Automobile dashboard support and dashboard

Abstract

The invention provides an automobile instrument panel support and an instrument panel, and belongs to the field of structural design of automobile instrument panel supports. The automobile dashboard support comprises a steering column support assembly, a tubular beam and welding small support assembly, a middle connecting support and an electric appliance module support, the steering column support assembly is formed by extruding aluminum alloy, the tubular beam is formed by a high-strength steel hot air expansion process, the welding small support assembly is formed by punching common steel, and the middle connecting support is connected with the electric appliance module support. The middle connecting support and the electric appliance module support are both made of microfiber plastics in an integrated injection molding mode. According to the invention, the design and development of the instrument panel bracket with light weight and high performance are realized, so that the mold of the instrument panel bracket is shared to the maximum extent, the investment of one-time tool cost is reduced, and the iteration of a low-cost high-end framework is realized.

Description

Technical Field

[0001] The invention belongs to the field of automobile instrument panel bracket structure design, and in particular relates to an automobile instrument panel bracket and an instrument panel. Background Art

[0002] At present, the raw materials of automobile dashboard brackets are mostly steel plates, mainly DC01 (stamping brackets, all brackets except tube beams) and Q215 (tube beams), and their processing technology is mainly stamping and welding.

[0003] like Figure 1 As shown, the above structure has the following problems:

[0004] 1) Steel has high density and heavy parts, which is not conducive to lightweighting;

[0005] 2) Stamping molds have high costs and long cycles;

[0006] 3) Compared with aluminum alloy, welded parts have lower modal under the same weight, which makes the steering wheel prone to resonance;

[0007] 4) The instrument panel bracket is welded using CO2 shielded welding, the welding accuracy is relatively poor and relies on later correction. Summary of the invention

[0008] The purpose of the present invention is to solve the problems existing in the above-mentioned prior art, to provide an automobile dashboard bracket and dashboard, to achieve the design and development of a lightweight, high-performance dashboard bracket, to maximize the sharing of the dashboard bracket mold, and to reduce the investment in one-time tooling costs.

[0009] The present invention is achieved through the following technical solutions:

[0010] A car dashboard bracket comprises a steering column bracket assembly, a pipe beam and a welded small bracket assembly, an intermediate connecting bracket, and an electrical module bracket. The steering column bracket assembly is formed by extrusion of aluminum alloy, the pipe beam is formed by a high-strength steel hot air expansion process, the welded small bracket assembly is formed by stamping of ordinary steel, and the intermediate connecting bracket and the electrical module bracket are both integrally injection-molded by ultra-fiber plastic.

[0011] Preferably, the steering column bracket assembly and the tube beam are riveted without rivets.

[0012] Preferably, the steering column bracket assembly comprises a steering connection bracket, a rotating shaft bracket and a steering mounting bracket; the steering connection bracket, the rotating shaft bracket and the steering mounting bracket are connected in pairs by MIG welding.

[0013] Preferably, the connection between the rotating shaft bracket and the steering connection bracket is a planar connection.

[0014] Preferably, a total of four upper and lower surfaces are formed in the steering column connection area of ​​the tube beam, and the steering mounting bracket and the steering connecting bracket are riveted to the upper and lower planes on the same side without rivets respectively.

[0015] Preferably, the electrical module bracket includes a fuse box bracket and an IBC bracket; rivet-free riveting is adopted between the upper end of the fuse box bracket and the pipe beam, and between the IBC bracket and the side of the steering connection bracket.

[0016] Preferably, rivet-free riveting is adopted between the intermediate connecting bracket and the tube beam.

[0017] Preferably, the rivet-free riveting is performed by connecting the upper layer with a steel plate and the lower layer with an aluminum plate.

[0018] Preferably, the welded small bracket assembly is connected to the pipe beam by CO2 shielded welding.

[0019] Preferably, the models of the aluminum alloy, high-strength steel, ordinary steel and ultra-fiber plastic are: 6063T6, Br1500Hs, DC01 and PA6+60GF respectively.

[0020] A car dashboard comprises a body and a car dashboard bracket as described above and arranged on the body.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. Under the condition of meeting the modal performance, it is lighter than the traditional steel structure bracket, achieving an overall weight reduction of 25%-35%, and improving the steering modal performance of the steering wheel by 10%-15%, realizing the design and development of a lightweight and high-performance dashboard bracket, which is conducive to the lightweighting and endurance improvement of new energy vehicles.

