The purpose of this SAE Recommended Practice is to present design recommendations for the direction-of-motion of hand controls found in passenger vehicles, multipurpose vehicles, and trucks. These recommendations are based on recent and past human factors research and are important considerations in the design of control layouts.

Controls and Displays Standards Committee

Say no to re-engineering

AUTOMAY08_095/1/2008

Engineers at IAC are inspired to complete product development tasks without a do-over in mind, says Maurice Sessel, Vice President of Product Engineering at IAC North America. The company's engineering mantra consumes only six words, but the wisdom bestowed in that short message is having long-lasting effects. “I'm always saying to the team, ‘do it right the first time,’” said Maurice Sessel, Vice President of Product Engineering at International Automotive Components (IAC) North America, a global supplier of instrument and door panels, headliners, flooring, acoustic systems, cockpits, and fascias headquartered in Dearborn, MI.

Buchholz, Kami

Development of an Instrument Panel with an Integrated Chute and Seamless Airbag Door

2008-01-13394/14/2008

Automobile manufacturers, designers, and cockpit system integrators are in constant search of solutions that reduce the number of interruptions across interior surfaces. Engineers require that this solution be efficient in terms of reliability, parts complexity, packaging space, and cost. The purpose of this paper is to describe the design and development of a cost effective, simplified seamless passenger airbag door system with an integrated chute for instrument panels. Through engineering thermoplastic material property advantages and scoring designs, this solution has a construction which may meet both styling and performance criteria while eliminating component parts such as a separate airbag chute, hinges, tethers, brackets, inserts, fabrics, and fasteners.

Jaarda, Eric, Chaturvedi, Manish, Wieczorek, Ted, Meyers, Amy, Chitteti, Ravi

System Level Noise Source Identification and Diagnostics on a Vehicle Door Module

2007-01-22805/15/2007

Noise problems are often system issues rather than component issues. Component manufacturers have been putting continued efforts into constantly improving the quality of their products. There are numerous tests and standards to assess the vibro-acoustic performance of individual components. But once all components are put together, the system response might be entirely different from those of individual components. Typical system level testing has primarily been used to identify bad assembled products from good ones. These tests are usually done as part of a quality control process and slow down production. Such tests usually provide little information about the root causes of noise and vibration problems and no insight into improving engineering designs for noise abatement. This paper presents a new way of conducting system level noise diagnoses by using the Helmholtz Equation Least Squares (HELS) based Nearfield Acoustical Holography (NAH) technology [1]. This approach allows for reconstruction of all acoustic quantities, including the acoustic pressure, particle velocity, and acoustic intensity, and creating 3D acoustic images produced by an arbitrary source based on the acoustic pressures measured on a hologram surface at very close range to the source. It enables one to establish a direct correlation between sound and vibration. The current study involves a noise diagnostic test on a vehicle door assembly to understand system level interaction of the motor and the door module to compliment continued efforts to refine the motor to manufacture quieter assemblies. To identify noise sources, a conformal microphone array, covering the entire door surface was used to measure the acoustic pressures. This data was used to reconstruct the acoustic pressure, normal velocity, and acoustic intensity on the door module surface. In particular, the acoustic intensity and normal surface velocity were analyzed to identify the noise sources and understand the noise generation mechanisms.

Beniwal, Ravinder, Wu, Sean F.

The Door Mounted Inflatable Curtain

2006-01-14374/3/2006

It has been shown that Inflatable Curtains have the potential to reduce head injuries in side impacts and the system has accordingly been introduced on a growing number of car models. There is also a potential benefit in rollover situations. This paper only consider performance in situations with belted occupants. To date, it has not been possible to implement an Inflatable Curtain in convertible vehicles because they lack a roof. The challenge of the Door Mounted Inflatable Curtain (DMIC) has been to overcome the lack of support and fixation possibilities offered by a roof. This paper includes a description of the DMIC and how it was integrated into the vehicle structure. The paper will also show how to create the space and support needed to utilize the internal stiffness and make it possible to fill the bag in time. The impact attenuation and ejection protection functions of the DMIC will be demonstrated.

