Automotive Interiors

1
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 kg/ vehicle tonnes
PP & Alloys 57.7 943000
PUR 18.1 296000
ABS & Alloys 9.5 155000
PE 10.3 168000
PA & Alloys 15.6 255000
PVC 3.7 60000
PBT+PET 3.1 51000
UP 1.9 31000
Others (PC, PMMA, POM, PPE, SM, PF,
13.2 216000
ASA…)
TOTAL 133 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 MAIN PLASTICS TYPES WEIGHT (Kgs)

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

4
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

5
6
Trend Drivers

Economics Innovation

Technical Performance and functionality

7
Technology Trend Areas

8
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

Euro’n 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

9
Automobile Interiors

10
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

11
Possible Applications of Plastics in Automobile Interior

Typical
Process Material
Resin/filler options Weight
options Options
Interiors Kg's
Internal Door Handles Injection PA CS
PBT CS 0.40
POM CS
Dashboard & Parts
Air Bag Systems Injection PA CS/Aramid
PET CS/Aramid 0.40
GMT PBT Mat continuous
Ashtray Injection PA CS 0.10
Air Ventilation Nozzles Injection PC ABS
ABS 2.00
PP MF
Dashboard Injection PP MF
ABS
7.00
PC ABS
MPPO
12
Possible Applications of Plastics in Automobile Interior

Dashboard Skins Thermo engraving PVC

Modified TPO
Plasticised 1.5
Slush Moulding PVC
Thermoform-
Backfoam ABS-PVC

Central Console Injection PC ABS

MPPO 2.00

ABS

Seating Components

Arm Rest Injection ABS CS 0.20

Seat Back rest S-RIM PU Mat continuous 6.00

GMT PP Mat continuous 6.00

Door Panels Injection PP MF

8.00
Compression UP Roving
13
Possible Applications of Plastics in Automobile Interior

Headliners RIM PU Mat continuous

Compression PU Roving
2.20
Fibre cushioning
Special Process PET and acoustic
insulation

Pillar trims Injection PP MF 4.00

Rear Package tray Injection PP MF

RIM PU Mat continuous 2.50

Compression UP Roving

Accelerator Pedal Injection PA CS

0.24
POM CS

Clutch Pedal Injection PA CS 0.23

14
 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.

15
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".

16
NOMENCLATURE
PILLARS

A B
C D

PILLAR TRIMS

A B
C

17
LOCATION

Pillar trim location in vehicle

A-PILLAR

B-PILLAR C-PILLAR
D-PILLAR

18
19
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.

20
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.

21
PART DETAIL

A-PILLAR TRIM
H/L SIDE

AIR BAG DISPLAY COVER.

TRIM

PUSH NUTS

IP SIDE CARTRIDGE
22
 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

23
 PART DETAILS

B-PILLAR TRIM

SLOT FOR BELT HEIGHTADJUSTMENT HEAT STAKE

FOUR WAY LOCATOR

24
 PART DETAILS

B-PILLAR WITH CARTRIDGE B-PILLAR WITH BELT SLIDER

CARTRIDGE

BELT SLIDER

25
 PART DETAILS
C-PILLAR TRIM
H/L SIDE

FITS TO BODY

26
 PART DETAILS

C-PILLAR TRIM

SEAT BELT SLOT WHAT ARE THESE FEATURE?

27
PART DETAIL

D-PILLAR TRIM

SEAT BELT SLOT

28
C / D - PILLAR

C-D COMBINED AS SINGLE TRIM

29
ASSEMBLY / ATTACHMENTS

B-PILLAR LOWER WITH DOOR PILLAR TRIMS WITH BIW

30
ASSEMBLY / ATTACHMENTS

A-PILLAR

INSTRUMENT PANEL
31
ASSEMBLY / ATTACHMENTS

A-PILLAR TO BIW

PUSH NUT

32
ASSEMBLY / ATTACHMENTS

B-PILLAR UPPER TO LOWER B-PILLAR LOWER TO BIW (DOOR SCUFF)

WHAT FOR THESE FEATURE

33
 B-PILLAR LOWER TO BIW

B-PILLAR LOWER
B-PILLAR LOWER

DOOR SCUFF
DOOR SCUFF

34
ASSEMBLY / ATTACHMENTS
C/D-PILLAR TO BIW

WHY THIS FEATURE AND HOW IT WORKS?

