Automotive Interiors

Index
 Plastics - Consumption in Automobiles  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

Plastics - Consumption in Automotive Sector

Materials PP & Alloys PUR ABS & Alloys PE PA & Alloys PVC PBT+PET UP Others (PC, PMMA, POM, PPE, SM, PF, ASA) TOTAL kg/ vehicle 57.7 18.1 9.5 10.3 15.6 3.7 3.1 1.9 13.2 133 tonnes 943000 296000 155000 168000 255000 60000 51000 31000 216000 2173000

This plastics consumption (2003) in European Union (27 countries) only figures the plastics parts weighed on passenger cars: production scraps and spare parts are not taken into account as well as commercial vehicles. 3

Plastics use by type and weight in an average car

PART Bumpers Seats Dashboard Fuel Systems Body (incl. body panels) Under the bonnet comp. Interior trim Electrical components Exterior trim Lighting Upholstery Other reservoirs Total MAIN PLASTICS TYPES PP, ABS, PC PUR,PP,PVC,ABS,PA PP,ABS,PA,PC,PE PE,POM,PA,PP PP,PPE,UP PA,PP,PBT PP,ABS,PET,POM,PVC PP,PE,PBT,PA,PVC, ABS,PA,PBT,ASA,PP PP,PC,ABS,PMMA,UP PVC,PUR,PP,PE PP,PE,PA WEIGHT (Kgs) 10.0 13.0 15.0 07.0 06.0 09.0 20.0 07.0 04.0 05.0 08.0 01.0 105.0

Styrenics - Consumption in Automobiles

MAIN DATAS (per vehicle): All Plastics
} 70 - 200 kg

(Average : 133 kg)

GF reinforced Plastics
} 6 - 40 kg

Approximately 24 % GF

STYRENICS (BLENDS & ALLOYS) 9.5 kg

Trend Drivers

Economics

Innovation

Technical Performance and functionality

6

Technology Trend Areas

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 Safety  Euron Cap ratings  Pedestrian collisions Leading to new designs of the front of the vehicle 3. More Comfort, notably sound level Leading to noise insulation systems

Automobile Interiors

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 Injection Material Options PA PBT POM Dashboard & Parts Air Bag Systems Injection PA PET GMT Ashtray Air Ventilation Nozzles Injection Injection PBT PA PC ABS ABS PP Dashboard Injection PP ABS PC ABS MPPO MF MF 7.00 2.00 CS/Aramid CS/Aramid Mat continuous CS 0.10 0.40 Resin/filler options CS CS CS 0.40 Typical Weight Kg's

Interiors Internal Door Handles

11

Possible Applications of Plastics in Automobile Interior

Dashboard Skins Thermo engraving PVC Modified TPO Slush Moulding ThermoformBackfoam Central Console Injection Plasticised PVC ABS-PVC PC ABS MPPO ABS Seating Components Arm Rest Seat Back rest Injection S-RIM GMT Door Panels Injection Compression ABS PU PP PP UP CS Mat continuous Mat continuous MF Roving 12 0.20 6.00 6.00 8.00 2.00 1.5

Possible Applications of Plastics in Automobile Interior

Headliners RIM Compression PU PU Mat continuous Roving 2.20 Special Process PET Fibre cushioning and acoustic insulation MF MF Mat continuous Roving CS CS CS 0.23 13 0.24 2.50 4.00

Pillar trims Rear Package tray

Injection Injection RIM Compression

PP PP PU UP PA POM

Accelerator Pedal

Injection

Clutch Pedal

Injection

PA

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 ? Hard trim which covers the Pillar, matching shape, color language and hence gives SIMILAR aesthetic as that of Head liner and other interior.

What is pillar ?

The Structural member that connects the roof and body. "A" PILLAR : The foremost pillar in the upper side structure of a vehicle. Successive pillars rearward are labeled "B", "C" and, for station wagons, "D".
15

NOMENCLATURE
PILLARS

B C D

PILLAR TRIMS D

16

LOCATION
Pillar trim location in vehicle

A-PILLAR B-PILLAR D-PILLAR C-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 LOOK 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 AIR BAG DISPLAY COVER. H/L SIDE

TRIM

PUSH NUTS

IP SIDE

CARTRIDGE
21

PART DETAILS
B-PILLAR TRIM AIR BAG DISPLAY COVER ATTACHES TO UPPER TRIM

UPPER TRIM

LOWER TRIM

ATTACHES TO 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 DETAILS
C-PILLAR TRIM H/L SIDE

FITS TO BODY

25

PART DETAILS
C-PILLAR TRIM

SEAT BELT SLOT

WHAT ARE THESE FEATURE?

