Manufacturing Process of a Car Dashboard - Essay Example

Manufacturing process of a car dashboard The dashboard can be seen as the centre of operations in a car. It takes precedence after the engine in importance and its evolution is evident now more than ever. The dashboard is a clear indication for the revolution of modern day technology into our everyday lives. Electrical functions incorporated within the dashboard are the main components that differentiate the modern day dashboard from the dashboard of the past decades. With end-user needs and demands on efficiency and modernization one can understand the reasons why the dashboard had to make its evolution. Besides that fact there is also the matter of durability and the usage of lightweight material which assist in the manufacturing process. These are not to be neglected as they assist in the formation and substituting to different types of material to more convenient materials that can withstand the demand made on today's dashboard. It is also clear that since the dashboard houses so many essential car functioning components the design therefore will also play an important and vital part. By thinking in terms of appropriate geometrical shapes, effective material that will become an essential part of the car one will more be more able to design and manufacture a dashboard with relative ease and very few industrial hiccups. The dashboard prides itself in offering housing for the interior electrical components like solenoids, fuse system, battery etc and not to mention the visible exterior components like the dials, sockets, front lights and steering wheel to mention the least. Before undertaking the daunting and sometimes challenging task of creating a dashboard one has to take into consideration many essential and vital aspects that will ensure success. This will enable all involved parties to work in a systematic and productive manner. Firstly one will have to choose the type of material that will be used. One might argue and say that perhaps design should be the first and uttermost propriety. The reason for the type of material taking president is due to the fact that sometimes having a basic foundation upon which one can work on makes it easier to avoid all the glitches that will most likely occur. The next step will then be to design the dashboard. The important aspects of this will be design analysis, geometric modelling and analysis and not forgetting prototype and testing. In the dashboard manufacturing industry the most dominating and commonly used plastic materials are polypropylene, styrene, nylon and polyester. Fibre glass is also used as part of the construction when making a dashboard. One has to remember that it is plastic in all its various forms that make the housing and operation, inclusion and interconnection of the devices possible. The most appealing material which I think is used in the manufacturing of today's dashboard is nylon. This is due to its easy industrial handling and the fact that it requires less property altering additives. This form of plastic is known for its durability, strength, consistency and the fact that it is also relatively lightweight. And since so many of today's cars are relying on electrical equipment nylon like its other plastic relatives has negligible magnetic field interference. Another thing that makes nylon so appealing is that it can withstand all wear. An important aspect of this is that car safety is a crucial issue of consideration. The association of this is that the dashboard plays a crucial part in this. The end-user appreciates the knowledge that the life saving essentials like airbags are encased in a dashboard that wont just crumble under the pressures of an accident. So by incorporating this type of thinking it is clear why nylon would be the better choice. Naturally all the other components of the dashboard like the plugs and wire cases can be made out of the other types of materials which have been endorsed by industrial standards. This is due to the undeniable fact that they have proven to be more efficient in more ways than one. But in this instance nylon will be the main denominator as it has proven to be the most attractive of the plastics in my eyes. Once that is established the design process can start. A practical design which is user friendly yet stylish must therefore be in all considerations during the design process. Meeting the demand of users with the aid of technology is also beneficial. In this instance one cannot overstate that to prevent the cost of production and manufacturing from escalating to unrealistic heights an inexpensive and perhaps traditional material must be used. To ensure that the whole process goes as planned it is important that the design analysis is done more frequently. This will ensure that the dashboard model being created is still adhering to the initial set standards. By incorporating the design analysis the creation process is closely monitored to ensure that no unrealistic and impractical design is being incorporated. These are essential in the dashboard as these will assist in all the necessary and expected functions that make a dashboard such an essential component of a car. In considering the seemingly vital aspects of the dashboard design the engineer has to also consider that geometric modelling is also an essential part of the design. The proper proportioning and scaling of the model with the aid of the CAD/CAM