Browse Topic: Instrument panels
As acoustic requirements for NVH trim components become increasingly constrained by mass, cost, and sustainability targets, traditional approaches to inner dash design based on spatially averaged Transmission Loss (TL) metrics are reaching their practical limits. In fully built vehicles, the acoustic performance of the inner dash is governed by its global insulation capability but also by strong spatial heterogeneity and its interaction with spatially distributed noise sources such as the power unit, gearbox, and tyre-road excitation. This paper presents a test-based methodology for the spatial optimisation of inner dash acoustic performance using reciprocal holography. By applying a calibrated sound power source within the vehicle cabin and measuring the reciprocal response in the engine bay and wheel-arch regions, a high-resolution spatial Transmission Loss “hologram” of the inner dash is obtained under in-situ conditions. The resulting spatial data enables the identification of localised acoustic weak points that are not observable using conventional testing methods. To bridge the gap between passive component characterisation and real-world vehicle operation, the spatial TL hologram is subsequently evaluated using representative operational source sound power data to prioritise acoustically relevant regions. This enables the transmitted acoustic energy to be evaluated under realistic driving conditions. The holographic data is then coupled with a parametric acoustic model of the inner dash system, allowing localised mass redistribution to be optimised using a genetic algorithm while respecting packaging and manufacturing constraints.
With the rise of software-defined vehicles and the emergence of cyber threats to vehicular systems, developing teams are compelled to conduct extensive testing on both virtual and physical prototypes at an accelerated pace. This new development landscape necessitates diagnostic tools that are both precise and adaptable. However, proprietary systems dominate this field, often hindering accessibility for students and researchers due to high costs and restrictive licensing. This paper presents the design and implementation of an open-source, low-cost remote testing system tailored for automotive development and diagnostics. The proposed system utilizes Arduino and Raspberry Pi processing units, along with relay-based switching modules, to provide secure remote control of vehicle components through a web-based dashboard equipped with authentication, scheduling, and real-time synchronization capabilities. The tested prototype showcased robust scalability, secure session handling, and seamless integration with the open-source Woodpecker EV platform at the University of Detroit Mercy. The affordability and open-source nature of the framework offer a practical alternative to proprietary tools, while also enabling future adaptation to diverse automotive contexts.
The integration of Advanced Driver Assistance Systems (ADAS) into modern vehicles necessitates innovative solutions for interior packaging that balance out safety, performance, and ergonomic considerations. This paper introduces an inverted U-shaped steel tube cross car beam (CCB) as a superior alternative to traditional straight tube designs, tailored for premium vehicle instrument panels. The U-shaped geometry overcomes the limitations of straight tube beams by creating additional packaging space for components such as AR-HUDs, steering columns, HVAC systems, and electronic control units (ECUs). This geometry supports efficient crunch packaging while accommodating ergonomic requirements like H-point, eyeball trajectory, and cockpit depth for optimal ADAS component placement. The vertical alignment of the steering column within the U-shaped design further enhances space utilization and structural integrity. This study demonstrates that the inverted U-shaped CCB is a transformative solution for ADAS packaging, providing superior durability, crash performance, and knee injury mitigation compared to traditional straight tube designs. By addressing challenges such as crunch packaging, structural stiffness, and manufacturing efficiency, the U-shaped beam sets a new standard for global automotive platforms. The findings underscore its potential to revolutionize vehicle interiors, enabling advanced technology integration while maintaining safety and efficiency.
In the early days of computers, interfaces were paper printouts or blinking lights, but as the technology matured, the graphical user interface (GUI) quickly became the standard.
