DESC:CROSS REFERENCE TO RELATED APPLICATION
This Application is based on and derives the benefit of Indian Provisional Application 202321053809 filed on 10th August 2023, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[001] The embodiments herein generally relate to cross car beams of vehicles and more particularly, to a cross car beam assembly for a vehicle and an assembly method thereof.
BACKGROUND
[002] Generally, a cross car beam is used for mounting of the steering wheel and forms an important part of the vehicle's overall structural framework. The cross car beam is primarily designed to provide a secure mounting point for the steering column and, in turn, the steering wheel. The cross car beam is typically located within the interior of the vehicle, directly behind the dashboard. In some vehicles, the cross car beam is also designed to facilitate mounting of various parts such as the glove box, control modules and display modules, HVAC system etc.
[003] Although the existing cross car beams provided in vehicles have rigidity, there are certain drawbacks associated with the existing cross car beams. Since the cross car beam includes a plurality of parts integrated to form a unitary structure, the assembly process of the cross car beam is complex and time consuming. Some of the cross car beams are entirely made from steel, which provides rigidity to the cross car beam but adds to the overall weight of the vehicle due to the use of heavy material, which can negatively affect fuel efficiency and vehicle performance. To overcome the issue of increased weight of the cross car beams due to use of heavy material, some of the cross car beams are entirely made from aluminum. Although the use of Aluminum reduces the overall weight of the vehicle, it increases the manufacturing cost.
[004] Further, due to the design and construction of the cross car beam, manufacturing complexity and cost increases. Cross car beams require complex, high-strength joints to connect them to the vehicle's body, which increases the production cost.
[005] Therefore, there exists a need for a cross car beam assembly for a vehicle which obviates the aforementioned drawbacks.
OBJECTS
[006] The principal object of embodiments herein is to provide a cross car beam assembly for a vehicle.
[007] Another object of embodiments herein is to provide the cross car beam assembly which is easy to assemble, light weight, easy to manufacture and includes lesser number of parts.
[008] Another object of embodiments herein is to provide a method for assembly of a cross car beam assembly in a vehicle.
[009] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0011] Fig. 1 is an isometric view of a cross car beam assembly, according to embodiments as disclosed herein;
[0012] Fig. 2 is another isometric view of the cross car beam assembly, according to embodiments as disclosed herein;
[0013] Fig. 3a is an isometric view of a first structure of the cross car beam assembly, according to embodiments as disclosed herein;
[0014] Fig. 3b is an isometric view of a second structure of the cross car beam assembly, according to embodiments as disclosed herein;
[0015] Fig. 4a is an isometric view of a center part of the cross car beam assembly, according to embodiments as disclosed herein;
[0016] Fig. 4b is a front view of the center part of the cross car beam assembly, according to embodiments as disclosed herein;
[0017] Fig. 4c is a rear view of the center part of the cross car beam assembly, according to embodiments as disclosed herein;
[0018] Fig. 4d is a top view of the center part of the cross car beam assembly, according to embodiments as disclosed herein;
[0019] Figs. 5a to 5d depict isometric views of the cross car beam assembly at different stages of assembling of the cross car beam assembly; and
[0020] Fig. 6 is a flowchart depicting a method for assembly of a cross car beam assembly in a vehicle, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0021] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0022] The embodiments herein achieve a cross car beam assembly for a vehicle which is easy to assemble, light weight, easy to manufacture and includes lesser number of parts. Further, the embodiments herein achieve a method for assembly of a cross car beam assembly in a vehicle. Referring now to the drawings Figs. 1 through 6, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0023] Figs. 1 and 2 depict isometric views of a cross car beam assembly (100) for a vehicle, according to embodiments as disclosed herein. The cross car beam assembly (100) includes a first structure (102), a center part (104), and a second structure (106). For the purpose of this description and ease of understanding, the cross car beam assembly (100) is explained herein with below reference to a four wheeled passenger car. However, it is also within the scope of the invention to use/practice the components of the cross car beam assembly (100) for any other vehicle such as a commercial vehicle, racing car, etc., without otherwise deterring the intended function of the cross car beam assembly (100) as can be deduced from the description and corresponding drawings. The first structure (102) and the second structure (106) are adapted to be connected with the center part (104). The first structure (102) is adapted to be mounted towards a front passenger side in the vehicle, and the second structure (106) is adapted to be mounted towards a driver side in the vehicle.
