Successful Diet for Cockpit

BURSCHEID, Germany, July 25 /PRNewswire/ --

-- Synergies Between Johnson Controls and ThyssenKrupp Used to Develop a Revolutionary Cockpit Structure

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How important is a cross-car beam in the cockpit? Is a one-piece component necessary? And is it possible to reduce cockpit weight? These questions have also occupied engineers from ThyssenKrupp Steel, ThyssenKrupp Presta and Johnson Controls. The result is a new cockpit design called EcoSpace that offers a weight saving of more than 20 percent compared to traditional solutions while ensuring the same passenger protection, and provides other benefits besides: improvements have also been made to functional integration and structural properties. In this way, the three companies have jointly developed a new cockpit structure for the automotive industry using a comprehensive system approach and their specific product expertise. They will present it for the first time at the 2007 International Motor Show (IAA).

"Take three competencies, two materials and one solution, and you have the recipe for a new concept in cockpit design," says Thomas Beer, Senior Product Business Manager at Johnson Controls. This created a synergy between Johnson Controls' experience in developing and manufacturing instrument panels and cockpits and ThyssenKrupp Steel AG's expertise in materials and body work. ThyssenKrupp Presta contributed the steering column and corresponding engineering know-how. "The idea is to simplify the assembly process for automakers by offering them a complete single-source cockpit structure that already includes the instrument panel, steering column and substrate," says Martin Hinz, Project Manager for cockpit structure design at ThyssenKrupp Steel AG. The assembly complexity has been significantly reduced, which means that all the automaker has to incorporate is individual components such as the radio and air-conditioning.

Hybrid construction renders one-piece cross-car beam unnecessary

The key to the new EcoSpace approach lies in a light hybrid construction, a composite steel and plastic structure, which makes it possible to do away with half of the cross-car beam. Since structural rigidity is required mainly in the steering column area, the engineers used the steel for the driver's side in the form of a tripod. The central component is a third-generation Thyssen Tailored Tube. This is a closed profile tube with load-dependent geometry, to which the steering column can be directly attached. The plastic, consisting of long fiber reinforced polypropylene, comes from Johnson Controls. The hybrid structure has all the advantages and none of the disadvantages of the traditional material combinations, such as low weight, high integration potential, good structural properties and general applicability. The plastic is used across the full cockpit width. Air channels, the connection to the airbag and the back of the glove box are integrated directly into the plastic structure. These parts also assume a reinforcing function. The result of these measures is that there is no need for a one-piece cross-car beam.

It goes without saying that the engineers paid attention to safety. Simulations of the entire cockpit structure show that it has such a homogeneous construction that there is no variation in safety level.

"Besides the assembly and system advantages, designers will also be pleased with our new EcoSpace structure," says Thomas Beer. "Concentrating the main structure on the driver side allows new options for different layouts, particularly on the passenger side." The new cockpit design is suitable for all sedans and could be in production with effect from the 2010 model year. The public will see it for the first time at the 2007 International Motor Show (IAA).

The full version of the press release as well as photos are available at www.johnsoncontrols-press.com.

Johnson Controls is a global leader in interior experience, building efficiency and power solutions with 136,000 employees in more than 1,000 locations serving customers in over 125 countries. The company provides innovative automotive interiors that help make driving more comfortable, safe and enjoyable. For buildings it offers products and services that optimize energy use and improve comfort and security. Johnson Controls' automotive product portfolio also includes seating systems, instrument panels/cockpits, door and overhead systems, interior electronics and electrical energy management. The company also provides batteries for automobiles and hybrid electric vehicles, along with systems engineering and service expertise. Founded in 1885, Johnson Controls (NYSE: JCI) is headquartered in Milwaukee, Wisconsin. The European headquarters is in Burscheid, Germany. Please visit www.johnsoncontrols.com for additional information.

ThyssenKrupp Steel AG is a holding company and is the largest individual operating company within the Steel segment of the ThyssenKrupp Group, which concentrates on the manufacture and sale of high-quality flat products made of high-grade steel and the provision of product-based services. ThyssenKrupp Steel employs about 38,000 staff and achieved turnover in excess of EUR 10.7 billion in FY 2005/2006. The company is headquartered in Duisburg. ThyssenKrupp Presta AG is a company in the Technologies segment of the ThyssenKrupp Group. It is one of the world's most successful manufacturers of steering systems, is a worldwide market leader in worked cam shafts and a technology leader in the field of massive forming. The company is headquartered in Eschen in Liechtenstein.

    
    Further information is available from:
    Johnson Controls GmbH
    Automotive Experience
    Industriestr. 20-30
    51399 Burscheid
    Germany
    Ina Longwitz
    Tel.: +49-2174-65-4343
    Fax: +49-2174-65-3219
    E-mail: ina.longwitz@jci.com
    ThyssenKrupp Steel AG
    Bernd Overmaat
    Kaiser-Wilhelm-Str. 100
    47166 Duisburg
    Germany
    Tel.: +49-203-53-45185
    Fax: +49-203-52-25707
    E-mail: bernd.overmaat@thyssenkrupp.com

Further information is available from: Johnson Controls GmbH, Automotive Experience, Industriestr. 20-30, 51399 Burscheid, Germany, Ina Longwitz, Tel.: +49-2174-65-4343, Fax: +49-2174-65-3219, E-mail: ina.longwitz@jci.com; ThyssenKrupp Steel AG, Bernd Overmaat, Kaiser-Wilhelm-Str. 100, 47166 Duisburg, Germany, Tel.: +49-203-53-45185, Fax: +49-203-52-25707, E-mail: bernd.overmaat@thyssenkrupp.com