35
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).
36
ASSEMBLY / ATTACHMENTS
A-PILLAR TO H/L B-PILLAR TO H/L

A-PILLAR TRIM 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

37
FEATURES

1.SEAT BELT

2.AIR BAG

3.CRUSH PAD

4.GRAB HANDLE

5.GAUGES

38
FEATURES

SEAT BELT ASSY

D-RING BELT MODULE

B-PILLAR TRIM

SEAT BELT

HOW THE SEAT BELT SYSTEM

GET ASSEMBLED
39
FEATURES

AIR BAG

AIR BAG DISPLAY COVER

WHERE DOES THE AIR BAG GET PLACED?

40
 FEATURES
CRUSH PAD

RIB CARTRIDGE

CRUSH PAD B-PILLAR TRIM

41
FEATURES

Model: U322
GRAB HANDLE
Customer: CHRYSLER

GRAB HANDLE

42
 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
43
GAUGES

44
PERFORMANCE SPECIFICATION
Performance Specification for Hard trim and Garnish
Environment Cycle
Heat Age
Infrared Heat Exposure
Adhesion
Safety

1. FMVSS 302 :

Parameters : - Determine the burn resistance within ½ inch of the occupant airspace.
Requirements : - 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.
2. FMVSS 201 :

Parameters : - Vehicle level test.

Test method : - FMVSS 201
Requirements : - HIC d value should be 1000 or less.

45
Floor Consoles

46
Center Console- Exploded view
11 1 FRAMEWORK FRT T/C
2 INS TOP PANEL HARD
28 3 INS TOP PANEL SOFT
10 4 TOP PANEL

12 9 27 5 HSG C/H TOP PNL

6 C/H LOWER
13 8 7 RUBR LIP C/H A/R
26
8 C/H UPR
7 25 9 K LID C/H ALUMINIUM
10 PNL GEAR LEVER PLA
14 24
6 11 RUBBER MAT GEAR LEVER
12 LID A/T FRT
15 23 13 HSG A/T FRT
5 14 HOUSING ASHTRAY REAR
16 22 15 ASHTRAY REAR
16 I-CUP STR TRAY
4 17 LID A/T STDRIM

36 18 LID A/T ALU

19 FRAWORK C/H LWR
3 20 HSG STORAGE TRAY
21
2 35 21 RUIBBER MAT TUN BKT
22 FRA TUN BKT FRT OPT
20 23 SHAFT HINGE ARMREST
34 24 HNG LWR
25 LID INNR UPPR

1 19 33
26 FRAMEWORK ARMREST
27 CARR FOIL
31 28 SURFACE COVERING
29 LOC HAN-T CON FLOOR OPT
32 30 RUBBER CAP RH
37 31 RUBBER CUP LH
32 BOT TUN BRKT FRT

18 30 33 CONTACT ELEM BKT

34 CVR PLT RR

17 29 47
35 BKT TUN CON FRT AU
36 BEARING ARMREST
37 IK CARPET
Floor Console Exploded View

377786
377805
1152463

377806
377799
377794

162
120 or 249
377791

377785 377798 1158258

1157881

377790
377784
377789
48
A B C of DOOR TRIMS/MODULES

49
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

50
FLAT DOOR PADS
Flat Hard board with vinyl and foamed backed fabric lamination

Tata Motors Sumo Door Ford Endevour Door Pad

51
FORMED DOOR PADS
Formed Hard board with vinyl and foamed backed fabric lamination

Ford Ikon Fiat Siena

52
PLASTIC DOOR TRIMS
Plastic and Hard Board combination

Ford Endevour

53
Manual Window Lifting Mechanism

54
Manual Window Lifting Mechanism

55
Manual Window Lifting Mechanism

56
Power Window

57
Power Window

58
Power Window

59
Power Window

60
Power Window

Electric Motor
Worm Gear
Spur Gear
Linkage

61
 Electric Motor

Normal DC motor
used to actuate the
lifting

62
63
64
Worm and Spur
Gear
Normal DC motor
used to actuate the
lifting

65
Linkage Rod

The Rod on which

glass is lifted.