Claeson, Niklas, Ryrberg, Stephan

Two-Reference Beam Double-Pulsed Holographic Interferometry with Direct Phase Measurement in Transient Processes Study

2006-01-07694/3/2006

Holographic interferometry has been successfully employed to characterize both static and dynamic behavior of diverse types of structure under stress. Double-exposure pulsed holographic interferometry has been extensively used in performing the vibration analysis and qualitative investigations of deformation of the non-stationary objects. One of the most important advantages of this technique is that it can be used for quantitative measurements of the transient processes (e.g. shock wave propagation). However, in conventional double-pulsed interferometry it is sometimes difficult to get phase information from a single set of holograms. Applying two-reference beam recording set-up to double-exposure pulsed holographic interferometry makes it possible to obtain phase-shifted interferograms from a single interferogram of the tested object and retrieve the phase information for OPD (optical path difference) map creation. Two-reference beam double-pulsed Ruby laser holographic interferometer has been adapted to transient and continuous phenomena studies. It is non-destructive, real-time, and definitive approach in identification of vibrational modes, displacements, and motion geometries. Results of a vibration study performed by double-pulsed Ruby laser holographic interferometry for wave excited by shaker with continuous sinusoidal excitation and propagated over the car door panel surface are presented in this paper.

Grabovskyy, Vitaliy, Yashnyk, Viktor

S/MA Resin Recovery System and Recycling in OEM Specification Foam / Covered Instrument Panels

2004-01-17503/8/2004

Several million pounds of S/MA glass reinforced resin has been successfully recovered from manufacturing offal and reject foamed / covered Instrument Panels (IP's) over the past ten years. ACI-WIPAG and Visteon recovered high quality S/MA resin, prepared blends with virgin resin and injection-molded IP substrates meeting OEM specifications. This “S/MA Resin Reclaim” process has been an economical and environmental success; minimized landfill volume, reduced landfill disposal costs, recovered a valuable resource, increased material utilization and reduced raw material costs. This paper reports on a new system and process to recover S/MA glass reinforced resin from manufacturing trim offal and reject IP's, blending and supplying OEM specification resin blends for molding instrument panel substrates. The system demonstrated economical recovery of an excellent quality “Reclaim” resin, blend consistency and uniformity for injection molding instrument panel substrates.

Lieberman, Mark, Latture, M., Juneau-Stetkiw, P., Gallihugh, Eileen, Rudd, Michelle, Masserant, Michael, McCollum, Timothy, Kottyan, Robert, Hmiel, Stanley

Light Weight Polypropylene Bonded Long Glass Fiber Technology - For Niche Vehicle Interior Trim

2004-01-12583/8/2004

The Ford GT is a niche vehicle with a very limited production volume. A solution was needed that would minimize cost, particularly up-front investment, and produce a lightweight, high-class vehicle interior, while maintaining the standard quality, material and design requirements.

Benninger, E.J., Hipwell, J.G., Ewing, Kip

Enhanced Security Flight Deck Doors-Commercial Airplanes

2003-01-30189/8/2003

In the wake of the 9/11/2001 hijacking events, the Federal Aviation Administration (FAA) has emphasized the need for enhanced flight deck doors on commercial airplanes. The paper describes enhanced flight deck door, which meets the new FAA requirements for intrusion resistance and ballistic protection. In addition, the new door meets the existing requirements for rapid decompression, flight crew security and rescue.

Movsesian, Sami

Wavelet-Based Visualization, Separation, and Synthesis Tools for Sound Quality of Impulsive Noises

2003-01-15275/5/2003

Recent applied mathematics research on the properties of the invertible shift-invariant discrete wavelet transform has produced new ways to visualize, separate, and synthesize impulsive sounds, such as thuds, slaps, taps, knocks, and rattles. These new methods can be used to examine the joint time-frequency characteristics of a sound, to select individual components based on their time-frequency localization, to quantify the components, and to synthesize new sounds from the selected components. The new tools will be presented in a non-mathematical way illustrated by two real-life sound quality problems, extracting the impulsive components of a windshield wiper sound, and analyzing a door closing-induced rattle.