Plasticized polyvinyl chloride (PVC) has many applications in automotive industry including electrical harnesses, door handles, seat and head rest covers, and instrument panel (IP) and other interior trim. In IP applications, the PVC skin plays a critical role in passenger airbag deployment (PAB) by tearing along the scored edge of the PAB door and allowing the door to open and the airbag to inflate to protect the occupant. As part of the IP, the PVC skin may be exposed to elevated temperatures and ultraviolet (UV) radiation during the years of the vehicle life cycle which can affect the PVC material properties over time and potentially influence the kinematics of the airbag deployment. Chemical and thermal aging of plasticized PVC materials have been studied in the past, yet no information is found on how the aging affects mechanical properties at high rates of loading typical for airbag deployment events. This paper compares mechanical properties of the virgin PVC-based IP skin material with the same material after it has been exposed to 110°C for 400h. Both, virgin and aged materials, were tested at three temperatures, viz. -30°C, 23°C and 85°C and at four strain rates ranging from 0.01/s to 100/s. Finally, effects of the aged material on the PAB deployment simulation are discussed.
Fused Deposition Modeling (FDM) is a widely recognized additive manufacturing method that is highly regarded for its ability to create complex structures using thermoplastic materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability. TPU has several applications, including automobile instrument panels, caster wheels, power tools, sports goods, medical equipment, drive belts, footwear, inflatable rafts, fire hoses, buffer weight tips, and a wide range of extruded film, sheet, and profile applications.. The primary objective of this study is to enhance the FDM parameters for TPU material and construct regression models that can accurately forecast printing performance. The study involved conducting experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses, including dimensional accuracy, surface quality, and mechanical properties. The utilization of design of experiments (DOE) methodology enabled a methodical exploration of parameters. Statistical techniques were employed to develop regression models that establish relationships between process parameters and performance indicators. These models offer a prognostic instrument for optimizing FDM parameters and attaining desired printing results. The results demonstrated the effectiveness of the regression models in accurately forecasting the printing performance for TPU material. The models provide valuable insights into the optimal parameter configurations for maximizing printing efficiency, quality, and mechanical robustness. This study enhances the comprehension of Fused Deposition Modeling (FDM) for Thermoplastic Polyurethane (TPU) material and provides useful techniques for optimizing the manufacturing process. Manufacturers can improve printing productivity and quality by utilizing regression models, thereby promoting the wider use of FDM technology in industries that need flexible and durable components.
The present research explores the potential of high-performance thermoplastics, Polymethyl Methacrylate and Polyurethane, to enhance the passive safety of automotive instrument panels. The purpose is to evaluate and compare the passive safety of these two materials through the conduct of the Charpy Impact Test, Tensile Strength Test, and Crush Test —. For this, five samples were prepared in the case of each material via injection moulding, which enabled reliability, and consistency of the findings. As a result, it was found that in the case of the Charpy Impact Test, the average impact resistance varies with PMMA exhibiting a level of 15.08 kJ/m2 as opposed to the value of 12.16 kJ/m2 for PU. The Tensile Strength Test produced the average tensile strength of 50.16 for PMMA and 48.2 for PU, which implied superior structural integrity under tension for the first type of thermoplastic. Finally, the Crush Test showed that PMMA is more resistant to crushes on average than PU with the measures of 18.5 and 16.2 KN. In this way, the results of the research allow concluding that PMMA has the capacity to absorb energy and support the development of forces better than PU, and is, therefore, more suitable for the purposes of improving passive safety in terms of automotive applications. The findings suggest that PMMA offers better protection for vehicle occupants by reducing the severity of injuries during collisions, especially automotive instrument panels.
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.
Vehicle HVAC noise performance is an important vehicle design validation criterion since it significantly links the brand image of a vehicle. It affects the customer’s buying decision and the business of selling vehicles because it directly affects driving comfort. Customers expect continuous improvement in HVAC noise without compromising cooling performance. The process of cascading vehicle-level acoustic performance to subsystem and component levels becomes an important factor in the vehicle NVH development process. It was found that the component-level [HVAC unit without duct] performance of an HVAC system measured in an anechoic chamber was at par when compared to targets, whereas the subsystem-level performance [HVAC unit with duct and dashboard] was on the higher side of the targets. Advanced NVH tools were used to identify the source of noise at the subsystem level. It helped to locate the source and its transfer path. A design modification done at the transfer path location gives a good improvement in HVAC noise at the subsystem level. However, when the same HVAC system was tested at the vehicle level, it showed an increase in noise as compared to the subsystem level. A detailed study was conducted to understand the acoustic behaviour of the vehicle environment. HVAC systems tested in an anechoic chamber and in a car are in a free-field and diffuse-field environment, respectively. In free-field sound propagation, there are no reflections, whereas in diffuse-field sound, it is reflected in many times that it travels in all directions with equal magnitude. Additionally, this paper encompasses a methodology aimed at attaining a less diffused field and fostering a more open environment within the vehicle, ensuring that HVAC performance measured at the subsystem level aligns with integration within the car.