[0023] 2. The mixed application of multiple materials meets the architecture platform strategy of the dashboard bracket while achieving low cost, maximizes the sharing of the dashboard bracket mold, reduces the investment in one-time tooling costs, and realizes the iteration of low-cost high-end architecture (low-end refers to the traditional sheet metal dashboard bracket, which is low cost and heavy weight; high-end refers to the dashboard bracket using multiple materials, which is light weight and slightly higher cost). BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a structural diagram of a traditional sheet metal welded instrument panel bracket;

[0025] Figure 2 A structural diagram of the instrument panel support provided by the present invention;

[0026] Figure 3 This is a process diagram of connecting the instrument panel bracket of the present invention;

[0027] Figure 4 This is a schematic diagram of the hot gas expansion process for forming a tube beam-high-strength steel;

[0028] Figure 5 This is a comparative analysis diagram of the steering column bracket assembly before and after optimization;

[0029] Figure 6 A schematic diagram of the architecture platform of the extruded aluminum-steering column bracket assembly;

[0030] Figure 7 A cross-sectional view of a rivet-free riveting method used in the present invention;

[0031] Figure 8 This is a test diagram of the mechanical properties of rivet-free riveting used in the present invention;

[0032] Fig. 9 It is a schematic diagram of the platform structure of the microfiber plastic-intermediate connecting bracket;

[0033] Fig.10 This is a comparative analysis diagram of the microfiber plastic-intermediate connecting bracket before and after optimization;

[0034] Fig.11 Schematic diagram of the architecture strategy of the electrical module bracket. DETAILED DESCRIPTION

[0035] The present invention is further described in detail below in conjunction with the accompanying drawings:

[0036] The "platformization" mentioned in the present invention refers to the realization of mold sharing of the instrument panel bracket.

[0037] like Figure 2 As shown, the present invention aims at the traditional sheet metal welded instrument panel bracket (CCB, full name Car Cross Beam), and develops an instrument panel bracket with mixed application of multiple materials, including a steering column bracket assembly 1, a pipe beam 2 and a welded small bracket assembly 3, an intermediate connecting bracket 4, and an electrical module bracket 5. The multiple materials include four materials, namely aluminum alloy 6063T6, high-strength steel Br1500Hs, ordinary steel DC01, and ultra-fiber plastic PA6+60GF; multiple connection methods are adopted, namely MIG welding (MIG full name Melt Inert-Gas Welding, molten inert gas shielded welding), CO2 shielded welding, one-piece injection molding, and rivet-free riveting. The multiple materials adopt a variety of connection methods, such as Figure 3 shown.

[0038] Compared with an all-steel instrument panel bracket, the present invention achieves an overall weight reduction of 25%-35%, improves the steering wheel steering modal performance by 10%-15%, and realizes the design and development of a lightweight, high-performance instrument panel bracket.

[0039] like Figure 4 As shown, the tube beam 2 is made of high-strength steel (Br1500Hs) by hot air expansion process, which can form a tube beam with complex cross-section. The ultra-high strength tube beam formed by hot air expansion can effectively improve the collision, stiffness and NVH (Noise, Vibration, Harshness) performance of the whole vehicle. In one embodiment of the present invention, relative to the Q215 material, the overall wall thickness of the tube beam 2 is reduced from 1.8mm to 1.2mm; in the steering column connection area on the tube beam 2, after the tube beam 2 is formed by hot air expansion process, the cross-sectional area is reduced from 3025mm shown in AA. 2 Raised to 4345mm as shown on BB 2 The present invention uses a high-strength steel hot air expansion process to achieve seamless cross-section variation of the tube beam 2, increase the thermal expansion rate by 30%-40%, and improve the performance of the steering mode while reducing weight. The tube beam 2 formed by the high-strength steel hot air expansion process is 30%-40% lighter than ordinary steel tube beams.

[0040] The welded small bracket assembly 3 is an existing structure, including brackets other than the steering column bracket assembly 1, the tube beam 2, the intermediate connecting bracket 4 and the electrical module bracket 5, and is stamped with DC01 material and connected to the tube beam 2 by CO2 shielded welding.