66
Cup Holder

Accessory to
hold your Cup .

67
Magazine Pocket

68
Audio Speakers

69
70
Reflectors

71
Reflectors

72
73
Air Bag

74
New Trends in Door Panel

Web Enabled Door Locks

Keyless Go! with Smart Cards
Blue Tooth
Power sliding doors

75
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

76
Blue Tooth : Voice Commands
The module allows user to make and receive
calls, this also enables voice commands to open
and close the doors.

77
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.

78
79
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 80

 Exploded Front Door SWITCH BEZEL
ANB40012 (LH)
ANB40023 (RH)

CLIPS
16754704
COVER (QTY- 05)
ANB40002 (LH) SWITCH
ANB50023 (RH) 10386129 (LH) WINDOW SWITCH
10386130 (RH) 10377668 (LH)
10377669 (RH)
SCREWS HANDLE UPPER SUBSTRATE
11509231 10396621 (LH) ANB50021 (LH) CLIPS COVER
(QTY- 61) 10396622 (RH) ANB40014 (RH) 16754704 ANB40004 (LH)
(QTY- 04) ANB40019 (RH)

ALUM. BEZEL FOAM

ANB40009(LH) ANB40012(LH)
ANB40016(RH) ANB40023(RH)

S CLIPS
ANB40006
(QTY- 04)

SUBSTRATE
ANB40003 (LH)
HANGER BKT ANB40021 (RH)
LOCK BEZEL LOWER ANB40008 (LH)
90560166 ANB40017 (RH) SCREWS
(QTY- 02) ANB40010
(QTY- 16)

LOCK BEZEL UPPER NUTS

13104077 11519497
(QTY- 02) (QTY- 04)

GASKET
ANB50007
(QTY- 04) LOGO
ANB50020
RETAINER (QTY- 02)
11519031
(QTY- 21) SPK. GRILL
10370444 (LH)
10370406 (RH)

BOLTS COVER
1158901074 10393132
(QTY- 04) (QTY- 02)
MAP POCKET
ANB40001 (LH) PANEL LOWER LAMP 81
ANB40018 (RH) ANB40000 (LH) 15021517 (LH)
ANB40013 (RH) 15021518 (RH)
DOOR SHEET METAL

82
 LOCATERS WITH GASKETS TO AVOID BSR

THESE RIBS TO AVOID

RATTLING SOUND DUE TO
SPEAKER VIBRATION

SCREW BOSSES
FOR MAP POCKET

83
LOWER DOOR SUBSTRATE
ARMREST SUBSTRATE
Material – PP+20%GF
84
 SKIN
Material - PVC

UPPER SUBSTRATE SUBSTRATE

Material - ABS

FOAM BUN (ARMREST) 85

 ARMREST SUB-ASSEMBLY

HANGER ASSY

86
SWITCH BEZEL

WINDOW SWITCH

87
ALLUMINIUM FOIL

HANDEL BEZEL PLASTIC

REMOTE HANDEL

88
SPEAKER GRILL
Material – Expanded metal, Powder coated

SEAT HEATTING SWITCH

89
90
 Locaters with gasket

H2 REAR DOOR
91
 SWITCH BEZEL
Exploded Rear door ANB43002 (LH)
ANB43003 (RH)