[0024] Fig. 3a depicts an isometric view of the first structure (102), according to embodiments disclosed herein. The first structure (102) is configured to facilitate mounting of a plurality of modules in the vehicle. The first structure (102) includes a first mounting portion (102A) which is adapted to facilitate the connection of the first structure (102) with the center part (104) of the cross car beam assembly (100). The first structure (102) further includes a cross beam (102C), a first mounting bracket (102B), a first module mounting portion (102F), a second module mounting portion (102S), and a plurality of extending members (102X, 102Y, 102Z). The cross beam (102C) extends between a first end (not shown) and a second end (not shown). The first mounting portion (102A) is provided on the cross beam (102C) towards the first end of the cross beam (102C). In an embodiment, the first mounting portion (102A) is integrated with the cross beam (102C). In another embodiment, the first mounting portion (102A) is connected separately with the cross beam (102C). Further, the first mounting bracket (102B) is connected near the second end of the cross beam (102C). The first mounting bracket (102B) is adapted to facilitate mounting of the cross car beam (100) on a body in white (BIW) of the vehicle. The first module mounting portion (102F) is adapted to facilitate mounting of at least one module of an instrument panel of the vehicle. In an embodiment, the first module mounting portion (102F) is adapted to facilitate mounting of at least a glovebox of the vehicle. Furthermore, the second module mounting portion (102S) is adapted to facilitate mounting of at least one another module of the instrument panel of the vehicle. In an embodiment, the second module mounting portion (102S) is adapted to facilitate mounting of at least a HVAC system of the vehicle. The plurality of extending members (102X, 102Y, 102Z) include a first extending member (102X), a second extending member (102Y), and a third extending member (102Z). Each of the plurality of extending members (102X, 102Y, 102Z) extends transversely from the cross beam (102C) of the first structure (102) towards a front of the vehicle. The first extending member (102X) is connected near the second end of the cross beam (102C) and is configured to facilitate mounting of a plenum of the vehicle. The second extending member (102Y) is connected near a center of the cross beam (102C) and is configured to facilitate mounting of a first airbag module of the vehicle. The third extending member (102Z) is connected near the second end of the cross beam (102C) and is configured to facilitate mounting of a first display module of the vehicle. In an embodiment, the first display module is a head-up display module of the vehicle. Further, the first structure (102) includes a first longitudinal member (102D) extending downwards from the first end of the cross beam (102D) and connected to the first mounting portion (102A) of the first structure (102). The first longitudinal member (102D) is adapted to be connected to a floor of the vehicle.
[0025] In an embodiment, the first structure (102) is a unitary structure made of steel. However, it is within the scope of the invention to have the first structure (102) with a modular construction, and made of any other material such as but not limited to aluminum, magnesium alloy, etc., without otherwise deterring from the intended purpose of the cross car beam assembly (100) as can be deduced from the description.
[0026] Fig. 3b is an isometric view of the second structure (106) of the cross car beam assembly (100), according to embodiments as disclosed herein. The second structure (106) is configured to facilitate mounting of a plurality of units in the vehicle. The second structure (106) includes a second mounting portion (106A) which is adapted to facilitate the connection of the second structure (106) with the center part (104). Further, the second structure (106) includes a second cross beam (106C) extending between a third end and a fourth end, a second mounting bracket (106B), at least one first extending arm (106X), and at least one second extending arm (106Y). The second mounting portion (106A) is provided on the third end of the second cross beam (106C). In an embodiment, the second mounting member (106A) is integrated with the second cross beam (106C). In another embodiment, the second mounting member (106A) is connected separately with the second cross beam (106C). Furthermore, the at least one first extending arm (106X) is connected with the second cross beam (106C), and extends transversely from the second cross beam (106C) towards the front of the vehicle. The first extending arm (106X) is configured to facilitate mounting of the first display module. In an embodiment, the first extending arm (106X) is connected near a center of the second cross beam (106C). The at least one second extending arm (106Y) extends downwards from the second cross beam (106C), and is adapted to facilitate mounting of another airbag module of the vehicle. The second extending arm (106Y) is connected near the third end of the second cross beam (106C). Further, the second mounting bracket (106B) is connected towards the fourth end of the second cross beam (106), and is adapted to facilitate mounting of the cross car assembly (100) on the BIW of the vehicle.
[0027] In an embodiment, the second structure (106) has a unitary construction and is made of steel. However, it is within the scope of this invention to have the second structure (106) with a modular construction, and made of any other material, such as but not limited to magnesium alloy, and aluminum.