Scholl, David, Yang, Barry

A Case Study on Airborne Road Noise Reduction of a Passenger Vehicle

2003-01-14075/5/2003

This paper presents a case study on reducing road noise of a passenger vehicle. SEA, insertion loss and sound intensity measurements were the tools used in the study. A SEA model was constructed to predict the primary paths (panels or area) contributing to the overall interior sound field. Insertion loss measurements were used to verify the primary contributing paths identified using SEA. To provide further details of the primary paths, intensity maps of identified panels were measured allowing detailed reconstruction of the contributory panels. The SEA model, insertion loss, and intensity maps aided in providing possible design fixes that will effectively reduce road noise. Finally, comparisons of predicted results versus actual results at both a subsystem and a full vehicle level are included in this paper.

Foulkes, Martin G., Rajan, Sailesh, Zeng, Xiandi, Woo, Jae-Hak

Enhanced Security Flight Deck Doors-Commercial Airplanes

2002-01-299811/5/2002

Movsesian, Sami

Performance Improvement in Leak Noise Reduction

2002-01-12383/4/2002

One of the most important quality required for luxury vehicle is quieter cabin. Up to the present, for its improvement, various countermeasures have been carried out. For example, additional weather-strips were added around door for noise reduction and quieter engines were developed. But, with all these performance improvements, local leak noise becomes major remaining. In order to achieve quieter vehicles, the noise has to be stopped by every possible means. In this report, performance improvement in noise reduction is studied by connecting both ends of inner belt weather-strip and glass run. And the influence of connecting portion for glass sliding durability is evaluated.

Goto, Teruhito, Kawai, Katsunori

Analysis and Design of Slow Build Studies During Sheet Metal Assembly Validations

2001-01-305210/16/2001

Several manufacturers are adopting six sigma programs in efforts to reduce stamping variation. This requires the crucial step of establishing dimensional relationships for the stamping dimensional outputs that become key process inputs to the assembly process. This paper describes a methodology used to determine the root cause of dimensional changes in a front door assembly. Among the key findings in this study are the importance of understanding the effects of the datum-locating scheme and the significant influence of assembly processing variables, rather than stamping variability, on the final door assembly dimensional quality.

Guzman, Luis Garcia, Hammett, Patrick C.

Optimisation of the Impact Behaviour of Injection Moulded Components Through Processing: A Case Study

2001-01-342610/1/2001

This work validates a methodology to optimise the impact properties of injection moulded semicrystalline polymers through the control of the processing conditions. This is applied to a case study: an interior door panel. The thermomechanical environment imposed during moulding is assessed by computer simulations of the mould filling phase, for a wide range of processing conditions. Two thermomechanical indices are then calculated aiming at interpreting the microstructure development. Based on relationships between these thermomechanical indices and the impact properties of plate-like mouldings, the impact behaviour of the door panel can be enhanced. The results are experimentally validated

Viana, J. C., Cunha, A. M., Dias, T., Lopes, A. R., Alegria, M.

Enlightened interiors

AUTOMAY01_045/1/2001

Product developers at Chicago Miniature Lamp discuss trends and advances in automotive interior lighting. Properly integrated into new-car designs, well-harmonized interior lighting is a powerful, cost-effective marketing tool. Besides improving safety, good lighting personalizes the interior for driver and passengers and makes the entire vehicle more appealing, convenient, and distinctive. Studies indicate three additional dollars spent on interior lighting broadens vehicle sales appeal more than $80 spent on audio equipment or $2000 on navigation systems. However, automotive lighting trends and recent advances in lighting technology present design opportunities and technical challenges for OEMs and Tier 1 suppliers. Complex lighting decisions make it important for interior designers to involve lighting experts early in the design process. A vertically integrated supplier offering a choice of light sources, optical technologies, and manufacturing approaches can integrate custom solutions at the lowest cost and shorten time-to-market. The number of interior lights in the average automobile more than tripled from the 1995 to 2000 model years. Safety legislation now requires lighted indicators for antilock brakes and other features on new passenger cars, vans, and heavy trucks. More plentiful than dashboard indicators are the vanity, map, and convenience lights that attract potential buyers.