COVER
ANB43200 (LH)
CLIPS ANB43300 (RH)
11609760
(QTY -04) FOAM
SUBSTRATE COVER ANB50002 (LH)
HANDLE ANB40029 (LH) ANB40026 (LH) ANB50003 (RH)
10396621 (LH) ANB43005 (RH) ANB43004 (RH)
GARNISH TRIM
ANB52496 (LH) 10396622 (RH)
CLIPS
ANB52526 (RH) ALUM BEZEL
ANB40006
ANB43008 (LH)
(QTY -04)
ANB43009 (RH)

SCREWS CLIPS
11509231 16754704
(QTY -36) SUBSTRATE
(QTY -04)
ANB50000 (LH)
ANB50001(RH)

SCREWS
ANB40010
(QTY -19)
GASKET
ANB50007
(QTY – 04)
LOCK BEZEL LOWER SPEKER
90560166 BOLT 25725733
(QTY – 02) 11589010 (QTY – 02)
(QTY – 04)
LOCK BEZEL UPPER
13104077
(QTY – 02)

NUT ALUM BEZEL

11519497 ANB43008 (LH)
(QTY – 04) ANB43009 (RH)
RETAINER
11519031
HANGER BKT (QTY – 18)
ANB43010 (LH)
ANB43012 (RH)

MAP POCKET
10370371 (LH)
10370399 (RH)

PANEL LOWER LAMP ASM

92 SPK. GRILL
ANB40027 (LH) 15021517 (LH) 10370897 (LH)
ANB43007 (RH) 15021518 (RH) 10370898 (RH)
Locaters

HEAT STEAKS
FOR MAP POCKET

LOWER SUBSTRATE
Material - ABS

93
 UPPER SUBSTRATE
Material – ABS with PVC skin

C- PILLER

LOCK BEZEL

UPPER SUBSTRATE ASSY

94
 HANDEL BEZEL

HANDLE ASSY

REINFORCEMENT FOR SIDE

CRASH TEST AS PER FMVSS-202

C – PILLER
Material - ABS 95
ARMREST ASSY

96
ARMREST ATTACHMENT POINTS
 ARMREST ATTACHMENT POINTS

ARMREST SUBSTARTE

FOAM BUN

ARMREST TRIM
97
DOOR LOADING
TESTING FOR MISSUSE
(FMVSS – 214)

98
 Door Module Experience

Sealing

Latch

Exterior
Handle
Loudspeaker

Side Impact
Bolster

Window Regulator 99
 Door Module Experience

Sealing

Latch

Loudspeaker

Exterior Handle
Window
regulator

100
DOOR MODULE

• Double Arm Window Lifter

Door trim panel

+
Mechanisms

101
DOOR MODULE

• Double Rail Window Regulator

Door trim panel

+
Mechanisms

102
DOOR MODULE
• Single Rail Window Lifter

Door trim panel

+
Mechanisms

103
DOOR MODULE
• Single Rail Window Lifter

Door trim panel

+
Mechanisms

104
Level of Modularity

Level 1 Level 2 Level 3 Level 4

Functional Systems
Components Full Door
Integration Integration Integration

Components Function Improvement Full Total

- Latches - Steel HW Module Modular Door Modular Door
- Trim ____________________ - Door HW Module - Outer Skin
- Regulators
- Hinges Up-Integration - Door Trim Module - DH Subsystems
- Handles - Door Structure - Door E/E Arch.
- Wiring - Super Plug Door Module
- Switches - Door Trim Module - Glass, Seals, etc. - Door Structure
- ‘X’ Frame / Hybrid HW Mod.
- Inner Trim, etc.

