Exterior-Interior Interface Connection Design for Optimal Performance in Automotive Systems 2023-01-0935

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.