While there is a tendency for new vehicles to have a focus on ride, handling, performance and other dynamic elements, the model year 2024 Lincoln Nautilus team added another element to how the driver will experience the midsize SUV. Not that the ride, handling, etc. were ignored, but the global design and engineering team wanted to do something different with this two-row SUV. Recognize that this is a vehicle with a sumptuous interior that includes not only first-class seating (24-way adjustable front seats) and materials (Alpine Venetian leather available on the seats; cashmere for the headliner) but also an available high-end Revel Ultima 3D audio system with 28 speakers. What's more, there's “Lincoln Digital Scent,” small electronically activated pods containing various aromas (e.g., Mystic Forest, Ozonic Azure, Violet Cashmere). Across the top of the instrument panel there is a 48-inch backlit LCD screen and a 11.1-inch touchscreen in the center stack.
The subsystem of front of dash (FOD) and instrument panel (IP) is a critical path to isolate the powertrain noise and road noise for vehicles. This subsystem mainly consists of sheet metal, dash mats, IP, and the components inside IP such as HVAC and wiring harness. To achieve certain level of cabin quietness, the sound transmission loss performance of this subsystem is usually used as a quantifier. In this paper, the sound transmission loss through the FOD and IP is investigated up to 10kHz, through both acoustic testing and numerical simulation. In the acoustic testing, the subsystem is cut from a vehicle and installed on the wall of two-rooms STL testing suite, with source room being reverberant and receiver room being anechoic. In the testing, various scenarios are measured to understand the contributions from different components. The numerical simulation is based on statistical energy analysis (SEA) because deterministic methods have difficulty to predict the STL up to 10k Hz due to problem size. Good correlations are obtained for all the scenarios. From the investigation, the contribution from different components to the overall STL performance is evaluated and ranked. Taking advantage of the correlated numerical models, design changes which are not feasible or easy to be measured are studied. As an example, in the “virtual” design changes related to the IP components, the influence from IP skin and leakages are checked.
The vehicle instrument panel (IP) system has several interactions with the surrounding components such as the Dash, Cowl, Cross Car Beam (CCB), Floor, Body Side etc. With such interactions comes different loadings, usage scenarios, interfaces and design challenges to overcome. For the specific case of the IP to Cowl & Dash interfaces, the position and performance in different load cases, such as, but not limited to, vibration and heat expansion loading as well as the assembly process. A design solution is required to enhance the performance in all these scenarios while maintaining the cost, weight & complexity as low as possible. This paper describes the development process of an optimized solution with a multi-disciplinary approach using advanced computer aided engineering (CAE) optimization tools, which involved performance in multiple virtual evaluations and mass. The achieved enhanced solution provides of multiple alternatives from early design stages to allow flexibility in the manufacture stage, it also proved to be effective to reduce complexity by using few parts in the assembly. The enhanced method reduces time required to assemble and the weight while meeting the performance required.
Premium instrument panels (IPs) contain passenger airbag (PAB) systems that are typically comprised of a stiff plastic substrate and a soft ‘skin’ material which are adhesively bonded. During airbag deployment, the skin tears along the scored edges of the door holding the PAB system, the door opens, and the airbag inflates to protect the occupant. To accurately simulate the PAB deployment dynamics during a crash event all components of the instrument panel and the PAB system, including the skin, must be included in the model. It has been recognized that the material characterization and modeling of the skin tearing behavior are critical for predicting the timing and inflation kinematics of the airbag. Even so, limited data exists in the literature for skin material properties at hot and cold temperatures and at the strain rates created during the airbag deployment. This paper presents tensile test results of one typical skin material conducted at four different strain rates of 0.01/s, 1/s, 10/s, and 100/s. Challenges in testing are discussed. A material modeling methodology is proposed that accounts for anisotropy, loading rate sensitivity and failure, and is verified by comparison of results from simulation and physical tests. Finally, recommendations for setting proper contact parameters between different parts in the model and for proper representation of the adhesive between the instrument panel substrate and skin are presented.