26

PART DETAIL
D-PILLAR TRIM SEAT BELT SLOT

27

C / D - PILLAR
C-D COMBINED AS SINGLE TRIM

28

ASSEMBLY / ATTACHMENTS
B-PILLAR LOWER WITH DOOR PILLAR TRIMS WITH BIW

29

ASSEMBLY / ATTACHMENTS
A-PILLAR

INSTRUMENT PANEL
30

ASSEMBLY / ATTACHMENTS
A-PILLAR TO BIW

PUSH NUT

31

ASSEMBLY / ATTACHMENTS
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 / ATTACHMENTS
C/D-PILLAR TO BIW

WHY THIS FEATURE AND HOW IT WORKS?

34

ASSEMBLY / ATTACHMENTS
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 / ATTACHMENTS
A-PILLAR TO H/L A-PILLAR TRIM B-PILLAR TO H/L 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. FMVSS 201 : Parameters Test method Requirements : - Vehicle level test. : - FMVSS 201 : - HIC d value should be 1000 or less. : - Determine the burn resistance within 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.

44

Floor Consoles

45

Center Console- Exploded view Console11 10 12 13 7 14 15 5 16 4 36 3 2 20 1 34 33 31 37 18 17 29 30 32 21 35 22 6 23 24 8 25 9 26 27 28

1 FRAMEWORK FRT T/C 2 INS TOP PANEL HARD 3 INS TOP PANEL SOFT 4 TOP PANEL 5 HS C/H TOP PNL 6 C/H LOWER 7 RUBR LIP C/H A/R 8 C/H UPR 9 K LID C/H ALUMINIUM 10 PNL EAR LEVER PLA 11 RUBBER MAT EAR LEVER 12 LID A/T FRT 13 HS A/T FRT 14 HOUSIN ASHTRAY REAR 15 ASHTRAY REAR 16 I-CUP STR TRAY 17 LID A/T STDRIM 18 LID A/T ALU 19 FRAWORK C/H LWR 20 HS STORA E TRAY 21 RUIBBER MAT TUN BKT 22 FRA TUN BKT FRT OPT 23 SHAFT HIN E ARMREST 24 HN LWR 25 LID INNR UPPR

19

26 FRAMEWORK ARMREST 27 CARR FOIL 28 SURFACE COVERIN

29 LOC HAN-T CON FLOOR OPT 30 RUBBER CAP RH 31 RUBBER CUP LH 32 BOT TUN BRKT FRT 33 CONTACT ELEM BKT 34 CVR PLT RR 35 BKT TUN CON FRT AU 36 BEARIN ARMREST 37 IK CARPET

46

Floor Console Exploded View

37780 5 37780 6 37779 4 162 37779 1 37778 5 377798 120 or 249 115825 8 37778 6 115246 3 377799

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 lifting

61

62

63

Worm and Spur Gear

Normal DC motor used to actuate the lifting

64

Linkage Rod
The Rod on which glass is lifted.

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 from 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

COVER ANB40002 (LH) ANB50023 (RH) SCREWS 11509231 (QTY- 61) HANDLE 10396621 (LH) 10396622 (RH) UPPER SUBSTRATE ANB50021 (LH) ANB40014 (RH) SWITCH 10386129 (LH) 10386130 (RH) CLIPS 16754704 (QTY- 04) COVER ANB40004 (LH) ANB40019 (RH)

SWITCH BEZEL ANB40012 (LH) ANB40023 (RH) CLIPS 16754704 (QTY- 05) WINDOW SWITCH 10377668 (LH) 10377669 (RH)

ALUM. BEZEL ANB40009(LH) ANB40016(RH)

FOAM ANB40012(LH) ANB40023(RH) S CLIPS ANB40006 (QTY- 04)

LOCK BEZEL LOWER 90560166 (QTY- 02) LOCK BEZEL UPPER 13104077 (QTY- 02) NUTS 11519497 (QTY- 04)

