製品紹介 異なる工法を両立させた新型 X-TRAIL 用 インストルメントパネル開発 Development of the Instrument Panel Design Method Adaptable to Multiple Manufacturing Processes for the New
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1 製品紹介 異なる工法を両立させた新型 X-TRAIL 用 インストルメントパネル開発 Development of the Instrument Panel Design Method Adaptable to Multiple Manufacturing Processes for the New X-TRAIL 西山敏夫 * 山口敦史 * Toshio Nishiyama Atsushi Yamaguchi 要 旨 新型 X-TRAIL はグローバルに生産される車種 ( 北米生産車は ROGUE, 欧州生産車は QASHQAI) であり, 搭載されるインストルメントパネル ( 以下インパネと記載 ) は新設工場を含む複数の拠点で生産を行う. 拠点毎に保有設備が異なるため, 既存工場においては現有設備 ( 真空凹引き成形機 ) を使用しての表皮生産とし, 新拠点工場においては汎用設備 ( 射出成形機 ) での表皮成形が可能な 射出成形表皮工法 を選択した. 本稿では, 設備投資を抑制し開発の効率化を実現するために 2 種類の表皮工法の生産要件を両立させたインパネの開発について紹介する. Abstract Instrument panels to be installed in New X-TRAIL, a globally produced model (called ROGUE in North America and QASHQAI in Europe), are being produced at multiple bases including new plants. Since these plants have different equipment, skins of the instrument panels will be produced by both of these two methods: negative vacuum forming with dedicated equipment at existing plants and injection molding with general machines at new plants ( injection molding skin manufacturing ). This paper describes development of the instrument panel that can meet two types of production requirements for skin manufacturing, which can lead to reduction in equipment investment and streamlining of the development activities. Key Word : Instrument panel,skin,negative vacuum forming,injection molding 1. はじめに昨今のグローバル化と設備投資の抑制, 開発効率向上が重要視される中,Fig. 1 に示す新型 X-TRAIL もそのコンセプトに沿って開発する必要があった. グローバル化の観点では近年の日産車の中で代表的な存在となる車種であり, その生産開始は北米を皮切りに, 日本, 中国, 欧州, ロシアの順に続く (Fig. 2). 勿論, 販売展開もグローバルであり, 各国のスペックを満たしながら同一意匠面のコックピットモジュール ( 以下 CPM と記載 ) を開発する必要があった. 乗員から見た CPM の代表的な部品としてメーターやオーディオ, エアコンパネル, グローブボックス, ベンチレータなどがあるが, その中でもインパネは意匠面としても大きな存在感のある部品である. Fig. 1 New X-TRAIL Instrument panel ( * CPM 内装事業本部 CPM 内装プロジェクト開発グループ 15
2 CALSONIC KANSEI TECHNICAL REVIEW vol 新型 X-TRAIL のインパネは樹脂の基材の上に発泡ウレタン層と表皮で構成されたソフトインパネとなっている. その表皮の工法は, 既存工場では設備投資抑制から前型車と同じ工法である真空凹引き成形 (1) を受け継ぐこととした. 新設工場では新たに真空凹引き成形の設備を導入するよりも汎用性が高い射出成形機で製造生産可能な世界初の開発技術である射出成形表皮工法 (2) を採用することとした. 課題は, 設備投資を抑制し, 開発の効率化を実現するために 2 種類の表皮工法の生産要件を両立させるインパネを開発することである 真空凹引き表皮工法真空凹引き表皮工法について製品形状を成形するまでの工程を Fig. 4 に紹介する. 1) シート状の表皮を加熱し軟化させる. 2) 加熱したシートを金型にセットする. 3) CAVITY 型とプラグを閉めシートを挟み込む. 4) CAVITY 型内を真空にし, 成形と絞の転写を行う. 以上のステップで表皮の成形が行われる. Fig. 2 Production bases 2. ソフトインパネの構造上記で述べたソフトインパネ構造について簡単に説明する. Fig. 3 で示すようにソフトインパネは樹脂の基材, 発泡ウレタン, 表皮の 3 層断面構造となっている. Fig. 4 Process of negative vacuum forming 2.2. 射出成形表皮工法射出成形表皮工法について成形の工程を Fig. 5 に紹介する. Fig. 3 Structure of instrument panel 今回, 最上層部の表皮成形工法を2 種類選択しており, 以下の真空凹引き表皮工法と射出成形表皮工法の詳細について紹介する. Fig. 5 Process of injection molding 1) CORE 型が移動し金型を閉じる. 2) 熱可塑性樹脂を射出し, 成形する. 3) 金型を開き,CAVITY 側に残った製品を取り出す. 以上のステップになるが, 汎用の射出成形機による表皮成形が可能である. 16
