ENVENTIVE® CONCEPT: AUTOMOTIVE
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
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
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
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
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
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
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…
|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.
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?…