HANGER BKT ANB40008 (LH) ANB40017 (RH)

SUBSTRATE ANB40003 (LH) ANB40021 (RH) SCREWS ANB40010 (QTY- 16)

GASKET ANB50007 (QTY- 04) RETAINER 11519031 (QTY- 21)

LOGO ANB50020 (QTY- 02) SPK. GRILL 10370444 (LH) 10370406 (RH) BOLTS 1158901074 (QTY- 04) COVER 10393132 (QTY- 02) LAMP 15021517 (LH) 15021518 (RH)

MAP POCKET ANB40001 (LH) ANB40018 (RH)

PANEL LOWER ANB40000 (LH) ANB40013 (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

SUBSTRATE Material - ABS

FOAM BUN (ARMREST)

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

Exploded Rear door

CLIPS 11609760 (QTY -04) HANDLE 10396621 (LH) 10396622 (RH)

SWITCH BEZEL ANB43002 (LH) ANB43003 (RH)

COVER ANB43200 (LH) ANB43300 (RH) SUBSTRATE ANB40029 (LH) ANB43005 (RH) COVER ANB40026 (LH) ANB43004 (RH) ALUM BEZEL ANB43008 (LH) ANB43009 (RH) CLIPS 16754704 (QTY -04) FOAM ANB50002 (LH) ANB50003 (RH) CLIPS ANB40006 (QTY -04)

GARNISH TRIM ANB52496 (LH) ANB52526 (RH)

SCREWS 11509231 (QTY -36)

SUBSTRATE ANB50000 (LH) ANB50001(RH) SCREWS ANB40010 (QTY -19)

GASKET ANB50007 (QTY 04) LOCK BEZEL LOWER 90560166 (QTY 02) LOCK BEZEL UPPER 13104077 (QTY 02) NUT 11519497 (QTY 04) HANGER BKT ANB43010 (LH) ANB43012 (RH) MAP POCKET 10370371 (LH) 10370399 (RH) PANEL LOWER ANB40027 (LH) ANB43007 (RH) LAMP ASM 15021517 (LH) 15021518 (RH) BOLT 11589010 (QTY 04)

SPEKER 25725733 (QTY 02)

ALUM BEZEL ANB43008 (LH) ANB43009 (RH) RETAINER 11519031 (QTY 18)

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

Level 2
Functional Integration Function Improvement
- Steel HW Module

Level 3
Systems Integration Full Modular Door
- Door HW Module - Door Trim Module - Door Structure - Glass, Seals, etc.

Level 4
Full Door Integration Total Modular Door
- Outer Skin - DH Subsystems - Door E/E Arch. - Door Structure - Inner Trim, etc.

Components
- Latches - Trim - Regulators - Hinges - Handles - Wiring - Switches

____________________ Up-Integration
- Super Plug Door Module - Door Trim Module - X Frame / Hybrid HW Mod.

104

Door Module Market Evolution

Door Module - Frame Concept

Components Carrier

105

Door Module Market Evolution

Structural Module

Door of the vehicleSmart

Metal 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 Metallic (or Plastic) carrier (AGT) Door Trim Module (DTM)

- 4 planes - Dry and wet areas

- 3 planes - Dry and wet areas

- 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 sheet metal to assembly openings to assembly completely open (door the door module (same the components stiffness reduced) stiffness than traditional - Reinforcements in the - More reinforced door due to the big opening door) critical areas (hinges, in the inner sheet metal - Same reinforcements latch, upper area, etc) 109 than in a traditional door

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 clips in the medallion part.

114

Door Module Description

Door trim support:

- Housing for the medallion clips. - Support for rails of the window lifter.