For an enterprise, product quality is the foundation of its further development. Therefore, how to detect the quality of the products produced by the assembly line and accurately identify the problematic parts has become an increasingly concerned issue for enterprises. In this paper, we propose a novel quality detection model combining the latest YOLOv5 model and convolutional neural network, which can further improve the recognition precision and accuracy of YOLOv5 on the basis of its lightweight and high recognition efficiency. The proposed model can meet the needs of complex quality problems that are difficult to detect directly in assembly-line products. In the experiment, our model can detect the automotive dashboard and judge whether the cable buckle is connected in place. The accuracy of each buckle in the picture being correctly detected is more than 98%, the classification accuracy is also expected to reach 98%.
Tactile feel of vehicle touch points and boom feel inside vehicle cabin are some of the important criteria of the customer choice while making the buying decisions in the dealership or on a test drive. This tactile and acoustic feel of a vehicle is majorly governed by the low frequency mode management achieved while designing the vehicle. Different parameters like inclusion of multiple powertrains on a vehicle program, choice of multiple way seating different at driver’s, front passenger’s and rear passengers’ seating positions, instrument panel and steering system layouts having higher torque delivery, suspension modes of the front and rear axles based on their articulation and degree of independency, global modes of the vehicle body, the cabin air cavity configuration and volume, etc. play a significant role in deciding this tactile and acoustic feel of the vehicle being designed. How these parameters were tuned and designed while developing a premium hatchback car has been elucidated with different subsystem development examples. The performance trade-offs considered while tuning all these parameters are discussed. How these parameters were revised in entire vehicle development cycle is outlined. The effect of this modal separation activity on full vehicle idle shake and road shake performance is explained.
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.
One of the top problems that every Indian automobile manufacturer struggles to manage is the clutch early failure less than 30000 Km. This is mainly due to the extreme heating of the friction lining due to the real-world user profile in the Indian market and users inappropriate driving behaviors like Overloading the goods more than the manufacturer’s recommendation, non-recommended attachments and increased wheel size, Thick traffic leading to high level of clutch modulation and Clutch riding while running and launching the vehicle at higher gears. Although many simulation and testing are done during the development phase, above listed real world user profile and customer driving habits are inevitable by any automobile manufacturer. Hence the prime goal of this experimental research is to indicate or alert the user on the clutch thermal condition due to the driving habit and to encourage the user on right driving habits. This objective is met through a standalone electronic system that consists of a set of thermocouples, a micro controller unit (ECU) and a digital LCD display. Analog output of the thermocouple is fed into the ECU which contains the wear calculation logic to convert the temperature input to the heat energy dissipated through flywheel surface during every clutch engagement. ECU then estimates the friction lining temperature caused due to the heat energy and calculates the wear of the friction lining. Finally, the percentage of facing lining worn due to the launch events along with the clutch housing temperature will be displayed through the LCD display which is fixed in the instrument panel. Hence, by using this system, it is expected that the user awareness with respect to the right driving behavior can be improved and thereby the clutch facing life, hence the reduced cost of warranty incurred by the manufacturer.