3 異なる工法を両立させた新型 X-TRAIL 用インストルメントパネル開発 3. 生産要件の差異 2.1 項で述べたように, 真空凹引き表皮工法では表皮の伸びに関する制約を受ける. 一方, 射出成形表皮工法の場合は型抜き方向に関する制約を受ける. これらの制約の両立が課題となる主要な技術項目を以下に示す. 1) アンダーカット部の形状 2) 最小角 R 3) 金型からの取り出し性 4) 型抜き方向上記の制約に対して両工法を比較し, より厳しい条件となる工法を明確にして設計形状に反映させる. 次に各要件の詳細を説明する アンダーカット部の形状アンダーカット形状とは Fig. 6 に示すように, 型を開く方向に成形品が取り出せない部位の形状の事であり, 射出成型では金型にスライド構造を設けアンダーカット形状の成形を可能にしている. カット部で表皮の局部的な伸びを抑制するため, 高さ (H) と深さ (D) と角度 (θ) が規制される. 射出成形表皮工法では Fig. 8 に示す通りアンダーカット部は厚肉となるがヒケを抑えるために厚肉量 (T) が制限される. 以上のことから制約は (H),(D),(θ),(T) で決定されるが (T) は (D) よりも許容値が小さいため, 条件の厳しい射出成形表皮工法の要件を選択した 最小角 R 射出成形表皮工法の要件として最小角 R は一律 1mm としている. 一方, 真空凹引き表皮工法の場合は一般形状の最小角 R は 1.5mm であるが,Fig. 9 で示すコの字の断面形状では表皮伸びを考慮し深さ (D), 幅 (W), の比率で最小角 R を決める必要があり, 上記より大きな角 R を必要とする場合がある. 以上のことから, 条件の厳しい真空凹引き表皮工法の要件を選択した. Fig. 6 Movement of injection mold [Negative vacuum forming] Fig. 9 Corner R requirement [Negative vacuum forming] [Injection molding] Fig. 7 Undercut requirement Fig. 8 Undercut requirement しかしながら, どちらの表皮成形工法でもスライド機構を設けなくても成形品が柔らかいため CAVITY 側に残った成形品を変形させて取り出すことが可能であり成形品を金型から取り出せない問題は基本的には解決される. 但し, 更に細かく検討すると真空凹引き表皮工法と射出成型表皮工法ではそれぞれ異なる制約が発生する. 真空凹引き表皮工法では Fig. 7 に示す通りアンダー Fig. 10 Requirement of mold release by L and θ 17
4 CALSONIC KANSEI TECHNICAL REVIEW vol 金型からの取り出し性成形後の表皮脱型をスムーズに行わなければならない課題がある.Fig. 10 に示す通り, 脱型方向に対しアンダーとなる面の長さ (L) と面の角度 (θ) の関係を OK エリアに入るよう設計する必要がある. 真空凹引き表皮工法と射出成形表皮工法を比較すると, 後者の場合アンダー部は厚肉となるので, 真空凹引き表皮よりも厳しく OK エリアが狭くなる. 以上のことから, 条件の厳しい射出成形表皮工法の要件を選択した 型抜き方向 Fig. 11 のように射出成形表皮についてはアンダーカット (Undercut) 量の制約に基づき型抜き方向を決定する. 一方, 真空凹引き表皮工法の型抜き方向は表皮の伸び率の制約を受けるため, 製品形状幅 (W) に対する意匠面沿い長さ (L) は Fig. 12 に示す OK エリアに設定する必要がある. 以上のことから射出成形表皮工法, 真空凹引き表皮工法でそれぞれ型抜き方向を決定する. 4. 課題解決への取組みこれらの生産要件をもとにデザインへのフィードバックを行った. ここでは 3.1 項の具体例として,Fig. 13 に示すインパネ側面とドアとの合わせ面のアンダーカット部の形状について紹介する. [Injection molding] Fig. 11 Die direction Fig. 13 Example of undercut improvement Fig. 14 Before improvement Fig. 15 After improvement [Negative vacuum forming] Fig. 12 Requirement by skin extension ratio 18
5 異なる工法を両立させた新型 X-TRAIL 用インストルメントパネル開発 初期のデザインでは Fig. 14 で示す通り, アンダーカットの面角度 (θ) と深さ (D) は真空凹引き表皮工法の要件を満足しているが, 射出成形表皮工法の場合, アンダー部が厚肉となるためその量 (T) が要件を満足していなかった. 従って, 条件の厳しい射出成型表皮工法の要件を適用させる必要があり, デザインへのフィードバックを行い Fig. 15 で示すように厚肉 (T) 寸法を小さくした形状へと変更した. 更に,3.2 から 3.4 項についても同様の検討を行い, 二つの工法の制約条件を両立させるためのデザインフィードバックを実施することで, 異なる生産設備を有するグローバルでの生産を可能とした. 参考文献 (1) 太田尚利, 山口敦史 : 深絞り真空凹引きインパネ紹介,Calsonic Kansei Technical Review vol.5_2008, p77-80 (2) 中村哲男, 小船義人, 小野田剛 : 射出成型表皮工法の開発,Calsonic Kansei Technical Review vol.9_2012, p おわりにグローバル生産車種においてはトータルコストデリバリーの観点で特に投資抑制を行う必要があり, 現有設備の有効活用が課題となる. 今回この課題解決の為, 拠点別の最適表皮工法を選択できる設計手法を確立した. また, デザイン形状を統一することによりインパネと周辺部品との合わせ建付け構造を同一にでき, 開発の効率化も実現することができた. 西山敏夫 山口敦史 19
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