Instrument Panel Cross Beam Assembly Using a Floor Console Load Path
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Solution Overview
Problem
Existing vehicle designs face challenges in achieving a sturdy structure with reduced material use, lower weight, and simplified assembly processes while maintaining structural integrity and safety.
Innovation Solution
The instrument panel cross beam is supported by a support strut that extends to a console on the vehicle floor via a load path, eliminating direct connection to the floor and utilizing the console to bridge the gap, thereby reducing material and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support strut directly connects the instrument panel cross beam to the vehicle floor, then structural stability is ensured, but material consumption and weight increase
Solution Approach 1:
The patent combines the support strut function with the console structure by integrating the support strut into the console assembly. The console serves dual purposes: as a functional vehicle component and as part of the load-bearing support structure, eliminating the need for separate heavy support elements and reducing overall material consumption while maintaining structural stability.
Solution Approach 2:
The console is designed to perform multiple functions: it serves as a functional vehicle component (storage, armrest, etc.) and simultaneously acts as part of the load-bearing support structure. This multi-functionality allows the same structural elements to provide both operational functionality and structural support, reducing the need for additional dedicated support components and thereby reducing weight.
2Strength
If the support strut directly connects to the vehicle floor, then load-bearing capacity is sufficient, but the number of assembly steps and connecting elements increases
Solution Approach 1:
The patent merges the support strut connection with the console attachment to the vehicle floor. Instead of requiring separate connecting elements for the support strut and the console, the integration allows both components to be attached together in a single assembly operation, reducing the number of connecting elements and simplifying the assembly process while maintaining adequate load-bearing capacity.
Solution Approach 2:
The support strut is pre-integrated into the console assembly during manufacturing, creating a pre-assembled unit that requires fewer on-vehicle assembly steps. This preliminary action of combining components before installation reduces the complexity of the assembly process and minimizes the number of connecting elements needed during final vehicle assembly.
3Loss of substance
If the support strut is shortened by using the console as an intermediate structure, then material usage is reduced, but the direct force-conducting connection to the floor is eliminated
Solution Approach 1:
The patent combines the support strut with the console structure, creating an integrated load path where forces are transmitted through the console's structural elements to the vehicle floor. This merging maintains reliable force-conducting connection while allowing the support strut to be shorter, as the console provides additional structural continuity and load transmission capability, thereby reducing material usage without compromising reliability.
Data Source
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AI summary
The invention relates to a vehicle (1), in particular motor vehicle, having a vehicle body (2) with side parts (3) opposite one another at a distance and with a vehicle floor (4), wherein an instrument panel cross beam (5) is arranged between the side parts (3) and attached thereto and a console (6) is arranged on the vehicle floor (4) and attached thereto, wherein at least one support strut (7) extends from the instrument panel cross beam (5) in the direction of the vehicle floor (4), wherein the console (6) is located in the load path between the support strut (7) and the vehicle floor (4). The invention further relates to a method for assembling an instrument panel cross beam (5) on a vehicle body (2) of a vehicle (1).