies space between the front seats in the car and has a lot of utilities and functionalities. The center console design can be very simple as just providing an enclosure for the gear shifter and parking brake and as complex as having storage bins with armrest which can slide. Now-a-days a lot of functionalities are being provided by the center console such as housing the AC vents at the rear, provision for USB and power outlets etc. All these utilities within the center console demand a certain amount of structural rigidity to meet the functional requirements as well as applicable regulatory requirements. The console mounting bracket usually serves to attach the plastic center console to the steel underbody. It also acts as a load carrier for the console and its design influences the overall stiffness and modal characteristics of the console system. In this paper, two different CAE optimization strategies are applied to two variants of console for a passenger minivan application. For one console model, topology optimization strategy is applied to optimize the material on its mounting bracket. In the other console model, which is relatively complex, topography optimization strategy is applied to its mounting bracket for meeting the functional requirements of the console assembly. The critical functional requirements are validated through CAE techniques and correlation with physical test for one of the variants is highlighted in this paper.