Browse Topic: Consoles
Head injuries from interior impacts during vehicle accidents are a significant cause of fatalities in India. Data from the National Crime Records Bureau (NCRB) for 2023 reveals that approximately 15% of the total 150,000 road fatalities were due to head impacts on vehicle interiors, resulting in about 22,500 deaths. Thus, head impact protection in a car crash is key during the design of vehicle interiors. IS 15223 and ECE-R21 provide specific guidelines for head impact testing of instrument panels and consoles in vehicles to ensure compliance with safety standards and minimize the risk of head injury during collisions. By systematically addressing each aspect of IS 15223 and ECE- R21 in the design, testing, and documentation phases, manufacturers can ensure that console armrests are optimized for safety. This approach not only helps meet regulatory standards but also enhances overall occupant protection in vehicles during collisions. The objective of this paper is to design a console armrest that meets stringent head impact testing requirements and thereby enhances occupant safety in automotive applications. The research focuses on optimizing the armrest’s structural integrity to withstand dynamic loads and to transfer or dissipate that impact energy effectively.
During the early phase of vehicle development, one of the key design attributes to consider are the interior storages for occupants. Internal storage is the pillar that is responsible for user’s comfort and make into customer comfort needs in engineer metrics. Therefore, it is one of the key requirements to be considered during the vehicle design. The vehicle has some interior storages, like storages on door trim, floor console and IP and to define the best solution for the customer, engineering team has certain internal vehicle characteristics such as the volume and size of storage are engineer metrics that influence the perception of comfort for occupants. One specific characteristic influencing satisfaction is the glove box volume, which is the subject of this paper. The objective of this project is to analyze the relationship between the glove box volume with the occupant’s satisfaction under real world driving conditions, based on research, statistical data analysis and dynamic clinics.
In this paper, an application process is studied at which the insertion loss (IL) test data of sound insulating parts or noise control treatments are utilized for the sound transmission loss (STL) simulation of the trimmed dash structure. The considered sound barrier assemblies were composed of a felt layer, a mass layer, and a decoupler layer. Flat samples of sound barrier assemblies with several different thicknesses were prepared, and ILs of them were measured by using a sound transmission loss facility. Flat samples were assumed to have mass-spring-mass resonance frequencies. The mass was set as the area mass of the sound barrier layer of the felt layer and the mass layer. The spring constant of the decoupler layer was assumed as the multiplication of that of an air spring and a spring correction factor. At the beginning, the spring correction factor was assumed to be 1, and the measured IL data vs frequencies are converted to IL data vs frequency ratios, frequency f over the resonance frequency fres. With the converted IL data, a trend line was analyzed below the frequency ratio of 1, and another trend line also analyzed above the frequency ratio of 1. It was assumed that the two trend lines had to be similarly matched at the frequency ratio of 1, and the spring correction factor was found by varying the spring correction factor and observing the values of the two trend lines. After the spring correction factor was decided, the high frequency drop curve of the barrier layer were decided. By using the estimated spring correction factor and the high frequency drop curve, IL data were calculated at each thickness, which were necessary for sound transmission loss simulation. The calculated IL data were applied to the STL simulation of a trimmed dash structure, and the simulated STL of the trimmed structure and IL of dash isolation pad (dashmat) are fairly acceptable compared to the test values.
Dashcam, which is considered essential parts of vehicles in Korea, are installed in most vehicles for proofs of accidents or threatened driving of other vehicles, and insurance premiums. Also global market is growing continuously. Aftermarket dashcams have been developed with many improvements such as higher resolution camera and a LCD, however still have technical limitations in usability and durability. The First limitation is that the dashcam which mounted on windshield can be separated and injure at an accident due to a collision impact, and the device obstructs the driver's vision. In addition, the connection of the power supply may cause a vehicle damages such as a fire due to a worker's mistake or a product defect. Secondly, in order to replay the recorded video, it is not easy to remove the SD card and check it on the computer. Moreover, since the LCD is so small, it is difficult to search and replay the wanted video from the list in many files. The third limitation is about durability and reliability, when operating in the high temperature condition, the device's own operating temperature limitation and product heat dissipation efficiency such as semiconductors are not sufficient, so that the device cannot operate or have physical damages. For this reason, it automatically shuts down at high temperatures to prevent damages. The Next, the micro SD card storage memory should be formatted by the customer at regular intervals and should be replaced regularly because of the low-durability. In addition, the terminal contact characteristic of the SD card is very weak to vibration, so if a big accent occurs, the recorded videos are often not properly saved due to a poor connection. Lastly, according to using vehicle’s battery for the parking recording, the battery can be completely discharged and the durability is degraded. This paper introduces the development of a built-in type dashcam with reliability and usability that can operate vehicle operation environment. The dashcam was launched under the brand name 'Built-in Cam’ applied to mass production starting with the SONATA model in 2019. Now over than 20 car model of Hyundai, Kia and Genesis brands had equipped Built-in cam in South Korea and Russia.
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.
