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This paper reviews the state of the art on analytical design of cockpit modules in two most crucial performance categories: safety and comfort. On safety, applications of finite element analysis (FEA) for achieving robust designs that meet FMVSS 201, 208 and 214 requirements and score top frontal and side NCAP star-ratings are presented. On comfort, focus is placed on Noise, Vibration and Harshness (NVH) performance. Cutting-edge analytical tools for Buzz, Squeak and Rattle (BSR) avoidance and passenger compartment noise reduction are demonstrated. Most of the analytical results shown in this paper are based on the development work of a real-life application program. Correlations between the analytical results and physical test results are included. Examples of Computational Fluid Dynamics (CFD) analysis for climate control are also included. At the end, the road map toward 100 percent virtual prototyping and validation is presented.

Components to provide instrument panel system structure have typically involved the use of steel, magnesium or aluminum or various combinations of these materials. Some concepts have also involved the use of plastic components to provide partial system structure. Most of these concepts have required the use of additional components to provide for air distribution ductwork. The concept which is the subject of this paper is the use of a composite structural plastic beam to provide total unassisted system structure while also providing HVAC air distribution ductwork. The analytical models used to develop this system will be described. Test results will be presented for actual injection molded and assembled composite beams and compared to those predicted by the analytical models.

The objective of this paper is to discuss the process, from design conception through analytical simulation to experimental test, of the development of a composite cross car beam for a passenger vehicle application. Over the past five years there has been considerable interest in the development of cross car beams, which serve as the main component for support of the Instrument Panel (I/P) structure and related systems. Stringent design requirements for vehicle Noise, Vibration and Harshness (NVH), durability and crashworthiness have driven the role of cross car beams to new levels. In addition, new styling trends, such as cabin forward design, and new vehicle manufacturing and assembly methods, such as cockpit build, have also placed demands on the role of cross car beams.