Closed-Loop Recycling of Monomaterial Door-Panel Systems

1999-01-31549/28/1999

Pressures to increase the recyclable and recycled content of passenger vehicles are accelerating. In Europe, there is interest in eliminating halogenated polymers. Globally, more and more concern is focused on materials and methods that are ecologically friendly. Automakers and their suppliers are being encouraged to design and assemble components in new ways to facilitate separation, identification, and resource recovery at the end of the vehicle’s useful life - something that is not only good for the environment, but also the bottom line. One area of the vehicle that has proved challenging for applying such design for disassembly and recycling (DFD/R) principles has been the interior, owing to the sheer number of materials used there, and the great number of laminate structures that make disassembly nearly impossible. A good example is a door panel inner, which typically consists of a rigid plastic substrate, a foam pad, and a vinyl, leather, or cloth covering. This component is usually comprised of different materials tied with adhesives and polyester scrim fabrics. Fortunately, recent material developments as well as process enhancements have now made it possible to quickly and efficiently manufacture all-olefin door panels without adhesives or scrim, making the monomaterial door panels excellent candidates for recycling. But how recyclable are these systems? A recent manufacturing study successfully recycled fully covered door-trim panels comprised of an olefin-based coverstock, a cross-linked olefin foam pad, and a polypropylene (PP) substrate. Processing scrap was chopped and reintroduced - at predetermined weight ratios - back into the virgin resin feedstream used to produce additional PP door substrates. A variety of tests were performed both on plaques and full door panels comprised of varying ratios of virgin + recycled material to see if the presence of the recycled material affected any physical or mechanical properties, processability, or other engineering specifications. The results of this testing program are presented here, along with recommendations for implementing a closed-loop recycling program.

Patel, Aashir, Olejnik, Daniela

A New Wavelet Technique for Transient Sound Visualization and Application to Automotive Door Closing Events

1999-01-16825/17/1999

Transient automotive sounds often possess a complex internal structure resulting from one or more impacts combined with mechanical and acoustic cavity resonances. This structure can be revealed by a new technique for obtaining translation-invariant scalograms from orthogonal discrete wavelet transforms. These scalograms are particularly well suited to the visualization of complex sound transients which span a wide dynamic range in time (ms to s) and frequency (∼100Hz to ∼10kHz). As examples, scalograms and spectrograms of door latch closing events from a variety of automotive platforms are discussed and compared in light of the subjective rankings of the sounds.

Scholl, David, Amman, Scott

Advances in Joining Technology Relative to Vibration Welding of Carpet and Fabric to Interior Door Panels and Other Automotive Interior Components

9809962/23/1998

Vibration welding has been acknowledged for decades as a viable, cost-effective alternative to the use of mechanical fasteners and adhesives in a range of automotive applications. These are primarily applications in which polymer parts are joined to like polymer parts to produce a weld which is more robust than that provided by other non-welding methods, such as hot melt adhesive. This technology and the equipment which supports it has enabled carmakers and Tier I suppliers to expand the use of state-of-the-art polymers into interior and exterior components which include those requiring a high level of structural integrity. The purpose of this paper is to illustrate in detail the use of similar, patented technology to create comparable robust fastening of polymer interior components (such as interior door panels) to carpet or fabric inserts which have previously been applied utilizing either other less effective or more costly processes, or processes requiring costly secondary operations. This paper explains the process and equipment used, requirements for specific parts to be welded, and the quality of the resulting components including performance and cost comparisons with alternative processes.

Laflamme, Raymond

Seamless Passenger Side Air Bag Doors

9604032/1/1996

Passenger side air bags have been rapidly accepted by the public for the protection they provide; however, in exchange, they have created an issue with fit and finish detracting from the harmony and flow-through styling presently in vogue in vehicles. With the current plethora of materials and processes used to manufacture separate passenger side air bag doors and the inability to build components to a line on line fit, attempts to tune all these factors is a lesson in frustration. In 1992, a design and development team from Textron, Chrysler, Dow, and Allied Signal were given the assignment of making the 1996 Voyager/Caravan the industies first fully integrated seamless passenger air bag (PAB) door. Several critical factors had to be addressed: 1) split seam appearance 2) pab deployment at all temperatures 3) instrument panel integrity 4) customer abuse 5) head impact 6) manufacturability 7) foam retention As a result of their effort, a padded surface instrument panel without any visible seams over the PAB, was implemented into production on the 1996 Chrysler Voyager and Plymouth Caravan models. A vinyl skin is cast with a preferentially weakened section to allow predictable tearing during air bag deployment. The shell is processed using conventional means to provide an instrument panel with a mid-mount PAB canister and an insert molded plastic/steel door that has no distinguishing features to indicate where the bag will deploy. This provides a seamless flow-through appearance, optimizing color, gloss, grain and dimensional match.

