Vehicle Upper Dashboard Stiffener Design for Rigidity and Noise Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing vehicle front structure has poor utilization of space under the upper dashboard for mounting parts, inadequate rigidity, and generates low-frequency noise due to resonance with vehicle vibrations, and the reinforcement of the upper dashboard is not efficient, especially when trying to suspend heavy loads or maintain brake parts.
Innovation Solution
A vehicle front structure with a stiffener extending in the vehicle width direction, integrally formed with transversal and longitudinal elements connecting the damper housings, and featuring cutout portions for exposing the damper housings to facilitate welding and load transfer, enhancing rigidity and allowing for the suspension of heavy loads while reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the upper dashboard is made large-sized to separate the engine compartment and vehicle compartment, then the space utilization under the dashboard is improved, but the rigidity and strength of the upper dashboard deteriorate, making it unable to support heavy loads
Solution Approach 1:
The upper dashboard is divided into multiple sections with longitudinal grooves formed at regular intervals, creating segmented structural units that maintain rigidity while allowing space utilization. The grooves create rigid hollow sections that prevent dashboard deformation without compromising the overall large size needed for space utilization.
Solution Approach 2:
The upper dashboard employs a composite structure combining the dashboard panel with integrated longitudinal grooves forming rigid hollow sections. This composite design creates a structurally reinforced configuration that simultaneously achieves large size for space utilization and sufficient rigidity through the hollow section reinforcement.
2Strength
If drain grooves with U-shaped cross section are formed in the upper dashboard to enhance strength, then the section modulus is reinforced, but the weight that can be suspended remains small and further rigidity reinforcement is desired
Solution Approach 1:
Multiple longitudinal grooves are formed at regular intervals across the upper dashboard, segmenting the dashboard into multiple rigid hollow sections. This segmentation multiplies the reinforcement effect, significantly increasing the suspension weight capacity beyond what a single U-shaped groove could achieve.
Solution Approach 2:
The reinforcement structure extends in the longitudinal direction of the vehicle with multiple grooves spaced at regular intervals, adding a dimensional aspect to the reinforcement. This longitudinal distribution of rigid hollow sections throughout the dashboard greatly enhances the overall rigidity and suspension capacity.
3Stability of the object's composition
If the end portions of the upper dashboard are joined to the damper housings to connect them, then the structural connection is achieved, but the space utilization under the dashboard deteriorates, making it difficult to mount brake-parts or other components
Solution Approach 1:
The damper housing is positioned within the engine compartment space, with the upper dashboard extending over it. The longitudinal grooves in the dashboard create nested rigid hollow sections that provide structural connection while preserving the underlying space for mounting brake-parts and other components beneath the dashboard.
Solution Approach 2:
The upper dashboard provides localized structural connection at specific points while maintaining open space in other areas. The longitudinal grooves create localized rigid sections for structural integrity, while the spaces between and beneath these sections remain available for component mounting, achieving local quality differentiation.
4Strength
If a stiffener is fixedly installed to the upper face of the upper dashboard to connect the right and left damper housings, then the body rigidity around the damper housing is improved, but the welding becomes difficult requiring at least three steel plates in overlapped state
Solution Approach 1:
The stiffening function is segmented into multiple longitudinal grooves distributed across the upper dashboard rather than requiring a single complex overlapped plate structure. Each groove creates an independent rigid hollow section that contributes to overall body rigidity, simplifying the manufacturing process.
Solution Approach 2:
The upper dashboard itself becomes a composite structural element with integrated longitudinal grooves forming rigid hollow sections, eliminating the need for separate stiffener plates. This integrated composite design achieves body rigidity enhancement without the welding complexity of multiple overlapped steel plates.
5Volume of moving object
If the upper dashboard is made large-sized, then low-frequency noise (drumming noise) is generated due to resonance with vehicle vibration, but noise suppression is demanded
Solution Approach 1:
The large-sized upper dashboard is segmented by longitudinal grooves into multiple rigid hollow sections. This segmentation prevents the dashboard from acting as a single large resonant surface, thereby suppressing low-frequency drumming noise while preserving the overall large size needed for space utilization.
Solution Approach 2:
The longitudinal grooves create curved hollow sections within the flat dashboard surface. These curved rigid hollow sections alter the vibrational characteristics of the dashboard, suppressing resonance and low-frequency noise generation while maintaining the large dashboard size for space utilization.
Data Source
AI summary
A vehicle front structure includes: a lower dashboard; an upper dashboard frontward extending from an upper end portion of the lower dashboard, both the lower and upper dashboards partially defining an engine compartment; damper housings disposed on a right side and a left side of the engine compartment, with right and left ends of the upper dashboard being joined to the respective damper housings; and a stiffener extending in a vehicle width direction which is fixed to an upper portion of the upper dashboard, wherein the stiffener is integrally formed of: a first transversal element connecting an upper portion of the right damper housing and an upper portion of the left damper housing; a second transversal element extending in the vehicle width direction and positioned rearward relative to the first transversal element; a plurality of longitudinal elements each connecting the first transversal element and the second transversal element.