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Home » Innovative Technology » SmartDoor®
Ultra Light Instrument Panel Structure
Background
Reducing weight is a key element in the OEM's drive to meet stringent emission and CAFE standards, while increased
attention on vehicle safety has required additional content and structure. Alternate materials and innovative designs are
increasingly being employed to meet these challenges in spite of potential negative impacts on cost and complexity.
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I/P structures play a key role in the fulfillment of customer and legislative requirements. Not only do they support the steering
column, audio equipment, climate control, dash skin and instrument cluster they are an important element of an overall NVH
reduction strategy (a key driver in perceived quality) and provide a structural element to the vehicle and the mounting points
for front airbags. While steel I/P structures have fulfilled all of these roles there has been limited success in the reduction of
their weight. Conventional I/P structures (including steering column support) have a typical weight of 20-30 pounds.
Magnesium, a relatively new option, has provided significant weight reduction but at a substantial price penalty, and with
new concerns for durability and crash worthiness.
Today's Innovative Solution
The goal of The Ultra Light Instrument Panel (TULIP) structure program was to shift the existing design paradigm by delivering
the weight of magnesium at the cost of steel. This was accomplished through the careful integration of state of the art
design, CAE, forming simulation, welding, manufacturing and material technologies.
Objectives
- Fully contented weight of less than 16 pounds (includes sole support of steering column)
- 1st natural frequency of greater than 35Hz when tested on a fixture with a 45Hz steering column
- Meet FMVSS 208 crash requirement
- Meet customer requirements for repeated firing of airbags
- Torsional rigidity of 1000Nm/degree
- Bending stiffness of 2500N/m
- Support and locate ducts, parking brake, OBD2 module, hood release, plenum, glove box striker, airbag, radio, substrate, junction module, glove box and wiring harness
Results
In addition to meeting all functional, safety and customer requirements the performance characteristics of TULIP include:
- Weight - 14.2 pounds
- 1st natural frequency - 36.5 Hz (tested on a fixture with a 45Hz steering column)
- Torsional rigidity - 1020Nm/degree
- Bending stiffness - 2620N/m
In the realization of these objectives, numerous novel and proprietary features were developed:
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BENEFIT |
- Manufactured from high strength and ultra high strength steel alloys
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- Offers the weight savings of magnesium with lower cost
- Excellent impact and fatigue resistance, high ductility, conventional
materials
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- Wedge Design - Left Hand Cowl Mounting
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- Bi-directional clamping strategy with unidirectional bolting
- Reduction of inner cowl structure due to more efficient load transfer
- Removable for ease of repair and reinstallation of I/P
- Supports modular assembly
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- Patented Steering Column Support Structure
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- Advanced low-mass design provides a structurally efficient platform
for steering column mounting
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COST AND MASS IMPACT
Cost Impact:
Approximately 45% less than similarly contented Magnesium designs
Mass Impact:
30 - 40% lighter than existing steel designs with equivalent functionality
IMPLEMENTATION STATUS
- The Ultra Light Instrument Panel utilizes existing production technology
- The design of TULIP is complete and is ready for production implementation
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