105
Door Module
Market Evolution

Door Module - Frame Concept

106
Components Carrier
Door Module
Market Evolution

Structural Module
Door of the vehicle“Smart”

Metal Carrier

Door Trim Module

Trim Panel as components carrier 107
Plastic Carrier
Door Module
Market Evolution

+
Door Trim Module
Door Structure Outer panel

New Door Concept

108
 Door Module
Market Evolution

Conventional Metallic (or Plastic) Door Trim Module

door carrier (AGT) (DTM)

- 4 planes - 3 planes - 2 planes

- Dry and wet areas - Dry and wet areas - Localized dry areas
109
 Door Module
Market Evolution

Conventional Metallic (or Plastic) Door Trim Module

door carrier (AGT) (DTM)

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

Door trim support:

Integrated
fixing system
for the door
trim

Fixation for the

window lifter
motor

Plastic
padding
Door sheet
111
metal
 Door Module Description

Door trim support:

Integrated Loudspeaker
clips for the
harnesses

WR
support 112
Door Module Description

Door trim support:

Latch
support 113
Door Module Description

Door trim support:

- Trim panel attachment to the door inner sheet metal

114
Door Module Description

Medallion:
- Low pressure injection technology.
- Cover with fabric.
- Integration of the clip’
clip’s in the medallion part.

115
Door Module Description

Door trim support:

- Housing for the medallion clip’
clip’s.
- Support for rails of the window lifter.

Medallion
clip’
clip’s

Support for
window lifter
rail

116
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

117
Door Module Description

Sealing system:

Section AA
Door trim

Sealing
A profile
Door sheet
metal

118
 INTRODUCTION
TO
INSTRUMENT PANELS

119
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

120
Instrument Panel Development

Engineering
Requirements

Styling Design
Requirements Options

Platform Needs
and
Architectural Requirements Material
Options Options

IP Assembly Vehicle GA
Process Process
121
Consumer Trends in Instrument Panels

 Comfort and Safety  Function

– Climate control – Cup holders
– Spacious – Electronics
– Ergonomics - ease of controls, – Electronic integration
buttons, features – Easy to read instrumentation
– Quiet – Heads-up display features
– Airbags – Storage
– Long lasting - durable
 Styling
– “Interior Designed”  Vehicle Affordability
– Sleek, modern, coordinated – Total cost
colors and textures
– Cost-performance-feature
– Luxurious look and feel ratio
122
Instrument Panel Requirements

 Static Steering Column Stiffness and NVH

– Static stiffness upon vertical and transverse loads
– Frequency response of column and column/support subsystems
 Instrument Panel NVH
– Frequency response of IP system
 FMVSS 208 Crashworthiness
– Knee intrusion and knee load management capability
– Occupant deceleration management
– Energy absorption capability of IP system
 FMVSS 214 Crashworthiness
– Maximum load carrying capability and collapse load
– Cross-vehicle load path continuity
 FMVSS 201/ECE 21/ADR 21 Head Impact Protection
– Local structural stiffness
– Local energy absorption and load carrying capability
 Offset Deformable Barrier Impact and NCAP
– Load management capability
123
– Steering column movement
Functional Performance Requirements

 Steering column static stiffness

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

oC
 Frequency response of IP
system
 IP system durability
 Long-term structural
performance
 Aging behavior
 Environmental response 124
Road Surfaces Engine
Functional Performance Requirements

FMVSS
FMVSS 208
208 Crashworthiness
Crashworthiness
 Upper torso load management
 Occupant deceleration
 Knee and lower leg energy and load 30mph / 48kmh
management Vehicle Pulse

 Knee intrusion
 Load transfer capability

ODB
ODB Impact
Impact
 Driver front end crash behavior
 Localized IP deflection behavior
 Front-of-Dash intrusion and
steering column deflection
 Load path between steering
column, IP and vehicle body125
Functional Performance Requirements

FMVSS
FMVSS 201,
201, ECE
ECE 21,
21, ADR
ADR 21
21 Head
Head Impact
Impact Protection
Protection

Top View
Excluded
Area Instrument Panel

Windshield

Steering Wheel
Headform 5"
Impact
Fixture Vertical Plane
Headform Steering
Wheel

Instrument
Panel
Windshield
Headform
Vertical Plane

Excluded
Right Side View Area

Instrument Panel

Left Side View 126

 INSTRUMENT PANEL
THE MOST IMPORTANT AND CRUCIAL
SUBSYSTEM FOR A CAR

?
HOW’S
THAT????????????????????