[0028] Figs. 4a, 4b, 4c, and 4d, respectively depict an isometric view, a front view, another isometric view, and a top view of the center part of the cross car beam assembly (100), according to embodiments disclosed herein. The center part (104) includes at least two mounting members (104A,104B) adapted to facilitate connection of the first structure (102) and the second structure (106) with the center part (104). A first mounting member (104A) is adapted to facilitate connection of the first structure (102) with the center part (104), and a second mounting member (104B) is adapted to facilitate connection of the second structure (106) with the center part (104). In an embodiment, each of the mounting members (104A, 104B) is a bar extending outwards from a body of the center part. The first mounting member (104A) is adapted to receive the first mounting portion (102A) of the first structure (102), and second mounting member (104B) is adapted to receive the second mounting portion (106B) of the second structure (106). The center part (104) further includes a plurality of mounting elements (104M, 104N, 104P) adapted to facilitate mounting of a plurality of components with the center part (104). In an embodiment, the plurality of mounting elements include a first mounting element (104L), a second mounting element (104M), a third mounting element (104N), and a fourth mounting element (104P). Each of the first and second mounting elements (104M) is a channel defined in the body of the center part (104). The center part (104) is adapted to accommodate/ receive a collapsing steering column between the first mounting element (104L) and the second mounting element (104M), during a frontal impact. The first mounting element (104L) is adapted to facilitate mounting of a mounting arm (not shown in Fig. 4). The second mounting element (104M) is adapted to facilitate mounting of a steering column of the vehicle. Further, the third mounting element (104N) is a bracket extending upwards from the body of the center part (104). In the embodiment, the third mounting element (104N) is provided between the first and second mounting elements (104M). Furthermore, the fourth mounting element (104P) is connected between the first and second mounting elements (104M), disposed opposite to the third mounting element (104N). The third mounting element (104N) and the fourth mounting element (104P) are configured to facilitate connection of said center part (104) with the instrument panel of the vehicle. In an embodiment, the center part (104) is a unitary structure made of magnesium. The center part (104) includes a plurality of ribs (104R) provided on the body of the center part (104) which act as reinforcement to increase rigidity of the center part (104).
[0029] Figs. 5a to 5d depict isometric views of the cross car beam assembly (100) at different stages of assembling, according to embodiments disclosed herein. The first structure (102) is adapted to be connected with the center part (104) by inserting the first mounting portion (102A) onto the first mounting member (104A) of the center part (104), and the second structure (106) is adapted to be connected with the center part (104) by inserting the second mounting portion (106A) onto the second mounting member (104B) (as shown in Fig. 5a). Each of the first mounting portion (102A), the second mounting portion (106A), the first mounting member (104A), and the second mounting member (104B) have a corresponding plurality of holes (102H, 106H, 104AH, 104BH) adapted to receive a corresponding fastening means. In an embodiment, as shown in Fig. 5b, each of the first structure (102) and second structure (106) is secured with the center part (104) through a plurality of first securing members (110). In an embodiment, the plurality of first securing members (110) are rivets adapted to be inserted into the corresponding holes (102H, 106H, 104AH ,104BH) of the first mounting portion (102A), the second mounting portion (106A), and the first and second mounting members (104A, 104B), thereby securely connecting the first and second structures (102, 106) with the center part (104). Further, in an embodiment, as shown in Fig. 5c, the mounting arm (108) is adapted to be connected with any one of the first and second mounting elements (104M) of the center part (104). In an embodiment, as shown in Fig. 5d, the mounting arm (108) is secured with the first mounting element (104L) of the center part (104) through a plurality of second securing members (112). Each of the first mounting element (104L) and the mounting arm (108) have a corresponding plurality of second holes (104MH, 108G) adapted to receive corresponding second securing members (112). In an embodiment, each of the second securing members (112) is a rivet. The mounting arm (108) is configured to facilitate connection of the cross car beam with a dash panel of the vehicle and provide stiffness near the steering column mounting area to reduce noise, vibration and harshness in the vehicle.
