Vehicle Instrument Panel Head Impact Issue Solving Based On DFSS

This thesis is focused on Interior Cockpit System of one Export program, beginning with deep diving into the Cockpit System structure and GB11552 Head Impact requirement, and manage the Head Impact issue solving process well with DFSS, so the issue is solved before the due date. During the issue solving, DFSS provide guidance on the issue definition, solving direction and optimization of proposals, and CAE tool ensures the issue solved timely.Due to removing the PAB on one of the cockpit system, and the structure of the original PAB area the vehicle failed to pass the physical verification test of GB11552. To simulate the serious deformation and the broken connection during the test using CAE method, the CAE method need to recur the physical failure, and the CAE analysis target need to be quantified. Pugh Concept selection method is used to find the key to the issue, and recurring to the CAE analysis of the different proposals, the key factors to the system is caught and they need to be optimized with different levels. After all of the virtual tests finished, the optimized proposal comes forth.The design part is manufactured in a short time, and the GB 11552 verification test with the optimized design is passed.The head impact issue solving process on cockpit system and the method used during the product development can be shared for the head impact issue solving later. The CAE usage on the issue prediction and issue solving of head impact provide a good example of CAE driving design in the vehicle development.