Iannazzi, Peter, Daris, Fred

Passive Learning; Putting Simplicity Back Into Driving

9519588/1/1995

The future of automotive transportation is very promising with many exciting systems and features designed to enhance customer comfort, convenience and safety. That technology will be meaningless if it is not designed to be readily accepted and easily understood by the customer. A passive system that quietly and unobtrusively “learns” driver tendencies and preferences and uses that knowledge to adjust various vehicle systems will minimize customer apprehension about new technology and increase it's acceptance and usage. Future transportation technology must be designed to adapt to each customer's expectations and abilities or we are apt to receive messages like ..... Disc Error On Driver One!

Doble, Michael E.

Low Frequency Design Considerations for Automotive Audio Systems

9501812/1/1995

The automobile interior is a challenging environment for the audio system designer. Yet, the literature related to automotive acoustics is sparse compared to the amount of published information on the acoustics of rooms and performance spaces. This paper addresses three areas of importance to the design of high fidelity autosound systems. First, it is difficult to accurately predict the nature of the listening acoustics in a car at low frequencies because complex interior geometries make mode calculations almost impossible. At the same time, the cabin interior introduces acoustic gain in the first three octaves of musical reproduction. Secondly, the car environment is subject to constantly changing levels of so-called road noise that mask musical material at low frequencies. Finally, a simplified model is proposed for the characterization of the car door as a loudspeaker enclosure. Measurement data are presented to illustrate the nature of low frequency gain in automobile cabins and to evaluate the feasibility of the proposed enclosure model.

Rieder, Robert Wm.

Intrinsically Foamed SMA in Interior Trim Applications

9407083/1/1994

Co-Polymers of styrene and maleic anhydride have been around since the '40's. The addition of maleic anhydride to the polymer backbone has a two fold effect; firstly, it increases chain stiffness and secondly chain-chain interactions are increased. Both of these effects increase the glass transition temperature of the co-polymer. A production technology has been developed which enables to generate co-polymers containing a relatively high maleic anhydride content (typically up to 35 wt %) resulting in materials with glass transition temperatures up to 170 °C. A technology has been discovered and patented whereby these high maleic anhydride containing co-polymers can, under the influence of the right chemistry and temperatures (between 230 - 260 °C), release carbon dioxide which is then used as the blowing agent to generate low density (intrinsically blown) foams. In general these foams are produced on tandem foaming lines and typically have the following property profile: The advantages of SMA-foam produced by the intrinsic foaming technology are obvious: High temperature resistance. Environmental friendly (no CFC or hydrocarbon emission). Low cost. Based on this intrinsically blown SMA foam, a new generation of headliners has been developed. The thermomechanical properties of these headliners are comparable to those of structures based on thermosetting polyurethane. The SMA used in the headliners can be recycled using a “solvent recycling” process. Due to the large segmental repulsion between the polar/a-polar monomer units SMA forms miscible or compatible blends with a large range of polymers or co-polymers, which effectively reduces this internal repulsion. Examples of polymers which are compatible with SMA are PMMA, SAN, PVC, PCL, ABS, PA and PET. This broad miscibility/compatibility range enhances options for recycling.

Gill, J. S., Härtel, V., Schoot, H. G.