Heavy commercial vehicles play an important role in creating the trade and economic balance of countries. Also, the durability and safety of heavy commercial vehicles come to the fore. Heavy commercial vehicles consist of two parts. These are the chassis area with the equipment that allows the vehicle to move and the cabin section where the driver is located. The cabin area is the most important area that ensures the highest level of driver safety. Considering that the production of trucks is increasing day by day, it is inevitable for companies to increase their R&D activities in the field of cabin and cabin suspension systems for much safer, durable, and comfortable trucks. This study aims to determine the safe torque value of the fasteners and their assembly sequence of the Cab Suspension Console, which is one of the most important connection parts in a truck and which can cause a fatal accident by breaking. In this study, the safe torque value of the fasteners of the cabin suspension console has been determined as 180 ± 15 Nm/180 ± 10 Grad for the outer fasteners and 225 ± 18 Nm/180 ± 10 Grad for the inner fasteners. In addition, two different assembly sequences are determined and permanent strains on the part are measured. At the end of the assembly test, permanent strains on the part and other factors affecting the strain are simulated. According to the results obtained, the assembly sequence with a low permanent strain value is chosen and commissioned in production.
The thermal comfort for the passenger inside the cabin is maintained by the HVAC system. To ensure a comfort for the 2nd row passengers in the cabin, it is very essential to design an efficient HVAC and rear console duct system which can deliver sufficient airflow with less pressure drop. The primary focus of the study is to assess existing airflow of the center console duct using CFD and propose improvement in its duct shape to meet the passenger comfort sitting in the rear seat. In this study, the vehicle cabin model, HVAC system and duct design was modeled using the design software UG. To analyze and estimate the behavior of the air flow of the system, a steady state simulation was performed using STAR CCM CFD software. The performance of the console duct system is judged by parameters like distribution of airflow, velocity at console duct outlet, pressure drop through the duct and the uniformity of the air flow at the passenger locations. Robust assessment methodology is followed for optimization of console duct to reduce the simulation iterations and arrive at the combination of appropriate design factors which influences the airflow, pressure drop within the duct and velocity at second row passenger locations within the short span of time. The impacts of each design factors on the output results have been analyzed extensively and best combination of design factors have been found out quickly through this methodology. Robust assessment methodology significantly aids in reducing the CFD simulation iterations by 40% and much faster than conventional optimization process. Vehicle testing was carried out for the existing and optimized console duct design to measure the improvement in airflow and velocity at passenger locations. There is a good correlation agreement between simulation and test results for the optimized design within the error of 10%. This methodology is very useful in reducing the number of prototypes, minimize the testing cost and reduce the simulation iterations during design and development stages of the program.
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.
A device commonly found in living rooms around the world could be an inexpensive and effective means of evaluating the walking difficulties of multiple sclerosis (MS) patients. The Microsoft Kinect is a 3D depth-sensing camera used in interactive video activities such as tennis and dancing. It can be hooked up to an Xbox gaming console or a Windows computer.
An automotive cockpit module is a complex assembly, which consists of components and sub-systems. The critical systems in the cockpit module are the instrument panel (IP), the floor console, and door trim assemblies, which consist of many plastic trims. Stiffness is one of the most important parameters for the plastic trims' design, and it should be optimum to meet all the three functional requirements of safety, vibration and durability. This paper presents how the CAE application and various other techniques are used efficiently to predict the stiffness, and the strength of automotive cockpit systems, which will reduce the product development cycle time and cost. The implicit solver is used for the most of the stiffness analysis, and the explicit techniques are used in highly non-linear situations. This paper also shows the correlations of the CAE results and the physical test results, which will give more confidence in product design and reduce the cost of prototype testing.
Automated testing of manufactured products reduces the lead time to considerable extent in the process of production to delivery. Products like automobiles demand automated testing, for which robots and vision systems are widely employed. The basic functionality of a vision system in automation is to detect an object and then recognize it. In current automotive industry such systems are being used for robotic guidance, component tracking, dimensional gauging etc. There is a need to test the proper functionality of a speedometer fitted on a motorbike in the production line itself. Focused work on detection and recognition of Analog type and Digital type speedometer console reading of a motorbike is described in this paper. A vision based system is proposed which recognizes the speedometer reading instantaneously at the desired time. Image binarization, connected component analysis combined with character recognition algorithms are used to achieve the desired recognition, which resulted in reduced lead time hence contributing to lean manufacturing
Quintron Systems will upgrade NASA Dryden Flight Research Center (DFRC) technology as it expands to IPbased mission command voice. To prevent expensive and difficult reconfiguration of the mission control room consoles, a new user station design allows direct-fit replacement of the existing, older DICES stations in use for many years. In addition, the use of three touchscreen panels will improve user features inherent in the DICES VoIP system architecture. Inclusion of appropriate circuitry and connectors will also allow DFRC to re-use existing high-investment legacy headsets.
According to a Nielsen survey at the time of this reporting, 41% of all households have a game console. This is one market in which NASA has been absent from education and outreach efforts. Kinect Engineering with Learning (KEWL) is made to enter into that market and bring NASA education and outreach to a very familiar venue. KEWL creates an education and outreach experience that is more participatory, both in a school and museum environment.
One of the most pervasive challenges in the world today is increasing energy efficiency. The consumer electronics industry is evolving towards higher efficiency due to newer and stricter energy standards as well as consumer awareness. The demand for higher efficiency drives innovative companies to develop technology with smarter power management. One of the fastest growing areas is in display backlighting. Whether it is in mobile phones, MP3 players, portable gaming consoles or GPS systems, the light source behind LCD screens helps bring the colors to life. Powering these screens, like so many engineering challenges, comes in various solutions depending on the specific application. In the portable display backlighting market, a newer and smarter solution will revolutionize the way LCD screens are lit.
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