[0041] like Figure 5 As shown, the steering column bracket assembly 1 includes a steering connection bracket 11, a shaft bracket 12 and a steering mounting bracket 13, all of which are extruded from aluminum alloy (6063T6). The steering connection bracket 11, the shaft bracket 12 and the steering mounting bracket 13 are connected in pairs by MIG welding. Aluminum alloy extrusion stamping profiles have better elongation performance, yield strength and tensile strength, and aluminum alloy has low density and light weight. Extrusion stamping can obtain excellent surface quality and dimensional accuracy. The extrusion stamping formed bracket can be combined with a CAE finite element simulation model to optimize the thickness of the cross section and the design scheme to achieve the lowest weight and the best mode, so that the steering column bracket assembly 1 can achieve a weight reduction of 45%-50%. In one embodiment of the present invention, the cross section of the bracket formed by extrusion stamping (attached Figure 5 The thickness of the M / V-shaped section was optimized from 2.5mm to 2.0mm, reducing the weight by 0.23kg; the first-order lateral mode was increased by 1.5HZ, and the first-order vertical mode was increased by 2.1HZ; the tolerance of welding accuracy was ±0.7mm, and the accuracy was also improved.

[0042] like Figure 6As shown, the steering column bracket assembly 1 and the tube beam 2 are riveted without rivets. Specifically, four upper and lower surfaces are formed at the connection of the tube beam 2 (left and right surfaces are set on the upper side, and left and right surfaces are also set on the lower side accordingly), and then the steering mounting bracket 13 and the steering connecting bracket 11 are respectively riveted with the upper and lower planes on the same side without rivets. Since the riveting is detachable, it can be rotated to any angle ① and moved to any position ② according to the overall layout of different vehicle models. After disassembly, it can be re-riveted based on the new angle, so that the extrusion mold of the steering column bracket assembly 1 can be shared, meeting the architecture platform strategy. Riveting can achieve that when the steering hard point of different vehicle models is different from the human-machine H point, the steering column bracket assembly 1 can rotate 360° around the tube beam 2 to meet the column position requirements of different H points of the architecture. The connection between the pivot bracket 12 and the steering connection bracket 11 is a planar connection, realizing four-way / two-way platformization of different architectures (the steering wheel drives the steering column bracket assembly 1 to rotate, adapting to the driver's human machine, the two-way adjustment is up and down adjustment, and the four-way adjustment is up, down, left and right adjustment). When the steering column is used, it is assembled through welding at different positions to meet functional requirements. The molds of the steering connection bracket 11 and the pivot bracket 12 can be shared, and the steering column bracket assembly 1 is platformized to meet the platformization strategy of the architecture dashboard bracket.

[0043] like Figure 7 , Figure 8 As shown, the mixed use of high-strength steel and aluminum alloy can maximize the lightweight of the dashboard bracket at a low cost. However, the current welding connection between high-strength steel and aluminum alloy is poor, and the natural cooling of the weld affects the performance of the high-strength steel at the connection point, and the strength limit is only 1 / 3 of the original. The present invention adopts a rivet-free riveting process to achieve the connection of dissimilar metals, and the connection of multiple materials has no stress concentration, good dynamic strength, high efficiency and low cost. Through mechanical property testing, it can be seen that rivets with larger diameters and lower hardness are more conducive to connecting high-strength steel; at the same time, from the modal analysis results, it can be seen that rivet-free riveting is suitable for connecting the upper layer with steel plate and the lower layer with aluminum plate.

[0044] like Fig. 9 , Fig.10 As shown, the intermediate connecting bracket 4 is made of ultra-fiber plastic (PA6+60GF) material and is integrally injection molded. Compared with the traditional DC01 stamping bracket structure, it is lighter and stronger. The intermediate connecting bracket 4 and the pipe beam 2 are riveted without rivets. The present invention can rotate to any angle ① and move to any position according to the overall layout of different vehicle models, meet the requirements of architecture platformization, realize the sharing of the intermediate connecting bracket 4, and reduce the one-time development cost of the injection mold. In one embodiment of the present invention, the integrally injection molded intermediate connecting bracket 4 achieves a weight reduction of 27.92% and a steering mode (first-order lateral) improvement of 2.4HZ.