127
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

128
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.

129
MAJOR COMPONENTS OF IP:

• Instrument Panel Assembly • Storage Bins, Cup holders, Coin

(Console as and when needed) holders

• IP Structure (cross car beam and brackets) • Transmission Shifter, Knob, Boot

• HVAC Module •Harness, Control Head

• Air Outlets, Side window
• Gear Shifter Assembly
Defoggers, Lap Coolers
• Glove box Bin, Door Latch, Striker, Lock
• Air Ducts, Defroster Ducts and Grills
• Ashtray assembly
• Parking Brake Handle/Actuator
• Steering Column Covers

130
INSTRUMENT PANEL ASSY

131
PANEL-ASM INST UPPER
Spray Skin

Carrier

NOZZLE-W/S DEFR

DUCT-AIR INL

132
PANEL ASM-INST LWR

PANEL-INST LWR

REINFORCEMENT ASM-I/P

133
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

134
GLOVEBOX ASM

135
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

136
DOOR ASM-I/P COMPT

HINGE-I/P COMPT

FASTENER-PEG, GLOVE BOX

ROD-I/P COMPT DR LAT REL

HINGE-I/P COMPT

PANEL-I/P COMPT DR INR LEVER-I/P COMPT DR LAT

ROD-I/P COMPT DR LAT REL

PANEL-I/P COMPT DR
SPRING- OTR
ACTUATOR

LEVER-I/P COMPT DR LAT LOCK-ASM I/P COMPT DR

137
INSTALLATION-I/P MLDG

MOLDING ASM-I/P CTR

CARRIAGE BOLD 20x12

138
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

139
COVER STEERING COLUMN

140
INST. COV. STEERING LHD

COVER ASM-STEERING COL TR

COUNTERSUNK SCREW

CAP-COUNTERSUNK SCREW
PAN HEAD SCREW

COVER ASM-STRG COL TR

141
COVER ASM-STEERING COL TR

MOUNTING RAIL

COVERING STEERING

COVER STRG COL HSG UPPER

142
COVER ASM-STRG COL TR

CRASHPAD ASM STEERING

COVER STRG COL HSG LOWER

143
PANEL ASM-I/P TR

CARRIAGE BOLD 20x12

PANEL ASM-I/P TR

144
PANEL ASM-I/P TR

SPRING

PANEL IN

PANEL OTR

145
DECOR MOLDING DR/PS
SPRING FEDER

MOLDING-I/P DECOR MOLD

DRIVER SIDE PASSENGER SIDE

146
ENVIRONMENT COMPONENTS

CROSS CAR BEAM

HVAC

NAVIGATION DISPLAY

147
Abbreviations

Abbrevations
HLU Hand Lay UP
RIM Reaction Injection Moulding
GMT Stampable Thermoplastics
IM/BMC Injection moulding ( Bulk moulding Compound)
RTM Resin Transfer Moulding
UP Unsaturated Polyester
VE Vinyl Ester
PU Poly urethane
EP Epoxy
MF Mineral Filled
CSM Chopped strand Mat ( Glass)

SMC Sheet Moulding Compound

CS Chopped Strands ( Glass )
LCP Liquid Crystaline Polymers
PI Polyimides
PTE Polyester Thermoplastic Elastomer
PPE Poly phenyelene ether
MPPO Modified Poly Phenylene Oxide
148
 Assembly
&
Attachment Methods
of IP