Squeak and rattle (S&R) are nonstationary annoying and unwanted noises in the car cabin that result in considerable warranty costs for car manufacturers. Introduction of cars with remarkably lower background noises and the recent emphasis on electrification and autonomous driving further stress the need for producing squeak- and rattle-free cars. Automotive manufacturers use several road disturbances for physical evaluation and verification of S&R. The excitation signals collected from these road profiles are also employed in subsystem shaker rigs and virtual simulations that are gradually replacing physical complete vehicle test and verification. Considering the need for a shorter lead time and the introduction of optimisation loops, it is necessary to have efficient and inclusive excitation load cases for robust S&R evaluation. In this study, a method is proposed to truncate and identify the important parts of the different road profiles that are often used for S&R physical verification and then merge them to develop one representative excitation load case. The criteria for signal truncation were based on the S&R risk and severity metrics calculated from the vibration response at the critical interfaces for S&R. the method was used in a case study involving the instrument panel of a passenger car. Results of the virtual simulation and the rig tests were compared with the complete vehicle test. The proposed synthesised signal generation strategy was validated by physical testing through measuring vibration signals. The results supported the possibility of replacing multiple S&R excitation signals with one single representative inclusive signal, while the quality of S&R risk prediction from the system response was maintained. The outcome of this work can lead to a more efficient physical and virtual S&R verification in the development process of passenger cars.
This paper presents a decoupled solution for mapping and validating complex and dynamic user interfaces (UI). Creating unique and satisfying user experiences are becoming the focus of products whereas digital user interfaces are a big part of this delivery. This tendency is coming to complex real-time systems, thus, growing the need of a proper validation of digital UIs considering its intrinsic requirements and limitations. The previous framework that ran the touchscreen tests required changes in case of UI updates while the matrix-like structure proposed gives a correlation between all to all clickable objects thus mapping all possible pathways to the many different screens. This application was implemented according to the following steps: 1) Adjustment of the adjacency considering the method of interaction with the UI. 2) Implementation of the methods created to read the matrix structure. 3) Implementation of the interaction between the software library and the hardware unit under test. The test of the proposed approach was done through the mapping and validation of radio, automotive instrument panel and infotainment system electronic vehicle control units UIs. Hardware-in-the-loop was implemented with the technique through LabVIEW and Python. Hence the exposed, this paper delivers a decoupled mapping structure from the test program, making it possible to reuse the same algorithm for different user interfaces and browse all screens and all their possible pathways by taking pictures of these interfaces. The previous method employed would require a complete revisiting of the screens and pathways mapped by the test operator while the current structure allows changes to be made only in the specific pathways and screens that have been changed with UI updates. This HMI (Human-Machine Interface) mapping method improves test setup time by five times.
Petroleum refining is a capital intensive and complex manufacturing environment faced with a wide range of challenges that must be navigated in order to maintain a company’s competitiveness and maximize its profitability. With Digital Platforms (Knowledge Management and Business Analytics), companies are turning these challenges into a competitive advantage. In today’s world, we can utilize Digital platforms from Research in Chemistry Labs to process optimization and asset utilisation in manufacturing. We can collect the data points and utilise them to help companies make informed decisions on the fly. The good news is that all of this data exists throughout the enterprise. The bad news is that most of it is buried in technology and data silos, some of the data is redundant or modified, and much of the important operational analytics are kept on undocumented spreadsheets. The biggest problem is that existing nonintegrated systems are incapable of generating useful management reports or operations dashboards.
Normal engine mounting system is designed to carry loads of powertrain in all driving conditions and also isolate the vibrations of powertrain. Softer mounts are good for vibration isolation but it is not recommended to have softer mounts because durability will be affected adversely. Optimum stiffness needs to be finalized which will have balance between durability and performance. In addition to durability many performance parameters needs to be checked during the time of development. This study includes the development of engine mounting system for elimination of drive away judder in first gear. Maximum peak torque value for the drive-away event is in the range of 80Nm - 120Nm. In the worst case, this peak torque can reach to maximum 170Nm depending on maneuver, engine rpm is around 1100-1200. Steering wheel, instrument panel and whole vehicle cabin will vibrate for few seconds and then vehicle will run smoothly. To eliminate this issue, various iterations were done in the mounting system and solution is proposed which has no launch judder in 1st gear. A 6-DOF rigid body model is also established to simulate launch judder. Powertrain mounting system design has been modified to achieve the reduction in above mentioned vibrations. The pros & cons of the suggested change in mounting system on the overall NVH performance is also discussed in this paper.
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