[0045] like Fig.11As shown, the electrical module bracket 5 includes a fuse box bracket 51 and an IBC bracket 52 (IBC stands for Intelligent Brake Control, intelligent brake control system), both of which are integrally injection molded with microfiber plastic (PA6+60GF) material. The upper end of the fuse box bracket 51 is connected to the pipe beam 2, and the IBC bracket 52 is connected to the side of the steering connection bracket 11, respectively realizing PRT connection with high-strength steel and aluminum alloy (in the present invention, it refers to rivetless riveting). This structure has no effect on the modality, realizes the architectural strategy of "using plastic instead of steel" for the module bracket, and reduces weight by 35%-45%.

[0046] The connection of multiple materials usually takes into account the differences between materials, such as thermal expansion coefficient, mechanical properties, etc., to ensure the strength and stability of the connection. The present invention targets the key technical field of multiple material connection technology, overcomes the self-piercing riveting connection technology and the hot-melt self-tapping connection technology, and realizes the research on multiple material connection. The mixed use of high-strength steel, aluminum alloy, high-glass brazing plastic and other materials in the dashboard bracket can maximize the lightweight of the car while saving energy and protecting the environment.

[0047] The present invention also provides an automobile instrument panel, which comprises a body and an automobile instrument panel bracket of any structure described above arranged on the body.

[0048] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] In the description of the present invention, unless otherwise specified, the terms "upper", "lower", "left", "right", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0050] The above technical solution is only one implementation mode of the present invention. For those skilled in the art, it is easy to make various types of improvements or modifications based on the principles disclosed in the present invention, and it is not limited to the technical solution described in the above specific embodiments of the present invention. Therefore, the above description is only preferred and does not have a restrictive meaning.

Claims

1. An automobile instrument panel bracket, comprising a steering column bracket assembly, a pipe beam and a small welded bracket assembly, an intermediate connecting bracket, and an electrical module bracket, characterized in that: The steering column bracket assembly is extruded from aluminum alloy, the tube beam is formed by hot air expansion process of high-strength steel, the welded small bracket assembly is stamped from ordinary steel, and the middle connecting bracket and electrical module bracket are both integrally injection molded from microfiber plastic.

2. The automobile dashboard bracket according to claim 1, characterized in that: The steering column bracket assembly and the tube beam are riveted without rivets.

3. The automobile dashboard bracket according to claim 2, characterized in that: The steering column bracket assembly comprises a steering connection bracket, a rotating shaft bracket and a steering mounting bracket; the steering connection bracket, the rotating shaft bracket and the steering mounting bracket are connected in pairs by MIG welding.

4. The automobile dashboard bracket according to claim 3, characterized in that: The connection between the rotating shaft bracket and the steering connecting bracket is a planar connection.

5. The automobile dashboard bracket according to claim 3, characterized in that: A total of four upper and lower surfaces are formed in the steering column connection area of ​​the tube beam, and the steering mounting bracket and the steering connecting bracket are riveted to the upper and lower planes on the same side without rivets respectively.

6. The automobile dashboard bracket according to claim 3, characterized in that: The electrical module bracket includes a fuse box bracket and an IBC bracket; the upper end of the fuse box bracket and the pipe beam, as well as the side of the IBC bracket and the steering connection bracket are all riveted without rivets.

7. The automobile instrument panel bracket according to claim 1, characterized in that: Rivet-free riveting is adopted between the middle connecting bracket and the pipe beam.

8. The automotive dashboard bracket according to any one of claims 2 to 7, characterized in that: The rivet-free riveting is performed by connecting the upper layer with a steel plate and the lower layer with an aluminum plate.

9. The automotive dashboard bracket according to any one of claims 1 to 7, characterized in that: The welded small bracket assembly is connected to the pipe beam by CO2 shielded welding.

10. The automobile dashboard bracket according to any one of claims 1 to 7, characterized in that: The models of the aluminum alloy, high-strength steel, ordinary steel and ultra-fiber plastic are: 6063T6, Br1500Hs, DC01 and PA6+60GF respectively.

11. An automobile instrument panel, characterized in that: The automobile instrument panel comprises a body, and an automobile instrument panel bracket as claimed in any one of claims 1 to 10 arranged on the body.

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