149
Assembly Techniques for Plastic parts

150
Assembly Techniques –Snap Fits

Snap fit cantilever beam type

Snap fit cylindrical Type

151
Assembly Techniques –Snap Fits

Factors for calculating cantilever beam for Snap fit

152
Assembly Techniques –Snap Fits

Mold Design For Snap Fits 153

Assembly Techniques –Spin Welding

154
Assembly Techniques –Ultrasonic Welding

155
Assembly Techniques –Hot Plate Welding

156
Assembly Techniques –Adhesive Bonding

157
Assembly Techniques –Ultrasonic Insertion

158
Assembly Techniques –Screw and Bosses

159
Assembly Techniques for Plastic parts

160
INDEX

ATTACHMENT METHODS USED IN IP

GMX-211 ASSEMBLY
ASSEMBLY LINE – JEEP LIBERTY
GENERAL PROCEES FLOW DIAGRAM

161
VARIOUS ATTACHMENT AIDE :
Screws & Nuts Self Retaining Speed Nuts
Rivets
Clips Cable Clips
Plastic Fasteners
Pour In Place
Gluing
Snap Fixing
Welding Vibration Welding
Ultrasonic
Insert Molding

162
SCREWS & NUTS :
Screws & Nuts:

High Bonding Strength

Resistance to Vibration
Standardized part Availability
Low Cost
Low Assembly Time

163
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.

164
 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

165
 NO ACCESS TO THIS AREA

SEATING LOCATION

166
SECTIONAL VIEW
167
ASSEMBLED VIEW

168
CENTER STAKE AREA

169
EXPANSION NUT
Expansion-Type Fasteners

170
SEATING LOCATION

171
ASSEMBLED VIEW

172
SECTIONAL VIEW
173
BLIND RIVETS: Types:
ECONOMICAL Dome Head
VERSATILE Most widely available and
commonly used head style.
EASY-TO-USE
Countersunk Head -120°
SPEED OF ASSEMBLY, The Countersunk Head Blind
CONSISTENT MECHANICAL PERFORMANCE AND Rivet is used in applications
requiring a flush surface.
EXCELLENT INSTALLED APPEARANCE,
Multi-Grip Blind Rivets
Plastic Blind Rivets
Olympic Mega-Grip Rivets
Very High strength

174
The graph illustrates the mechanical function of a blind break-mandrel rivet during installation.

BLIND RIVET
175
Dome Head Rivet
176
ASSEMBLED VIEW

177
TUBULAR RIVET

BEFORE PROCESSING AFTER PROCESSING

178
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

179
 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

180
KNEE BOLSTER ASCRY PLATE

SEATING LOCATION
181
ASSEMBLED VIEW

RETAINER & TRIM PLATE

182
ASSEMBLED VIEW

183
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

184
CABLE ROUTING CLIPS

185
SEATING LOCATION

186
ASSEMBLED VIEW

187
SECTIONAL VIEW
188
ADJUSTABLE CABLE CLAMP

189
ASSEMBLED VIEW

190
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.

191
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

192
POUR IN PLACE : STEP - I

193
POUR IN PLACE : STEP - II

194
POUR IN PLACE : STEP - III

195
FINISHING ACHIEVED USING POUR N PLACE

Dylark
196
GLUEING

197
SNAP FIXING :

Reduces Part Count TYPES

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

198
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 Figure 2: This bottle cap uses an
annular snap fit. annular snap fit.

199
Snap Fixing : CANTILEVER

Figure 4: These four snap fit designs allow Figure 5: The stages of a U shaped cantilever snap fit.
different types of disassembly.

200
SNAP IN GLOVE BOX

201
SNAP IN AIR DUCTS

202
Welding : VIBRATION WELDING Advantages of Welding
Speed
ULTRASONIC WELDING
Strong Joints
FUSION WELDING
Tolerance of Contaminated
Surfaces.
Joins Difficult Substrates, Such As
Polyolefins
Improved Recyclability

DECKEL INNER FUSION

WELDED TO DECKEL OUTER
203
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

204
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

205
Insert Molding :

206
Over Head Systems

207
208
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

209
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

210
TYPES OF HEADLINERS

Standard

Sunroof

Moon roof

211
 STANDARD HEADLINER
CUTOUT FOR
GRAB
`C’ PILLAR
HANDLE
CUTOUT

CUTOUT FOR
`B’ PILLAR
CUTOUT FOR
`A’ PILLAR

CUTOUT
FOR
?
CUTOUT
FOR VIOSR

CUTOUT FOR
RECEPTACLE

CUTOUT FOR
BEZEL
CUTOUT FOR
MAP LAMP

212
SUNROOF / MOONROOF HEADLINER

SUNROOF /
MOONROOF
OPENING

213
MAJOR TYPES OF SUNROOF/MOONROOF H/L

Top Slider

Pop-up

Electric
Spoiler

Folding Type

214
TOP SLIDER

215
POP-UP

216
ELECTRIC SPOILER

217
FOLDING TYPE

218
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’
SURFACE
CLOSING
SURFACE