[0030] Fig. 6 is a flowchart depicting a method (200) for assembly for a cross car beam in a vehicle. At step (202), the method (200) includes connecting the first structure (102) of the cross car beam assembly (100) with the center part (104) of the cross car beam assembly (100). In an embodiment, at step (202), the method (200) includes inserting the first mounting portion (102A) of the first structure (102) onto the first mounting member (104A) of the center part (104), and fastening the first structure (102) with the center part (104) by fastening the plurality of first securing members (110) with the first mounting portion (102A) and the first mounting member (104A). At step (204), the method (200) includes, connecting the second structure (106) of the cross car beam assembly (100) with the center part (104) of the cross car beam assembly (100). In an embodiment, at step (204), the method (200) includes inserting the second mounting portion (106A) of the second structure (106) onto the second mounting member (104B) of the center part (104), and fastening the second structure (106) with the center part (104) by fastening the plurality of first securing members (110) with the second mounting portion (106A) and the second mounting member (104B). Further, at step (206), the method (200) includes, mounting the mounting arm (108) on any one of the plurality of mounting elements (104M, 104N, 104P). In an embodiment, the method (200), at step (206) includes, mounting the mounting arm (108) on the first mounting element (104L) of the center part (104), and securing the mounting arm (108) with the center part (104) by fastening the mounting arm (108) with the first mounting element (104L) through the plurality of second securing members (112). Further, at step (208), the method (200) includes, mounting the cross car beam assembly (100) in the vehicle by connecting the first mounting bracket (102B) and the second mounting bracket (106B) with the body in white of the vehicle. The various actions in the method (200) may be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in Fig. 6 may be omitted.
[0031] The technical advantages of the cross car beam assembly (100) for a vehicle and the method (200) for assembly of the cross car beam assembly are as follows. Integrating light weight and structurally rigid Mg alloy parts in steering mounting area of cross car beam reduces the overall weight of the vehicle, improves the performance of the vehicle, and makes the production of the cross car beam assembly cost effective. Reduced number of parts in the cross car beam assembly reduces process time and geometric accuracy and structural performance.
[0032] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein ,CLAIMS:We claim,
1. A cross car beam assembly (100) for a vehicle, said assembly (100) comprising:
a first structure (102) adapted to mount a plurality of modules of the vehicle;
a center part (104) having at least two mounting members (104A, 104B); and
a second structure (106) adapted to mount at least one unit of the vehicle,
wherein
a first mounting member (104A) of said at least two mounting members (104A, 104B) of said center part (104) is adapted to connect said first structure (102) with said center part (104), towards a front passenger side in the vehicle, and
a second mounting member (104B) of said at least two mounting members (104A, 104B) of said center part (104) is adapted to connect said second structure (106) with said center part (104), towards a driver side in the vehicle.
2. The cross car beam assembly (100), as claimed in claim 1, wherein said first structure (102) has a first mounting portion (102A) adapted to be connected with said first mounting member (104A) of said center part (104), thereby facilitating connection of said first structure (102) with said center part (104),
wherein said second structure (106) has a second mounting portion (106A) adapted to be connected with said second mounting member (104B) of said center part (104), thereby facilitating connection of said second structure (106) with said center part (104),
and wherein said center part (104) comprises a plurality of mounting elements (104M, 104N, 104P) provided on a body of said center part (104), wherein said center part (104) is adapted to receive a collapsing steering column between a space defined between a first mounting element (104L) and a second mounting element (104M) of said plurality of mounting elements (104M, 104N, 104P) of said center part (104).
3. The cross car beam assembly (100) as claimed in claim 2, wherein,
each of said first mounting element (104L) and said second mounting element (104M) is a channel defined in said body of said center part (104), wherein a mounting arm (108) is adapted to be mounted on said first mounting element (104L), and said second mounting element (104M) is adapted to facilitate mounting of a steering column of the vehicle;
a third mounting element (104N) of said plurality of mounting elements (104M, 104N, 104P) is provided between said first and second mounting elements (104M); and
a fourth mounting element (104P) of said plurality of mounting elements (104M, 104N, 104P) is connected between said first and second mounting elements (104M), disposed opposite to said third mounting element (104N),
wherein said third mounting element (104N) and said fourth mounting element (104P) are configured to facilitate connection of said center part (104) with an instrument panel of the vehicle.
4. The cross car beam assembly (100) as claimed in claim 2, wherein, said first structure (102) comprises:
a cross beam (102C) extending between a first end and a second end, wherein said first mounting portion (102A) is provided on said cross beam (102C) towards said first end of said cross beam (102C);
a first mounting bracket (102B) adapted to facilitate mounting of said cross car beam (100) on a body in white (BIW) of the vehicle;
a first module mounting portion (102F) adapted to facilitate mounting of at least one module of the vehicle;
a second module mounting portion (102S) adapted to facilitate mounting of at least one another module of the vehicle; and
a plurality of extending members (102X, 102Y, 102Z) extending transversely from said cross beam (102C) of said first structure (102) towards a front of the vehicle.