Medallion clips

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 Door sheet metal
117

INTRODUCTION TO INSTRUMENT PANELS

118

AIM
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 Design Options

Architectural Options

Platform Needs and Requirements

Material Options

IP Assembly Process

Vehicle GA Process
120

Consumer Trends in Instrument Panels

Comfort and Safety

Climate control Spacious Ergonomics - ease of controls, buttons, features Quiet Airbags

Function
Cup holders Electronics Electronic integration Easy to read instrumentation Heads-up display features Storage Long lasting - durable

Styling
Interior Designed Sleek, modern, coordinated colors and textures Luxurious look and feel


Vehicle Affordability
Total cost Cost-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 Frequency response of IP system Knee intrusion and knee load management capability Occupant deceleration management Energy absorption capability of IP system Maximum load carrying capability and collapse load Cross-vehicle load path continuity Local structural stiffness Local energy absorption and load carrying capability Load management capability Steering column movement

 

Instrument Panel NVH

FMVSS 208 Crashworthiness

FMVSS 214 Crashworthiness

FMVSS 201/ECE 21/ADR 21 Head Impact Protection

Offset Deformable Barrier Impact and NCAP

122

Functional Performance Requirements



Steering column static stiffness upon vertical and transverse loads Steering column frequency response Steering column and column support system frequency response

Frequency response of IP system IP system durability Long-term structural performance Aging behavior Environmental response Road Surfaces Engine

oC

 

 

123

Functional Performance Requirements

FMVSS 208 Crashworthiness
  

Upper torso load management Occupant deceleration Knee and lower leg energy and load management Knee intrusion Load transfer capability
30mph / 48kmh Vehicle Pulse

 

ODB Impact
  

Driver front end crash behavior Localized IP deflection behavior Front-of-Dash intrusion and steering column deflection Load path between steering 124 column, IP and vehicle body

Functional Performance Requirements

FMVSS 201, ECE 21, ADR 21 Head Impact Protection
Top View
Excluded Area Windshield Steering Wheel Headform Impact Fixture Headform Steering Wheel Vertical Plane 5" Instrument Panel

Instrument Panel

Windshield 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

?
HOWS 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 appearance Human 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) IP Structure (cross car beam and brackets) HVAC Module Gear Shifter Assembly Glove box Bin, Door Latch, Striker, Lock Ashtray assembly Parking Brake Handle/Actuator Steering Column Covers Storage Bins, Cup holders, Coin holders Transmission Shifter, Knob, Boot Harness, Control Head Air Outlets, Side window Defoggers, Lap Coolers Air Ducts, Defroster Ducts and Grills

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
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 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, GLOVE BOX

HINGE-I/P COMPT

ROD-I/P COMPT DR LAT REL

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/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

SPRING FEDER

MOLDING-I/P DRIVER SIDE

DECOR MOLD PASSENGER SIDE

145

ENVIRONMENT COMPONENTS

CROSS CAR BEAM HVAC

NAVIGATION DISPLAY

146

Abbreviations
Abbrevations HLU RIM GMT IM/BMC RTM UP VE PU EP MF CSM SMC CS LCP PI PTE PPE MPPO Hand Lay UP Reaction Injection Moulding Stampable Thermoplastics Injection moulding ( Bulk moulding Compound) Resin Transfer Moulding Unsaturated Polyester Vinyl Ester Poly urethane Epoxy Mineral Filled Chopped strand Mat ( Glass) Sheet Moulding Compound Chopped Strands ( Glass ) Liquid Crystaline Polymers Polyimides Polyester Thermoplastic Elastomer Poly phenyelene ether Modified Poly Phenylene Oxide

147

Assembly & Attachment Methods of IP

148

Assembly Techniques for Plastic parts

149

Assembly Techniques Snap Fits

Snap fit cantilever beam type

Snap fit cylindrical Type 150

Assembly Techniques Snap Fits

Factors for calculating cantilever beam for Snap fit

151

Assembly Techniques Snap Fits

Mold Design For Snap Fits

152

Assembly Techniques Spin Welding

153

Assembly Techniques Ultrasonic Welding

154

Assembly Techniques Hot Plate Welding

155

Assembly Techniques Adhesive Bonding

156

Assembly Techniques Ultrasonic Insertion

157

Assembly Techniques Screw and Bosses

158

Assembly Techniques for 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 Rivets Clips Plastic Fasteners Pour In Place Gluing Snap Fixing Welding Vibration Welding Ultrasonic Insert Molding Cable Clips Self Retaining Speed Nuts

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:
ECONOMICAL VERSATILE EASY-TO-USE SPEED OF ASSEMBLY, CONSISTENT MECHANICAL PERFORMANCE AND EXCELLENT INSTALLED APPEARANCE,

Types:
Dome Head Most widely available and commonly used head style. 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

KNEE BOLSTER

ASCRY PLATE

SEATING LOCATION
180

ASSEMBLED VIEW

GMX-211

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 Eliminate Screws, Clips, Adhesives, Or Other Joining Methods Faster Cheaper Flexibility Of One Time Assembly/ Service Assembly
TOOL BECOMES COMPLEX

TYPES ANNULAR CANTILEVER TORSIONAL

197

SNAP FIXING : ANNULAR

Figure 1: A pen sometimes utilizes an annular snap fit to retain the cap.