is also important. By first creating a rough sketch of the dashboard the engineer is able to get a rough idea of what is needed. The CAD/CAM software then assists the engineer to make a surface model and by doing this the dashboard model's outside surfaces are presented. Furthermore the complex shapes are further enhanced and incorporated by geometrical modelling. This also ensures that all the essential tiny bits like the dials that encompass the body of the dashboard are evident and have realistic and applicable proportions. This will also enhance the moulding of the dashboard to ensure correct industrial productivity. The manufacturing of the dashboard is also an essential component of consideration. The next relevant details are dictated by proper knowledge and application of industrial manufacturing tools and mechanism. This ensures that the product is done to all required specifications. It is standard industry knowledge that all plastic moulded products need their own moulds. It also goes without stating that forming the cavity into which the plastic is inject is done though the usage of milling steel plates which also incorporate release and eject mechanism so that the solidified and hardened end product can be released. In order to make this a possibility the mould tool industry is assisted by advanced 3D - CAD technology. The complex surfaces of the mould plates are further defined by the assistance of this technology. By passing these definitions onto the CAM software the milling process is made easier and practical. The most critical of the entire process is the correct tolerance. This is due to the industry evaluation that is the tolerance specifications are too small then too high manufacturing costs are to be expected. However if the tolerance specification is too large then the CAD/CAM will not function properly. So care is essential as all necessary errors could end up being highly costly. It is important to note that the design process and software which is commonly used in the plastic moulding industry is CAD/CAM. The main focus in using the software is to make a realistic and applicable dashboard shell. In this way there is a better option to view the digital version of the dashboard. All the important aspects that encompass the geometrical shape are there and by constantly applying the design analysis the product can be created with minimal changes and therefore ensuring that the costs involved are also minimal. Engineers and manufacturers alike appreciate the fact that quality has its price. In order to ensure high quality with minimal cost they have to be willing to ensure less preventable mistakes By creating a geometric model one is able to see the end result and curb any errors that might occur during the initial design process. It makes the process of working with the design much faster. This is the reason why CAD/CAM was developed. By using this system one is more able to create a visual of the model in less time and with all the required data. This part of the dashboard development process is not to be ignored or taken lightly. This way the manufacturer also knows what the client is after and will therefore easily fit to work towards meeting those needs. CAD/CAM is more than just a designer's assistant it is also the universal communicator. Which will assist in the dashboard moulding process which often follows. One cannot stress enough how this technology aids in the visual process of a dashboard. Another important thing is that using this type of technology helps in rapid prototyping. In this way the design analysis is incorporated again and the product is put to the test. It is to be expected that often a design concept will not be exactly up to scratch. In that way rapid prototyping will assist in getting all the concepts functioning as one. The dashboard will be created to have the exact shape as required. Rapid prototyping also helps manage the cost that might otherwise be incurred. It also makes it easier to make all necessary corrections while the ideas are still fresh and the problems are still solvable. In the dashboard manufacturing industry and the automotive industry as a whole getting immediate results is crucial and rapid prototyping is the best way to ensure this. Conclusion It is clear that the process of manufacturing a dashboard does require hard work and persistence. But is also clear that the rewards that come from all those effort make the work worthwhile and often it is the accomplishment of a job well done that is reward enough. Nothing can compensate for knowledge applied. Working with the industry approved software does make things a whole lot easier for the manufacturer. Constant testing and evaluation will ensure that the product produced meets all the standard safety requirements. An idea is just the beginning of the process, just like a seed. It takes patience time and application of all acquired industry knowledge to ensure ultimate success for both the manufacturer and the end-user. Reference: 1) Plastic applications in cars http://www.drivinginnovation.com/applications/electrical.html (Viewed: 5 March 2006, 11:50am) 2) CAD support for assembly designers http://europa.eu.int/comm/research/success/en/ind/0028e.html (Viewed: 5 March 2006, 12:01pm) 3) About CNC Controllers http://motion-controls.globalspec.com/LearnMore/Motion_Controls/Machine_Motion_Controllers/CNC_Controllers (Viewed 5 March 2006, 12:35pm) Read More