Shaping the future of mobility

In the mobility race, OEMs increasingly ask for proof of simulation at RFQ stage to ensure that 1st tier suppliers have the necessary tools to design products right and from the first attempt. Used at an early stage of the design, Enventive Concept is the leading tool to master product performance and secure robust tolerance analysis.

Mastering tolerance variations in the automotive

Reducing to minimum the number of controls in manufacturing lead to significant savings and ultimately drive new business. Enventive Concept enable the engineering teams use the largest tolerances possible

Tolerance analysis of an automotive seat latch

Problem: Errors in the design are identified only in production phase (high rate of rejected assembled products)

Solution: Use Enventive Concept to identify handle’s angle at which the system triggers.

Benefits:  Predicting tolerance variations early in design removes the risk of being hit by costly stack up problems in the production phase

Tolerance analysis of an automotive door handle

Problem: The critical stack-up has contributors coming from different views

Solution: Use the 2.5D projection approach to calculate tolerance variation trhoughout kinematics

Benefits:  Calculates complex 3D stack-ups using a robust approach

Tolerance analysis of a motorbike gearbox

Problems: Control the pressure on the disk. This parameter could be affected by hundreds of possible contributors. 

Solution: Build a complete model of the gearbox

Benefits:  Run a tolerance analysis that includes the effect of friction, temperature variation and multi-view combined effects 

Tolerance analysis of an automotive blinker

Problems: The force delivered by the user on the lever must fall between a minimum and maximum value. This way, the system provides stability and at the same time avoids excessive wearing of the components.

Solution: Run a Tolerance In Motion study (TIM) combined with a force equilibrium.

Benefits:  Study the evolution of forces and their tolerance intervals along a kinematic

Tolerance analysis of an automotive pedal box

Problems: Control the position of the pedal pad

Solution: Run a Combined Tolerance Analysis to see on a single report the X and Y position of the pedal

Benefits:  Study many stack-up in parallel

Tolerance analysis of an automotive connector

Problems: A set of x pins must fit in a set of x holes 

Solution: Build a parametric model of the connector using the Pin-in-Hole Pattern tool

Benefits:  The user simply modifies a set of input parameters to change the amount of pins of the connector

Example on how to improve product robustness

Let’s see how Enventive Concept ensure product tolerances remain within their functional limits…

FunctionPotential failureCauseSolution
Switch must work within specific forces (30 ± 20%)1) Too low means that accidental operation is possible
2) Too high means
       a) user fatigue
       b) broken switch
3) Testing cycle over-runs
4) Field failure returns
1) Manufacturing Tolerance variations
2) Frictional variations
Use Enventive to optimise consequence of variations on switch operating efforts

Forces target values = between 24/36N with a Cpk = 1.00

As we are at the conceptual design phase we want to identify the maximum dispersions that occur throughout the kinematics so that we can spot the worst position.

Enventive Worst Position Report Blinker

We take into consideration the dimensional, geometrical and physical aspects contributing to the dispersions. We plot these dispersions displaying both the worst case (WC) and statistical dispersions (RSS)

MEAN IMPROVEMENT •Optimizing stiffness value

CPK IMPROVEMENT •Reduction of stiffness variation and the  free length • Further possible improvement by reducing the profile tolerance

After optimization of the tolerance anlysis report we run a “tolerance in motion” study to check thanks to a force vs movement graph that the force value remains within the 36/24N (30 ± 20%) objective with a Cpk = 1.00


Add here keywords content by asking questions: Can Enventive Concept helps with complex mechanisms in 3D?…

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