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 surfaces Terminologies used in headliners Major Subsystems Additional Subsystems Design Consideration Headliner Manufacturing Process Assembly Sequence Vehicle environment for headliners

208

WHY HEADLINERS ARE USED?

The function of the headliner over the past years has evolved from merely a "liner to that of a vital player in both structural 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 `B PILLAR CUTOUT FOR `C PILLAR

CUTOUT FOR `A PILLAR

CUTOUT FOR VIOSR

CUTOUT FOR ?

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, SURFACE From the design point of view, only 3 surfaces are considered; A-Surface The fabric side or Interior show surface. B-Surface Surface from the back side of the fabric to the laminated blank outer surface. C-surface Top most surface which is closest to the sheet metal (Roof) and is opposite the A surface Closing Surface 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 SURFACE

A 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 chopped 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

Face Fabric: Comes in many types with base thread of either 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 protection from human contact against the fiber glass. Adhesive: Material which bonds the substrate to the fiberglass to the scrim to the cover goods.
220

TERMINOLOGY - PERFORMANCE Sag: The deviation from initial installed position to the final position after complete environmental cycling. Peel Strength: The ability of the fabric to withstand a 180 degree pull from the formed substrate. Acoustic Ability: Ability to absorb sound from varying sources such as roof panel noise, road noise, engine noise, and BSRs. Fogging: The ability to not have materials gas out and leave deposits on the interior glass. Flammability: Must comply with government regulations for flame propagation.

221

MAJOR SUB-SYSTEM FOLLOWING ARE THE SUB-SYSTEMS WHICH FORM PART OF OVERHEAD SYSTEM:  OVERHEAD CONSOLES  VISOR ASSEMBLIES  GRAB HANDLES  MAP, DOME AND COURTESY LAMPS  HEAD IMPACT MANAGEMENT (HIC) ADDITIONAL SUB-SYSTEM:  SIDE IMPACT AIRBAGS  HVAC  CONVENIENCE ELECTRONICS INCLUDING:  INTRUSION SENSOR  REAR PARKING ASSIST MODULES  VIDEO ENTERTAINMENT SYSTEMS

222

MAJOR SUBSYSTEM

223

OVERHEAD 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 for 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: COMPONENTS (FSU)

240

STATION 2: COMPONENTS (FSU)

241

STATION 2: COMPONENTS (FSU)

Components are attached to clips and retainers by skilled operator

242

STATION 3: OHC AND WIRE HARNESS (FSD)

243

STATION 3: OHC AND WIRE HARNESS (FSD)

Overhead Consoles (OHC) is nested into fixture prior to Headliner arrival

244

STATION 3: OHC AND WIRE HARNESS (FSD)

Headliner is placed FSD over Consoles and wire harness is placed Temporarily on the back of the H/L

245

STATION 3: OHC AND WIRE HARNESS (FSD) Wire connections are made to the console, Loosely routed and retainer is positioned

246

STATION 3: OHC AND WIRE HARNESS (FSD)

247

STATION 3: OHC AND WIRE HARNESS (FSD) Skilled operator applies glue bead and adheres wire harness to it

248

STATION 4: QUALITY CHECK (FSU)

Wire Harness is plugged into table and electrical check is performed and 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 Reference 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 in body or in vehicle position

Design position is point of view you draw the part from

261

Location Terminology
Right Hand Outboard

Fore

Inboard Inboard

Aft

Outboard Left 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 occupants 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 drivers 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 cant see properly, vehicle is not safe
264

Seating Reference 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 Define...

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 Helps determine design H-Point, the pivot point of thigh and torso Design H-Point should match SgRP

Shows designers how occupant will sit in seat

268

D-Point and Accelerator 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 Oscars 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 Comfort

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

Wanna a Break!
(See u next time)

273