New Developments in Low Density RIM Composites for Interior Trim

9407033/1/1994

The use of low density reinforced Reaction Injection Molded (RIM) substrates for covered interior automotive articles continues to increase globally. Reduced party mass, consolidation of manufacturing steps (labor), and the use of aluminum tooling, instead of steel, are cited advantages that LD-RIM offers when compared to traditional wood based and thermoplastic materials. Two RIM processes are successfully being used to produce covered interior door panels. Low density structural RIM (LD-SRIM), utilizing conventional RIM equipment, involves the placement of a pre-cut fiberglass mat in the tool cavity prior to open-pour injection of the 2-stream liquid urethane components. Low density reinforced RIM (LD-RRIM), utilizing lance cylinder RIM equipment, incorporates reinforcing fibers, such as milled fiberglass or wollastonite, in the liquid resin component. The liquid resin containing reinforcing filler is injected with the isocyanate component into a closed mold. Both LD-SRIM and LD-RRIM covered door panels meet OEM performance specifications. Little difference exists between LD-SRIM and LD-RRIM substrates, aside from tool design considerations and processing with either glass mat or reinforcing filler. In-mold polymer cure times and pressure/temperature profiles are essentially the same for both processes, and are dependent on the polyurethane components (i.e. polyol, catalysts etc.) employed, polyurethane wall thickness, and polyurethane density (1). Aluminum production tools are preferred because: 1) the polyurethane substrates are “class B surfaces” and do not have the distinctness of image requirements which “class A” parts obtain from steel surfaces, 2) the low level of reinforcement (< 20 percent by weight of the substrate) is non-abrasive to the tool surface, and 3) the low tonnage (<100 ton) RIM clamps which are used. Advancements have been made in LD-RIM substrates to reduce weight further, to proliferate the LD-RIM substrate to other automotive applications, to demonstrate the recyclability of both PVC covered LD-SRIM and LD-RRIM substrates, and to impart “self-release” properties of the LD-RIM substrate from aluminum production tools.

Weaver, Laura B., Ference, Donald M., Laux, Joseph J.

Measurement of Airborne Noise Reduction of Production Door Components on a Buck

9312695/1/1993

Various automobile door components were evaluated for air-borne noise reduction using production and prototype door assemblies which were modified to fit an SAE J-1400 test fixture. The in-door laboratory evaluation provided a single noise reduction rating in decibels for diverse door assembly components, with different noise reduction mechanisms. This test method overcame some of the shortcomings associated with evaluating each component individually in accordance with an acoustical material test standard.

Kawenski, Ted M.

Adding New Dimensions to Automotive Interiors with Lightweight RIM Composites

9204982/1/1992

The use of lightweight reinforced RIM composite substrates is increasing globally with primary focus on interior door panels, instrument panels, and package shelves. Each of these automotive interior applications has unique performance requirements. This paper will describe advances in polyurethane chemistry and low cost fillers suitable for current fully covered interior door panel production programs. Advances in polyurethane chemistry include improvements in polyurethane release characteristics from the mold by incorporation of internal mold release agents. A 7-10 % reduction in raw material cost is achievable by using low cost fillers, such as wollastonite, yielding mechanical properties essentially equivalent to door panel substrates utilizing fiberglass mat reinforcement. A method of obtaining value by recycle of in plant scrap and trim into like products will also be reviewed.

Weaver, Laura

Transient Vibration Analysis During the Door Closing by Using the Laser Holography Method

91251811/1/1991

The door closing sound is one of the important quality of a vehicle, and it is useful to study the improvement method of closing sound. As a step to clarify the relationship between the door structure and closing sound, it is attempted to correlate the formation of closing sound with the vibration, and explained that the effect of structural modification aimed to improve the closing sound from the viewpoint of vibration. First, the formation process of the vibration during the door closing is clarified through the analysis method of transient vibration using the pulse laser holography. And the quality of closing sound are evaluated based on the time historical fluctuation of frequency characteristics. Next, the correlation between the closing vibration and sound are studied, and for the case of that the closing sound are changed by the structural modification, the correlation are confirmed.

Kurata, Yuji, Oka, Yoshio

Overview of a Study on Direction-of-Motion Stereotype Strengths for Automobile Controls

910115

2/1/1991

Virginia Polytechnic Institute and State University recently conducted an SAE sponsored research study investigating directional stereotypes of six types of automobile controls: power mirrors, power windows, manual windows, stalks, generic controls, and power door locks. The objective was to determine stereotype strength and the reasons for the strengths. Two hundred subjects participated in this study. This paper provides an overview of the results of the study and recommendations made therefrom.

Wierwille, Walter W., McFarlane, John

Advances in Urethane Foam Composites for Interior Trim

910520

2/1/1991

The use of low density urethane foam composites in automotive interior trim is an established technology. In existing applications such as door trim panels, increasing production volumes are providing the impetus for process modifications and improved formulations. In emerging applications such as instrument panel covers new performance requirements must be met. The development of new Baydur STR/F formulations to address these needs are discussed.

Dempsey, Michael P., Hurley, Michael F.

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