What Are the Advantages of Cross Car Beam Assembly？

The cross car beam design does not change between internal combustion engine (ICE) vehicles and electric vehicles. The design cues may be different between the ICE and EVs as many EVs use a large screen in lieu of buttons and knobs, while the attachment points, steering wheel support, and airbag mounts are the same. The design and materials create a value proposition that includes weight, cost, customer appreciation, safety, prototype, and production tooling, and the ability to make changes within the program development.

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The cross car beam is the backbone of the instrument panel. From a structural perspective, the ends are mounted to the body walls and the firewall. This means there needs to be ample structural support for the steering column for both safety and driver comfort.

Vibration control is a major element in the design of the cross car beam. If the steering column shakes, we associate it with a steering or a brake issue. That is, if the cross car beam is not flexing. Likewise, if the display screen on the dash or the center console is vibrating, customers would perceive the vehicle to be low quality. The major areas of focus on a cross-car beam are identified here:

• Drive side main beam
• Steering column support knee bolsters 
• Steering hanger beam
• Instrument panel structure 
• Airbag mount glove box 

Cross car beams are subject to twisting loads from road loads, so it is advantageous to use hollow structures that naturally provide torsional stiffness. Aluminum extrusions have a clear advantage in weight-sensitive designs because it is a low-density, easy to fabricate, and readily available material.

The Cadillac CTS program optimized a magnesium design with extrusions and cut 36% of the weight. The series alloys are common, namely the easy-to-extrude , and stronger and A when required in localized areas.

Alloy selection varies for product performance and manufacturing requirements. For example, A is sometimes selected over or in the main tube because there is less distortion due to quench rates, and with welding, which reduces tolerance stack-up in assembly.

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Of course, these areas of concern can also utilize the temper that is best suited to strength, toughness,  and product performance.
The benefit of using series alloys throughout is that they can all be easily joined using traditional aluminum welding, adhesives, and other joining techniques.

Assembly features like datums are easy to incorporate for installation and assembly.

Casting designers like to use consistent wall thickness to maximize material properties. With extrusion-based cross car beams, the integration process is made easier. Designers can use their imaginations for wall thickness and geometry and can utilize metal where required for product performance (value and optimization).

In addition, the extrusion process allows versatile shapes to provide localized strength and stiffness as needed.

The automotive industry is continuously evolving with a focus on light-weighting and enhanced vehicle performance. One crucial component that reflects this trend is the Cross Car Beam (CCB) or Instrument Panel (IP) Carrier. The CCB supports the instrument panel and contributes significantly to the structural integrity and functionality of the vehicle's interior.

Our hybrid metal-plastic Cross Car Beam represents a significant advancement in automotive component design. By leveraging the strengths of both materials, we offer a solution that is lighter, more flexible, and capable of integrating additional functionalities. This innovative approach not only meets the current demands of the automotive industry but also sets the stage for future developments.

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