5. The cross car beam assembly (100) as claimed in claim 4, wherein said first module mounting portion (102F) is adapted to facilitate mounting of a glove box of the vehicle, said second module mounting portion (102S) is adapted to facilitate mounting of a HVAC system of the vehicle, and wherein said plurality of extending members (102X, 102Y, 102Z) comprise:
a first extending member (102X) connected near said second end of said cross beam (102C), said first extending member (102X) configured to facilitate mounting of a plenum of the vehicle;
a second extending member (102Y) connected near a center of said cross beam (102C), said second extending member (102Y) configured to facilitate mounting of a first airbag module of the vehicle; and
a third extending member (102Z) connected near said second end of said cross beam (102C), said third extending member (102Z) configured to facilitate mounting of a first display module of the vehicle.
6. The cross car beam assembly (100) as claimed in claim 2, wherein said second structure (106) comprises:
a second cross beam (106C) extending between a third end and a fourth end, wherein said second mounting portion (106A) is provided on said third end of said second cross beam (106C);
a second mounting bracket (106B) connected towards said fourth end of said second cross beam (106), said second mounting bracket (106B) adapted to facilitate mounting of said cross car assembly (100) on said BIW of the vehicle;
at least one first extending arm (106X) connected with said second cross beam (106C) and extending transversely from said second cross beam (106C) towards a front of the vehicle; and
at least one second extending arm (106Y) connected near said third end of said second cross beam (106C) and extending downwards from said second cross beam (106C), wherein said at least one extending arm (106X) is adapted to facilitate mounting of a first display module of the vehicle, and said at least second extending arm (106Y) is adapted to facilitate mounting of another airbag module of the vehicle.
7. The cross car beam assembly (100) as claimed in claim 1, wherein each of said first structure (102) and said second structure (106) is a unitary structure made of material comprising steel, and wherein said center part (104) is a unitary structure made of material comprising magnesium.
8. The cross car beam assembly (100) as claimed in claim 2, wherein each of said first mounting member (104A) and said second mounting member (104B) is a bar extending outwards from a body of said center part (104), wherein said first mounting member (104A) is adapted to receive said first mounting portion (102A) of said first structure (102), and said second mounting member (104B) is adapted to receive said second mounting portion (106A) of said second structure (106), wherein each of said first structure (102) and said second structure (106) is secured with said center part (104) through a plurality of first securing members (110).
9. A method (200) for assembly of a cross car beam assembly (100) in a vehicle, said method (200) comprising:
connecting a first structure (102) of a cross car beam assembly (100) with a center part (104) of said cross car beam assembly (100);
connecting a second structure (106) of said cross car beam assembly (100) with said center part (104) of said cross car beam assembly (100); and
mounting said cross car beam assembly (100) in the vehicle by connecting said first structure (102) and said second structure (106) with a body in white (BIW) of the vehicle, wherein said first structure (102) is connected towards a front passenger side and said second structure (106) is connected towards a drive side.
10. The method (200) as claimed in claim 9, wherein
said connecting of said first structure includes inserting a first mounting portion (102A) of said first structure (102) onto a first mounting member (104A) of said center part (104), and fastening said first structure (102) with said center part (104) by fastening a plurality of first securing members (110) with said first mounting portion (102A) and said first mounting member (104A);
said connecting of said second structure (106) includes inserting a second mounting portion (106A) of said second structure (106) onto a second mounting member (104B) of said center part (104), and fastening said second structure (106) with said center part (104) by fastening said plurality of first securing members (110) with said second mounting portion (106A) and said second mounting member (104B); and
mounting said cross car beam assembly (100) in the vehicle includes connecting each of a first mounting bracket (102B) of said first structure (102) and a second mounting bracket (106B) of said second structure (106) with the body in white (BIW) of the vehicle.
11. The method (200) as claimed in claim 10, wherein said method (200) includes mounting a mounting arm (108) on said first mounting element (104L) of said center part (104), wherein said mounting of said mounting arm (108) includes securing said mounting arm (108) with said center part (104) by fastening said mounting arm (108) with said first mounting element (104L) through a plurality of second securing members (112).