‘A’ `B’
SURFACE SURFACE

219
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).
220
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.
221
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 BSR’s.

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.

222
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

223
MAJOR SUBSYSTEM

224
OVERHEAD CONSOLES

225
VISOR ASSEMBLIES

226
GRAB HANDLES

227
MAP, DOME AND COURTESY LAMPS

228
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

229
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.

230
HEAD IMPACT LOCATIONS IN CAR

231
HEAT VENTILATION AND AIR
CONDITION

232
VIDEO ENTERTAINMENT SYSTEMS

233
TOPICS

There are three major process for

manufacturing headliners :

• ACOUSTICOR
• POLYBOND
• THERMOBOND

234
ACOUSTICOR

235
POLYBOND

236
THERMOBOND

237
ASSEMBLY SEQUENCE

238
STATION 1: HIC FOAM (FSD)

239
STATION 1: HIC FOAM (FSD)

240
STATION 2: COMPONENTS (FSU)

241
STATION 2: COMPONENTS (FSU)

242
STATION 2: COMPONENTS (FSU)

Components are
attached to clips and
retainers by skilled
operator

243
STATION 3: OHC AND WIRE HARNESS (FSD)

244
STATION 3: OHC AND WIRE HARNESS (FSD)

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

245
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

246
STATION 3: OHC AND WIRE HARNESS (FSD)
Wire connections are made to the console,
Loosely routed and retainer is positioned

247
STATION 3: OHC AND WIRE HARNESS (FSD)

248
STATION 3: OHC AND WIRE HARNESS (FSD)

Skilled operator applies glue bead and

adheres wire harness to it

249
 STATION 4: QUALITY CHECK (FSU)

Wire Harness is plugged into table

and electrical check is performed
and results are stored in computer.

250
VEHICLE ENVIRONMENT

251
HEADLINER ATTACHMENT

252
SLIDER MECHANISM

253
VEHICLE STRUCTURE

ROOF RAIL
REAR

ROOF
BOW

RAIL
ROOF RAIL SIDE ROOF
FRONT

A PILLAR B PILLAR REAR

INNER
PANEL

254
VEHICLE STRUCTURE FOR S/R & M/R

ROOF RAIL
REAR

ROOF RAIL
FRONT

REAR
INNER
PANEL

255
256
Vehicle classifications as per ECE

257
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
258
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

259
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 260

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
261
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
262
Location Terminology

Right Hand
Outboard

Fore Inboard Aft

Inboard

Outboard
Left Hand

• Other terms used to describe locations

• Centerline
• Left Hand and Right Hand
• Inboard and Outboard
• Fore and Aft 263
Locating Points Within the Vehicle

• Many locating points are used to define

occupant’s 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
264
Eyellipse

• Statistical representation
of the driver’s 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 can’t see
properly, vehicle is not safe

265
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

266
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
267
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

268
Oscar and H-Point

Oscar is used to measure seating accommodations

• Oscar template is two-dimensional
• Oscar machine is three-dimensional
Shows designers how occupant will sit in seat
• Helps determine design H-Point, the pivot point of thigh and torso
• Design H-Point should match SgRP 269
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 Oscar’s heel point with shoe on un-depressed accelerator
• Altering heel point affects comfort and safe operation of foot controls
270
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

271
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 H-
Point
– Design and actual H-Point are measured
using two- and three-dimensional Oscar
templates and manikins

272
Measuring H-Point

273