Enventive Engineering is a company that works in the field of design of complex mechanical and electro-mechanical systems. It is a system that is used in the preliminary design stage, in order to ensure the engineering team make the right decisions on datum's, nominal and tolerances of key parameters taking into account all the functional tolerancing and complex aspects of the design such as forces, friction, complex contacts, wear and deformation. This typically saves 1,2, or more prototypes.

2. Solution Desired by Managers
 Managers want pushbutton tolerance analysis from CAD system
 This solution does not currently exist, since the CAD mathematical
structure is inadequate for tolerance analysis.
 But During CAD - All the critical decisions about materials,
manufacturing process, datums and tolerances have already been
made – Issues will have been created
 Specialists and their tools are required to validate result, which creates
an expensive bottleneck
 Would it not be better for ordinary engineers to carry out
Tolerance Analysis before CAD, and then export the results into
the CAD?

3. Process Change:
Pre-CAD Tolerance Analysis-Based Design Optimization.
• Process capabilities taken into
account early in investigation.
• Diverse types of complex analyses:
• Complex kinematics.
• Complex ISO tolerancing.
• Physical aspects (forces,
contacts): need for DOE and
prototypes reduced.
• Structured Transfer Function
optimization (focused on costs):
 Number of contributors.
 Sensitivities.
 Tolerances
 Process Capabilities
 Tolerances on small impacts
contributors.
• Design reliability justification from
consultation phase.
 Customer Confidence.
• Ease of use and of deployment
among engineers (no full time
specialist required).
Voice of the
Customer
Product
Release to
Manufacturing
Pilot Program
(soft Tooling)
Product
Release (hard
Tooling)
Problem
Resolution
Traditional
Tolerance
AnalysisProduct
Requirements
Specifications
Conceptuel
design Initial
Prototypes
Detail Design
Further
prototypes
Tolerance
Analysis-Based
Design Optimization
Traditional
Tolerance
Analysis

4. Piston / Valves assembly design optimisation:
-Statistical analysis and optimisation of the
lifting of the valves at any angular position
of the camshaft.
-Statistical analysis and optimisation of the
distance between the valve and the
different possible interference elements
(notably the piston).
-Inclusion in the model of the tilting effect
of the valves and any position
(this tilting may have an effect on
the accuracy of the system).
-Statistical analysis and optimisation
of the swept volume
(the volume between the head of the
piston and the top of the cylinder.

5. Chain layout design & statistical optimisation:
- Statistical analysis and optimisation of
the position of the tensionner piston in
function of all the tolerances of the other
components present in the system.
- Inclusion in the model of all contact
conditions (including complex chain /
cam contact) and tolerances.
- This statistical analysis and
optimisation may also include the forces
applied on the chain and the
corresponding elongation of the chain.

6. System level Engine design optimisation:
- Any system level parameter of the
engine that involves non dynamic effects
can be easily analysed.
- Wear / thermal effects laws can be
included so that for example the Mean
Time Between Failure can be evaluated
and optimised.

7. Turbo systems design optimisation:
- Statistical analysis and optimisation of
the tilting angle of the fan’s shaft in
function of all the tolerances present on all
the components (including the tolerances
on the bearings).

8. Transmissions design optimisation:
- 1D tolerance stacks relative to the fitting
Of the different components of the
transmission.
-Statistical optimisation of the operation of
transmission actuation elements (Clutch
and gear changing mechanisms).
-Statistical analysis and optimisation of
automatic transmissions park brake
mechanism.

9. Optimizing Process with Enventive
 During the design process, functional
models will typically start simple and
become more complex
 Simple stick figures with simple force
diagrams
 Simple parts with simple assembly
methods and simple force diagrams
 Simple parts with more complex force
diagrams that include friction and force
bias effects in joints
 More complex parts for layout purposes
and for identification of key datum
features.

10. Optimizing Process with Enventive
 Simulate product functionality
 Simulate alternative functional models
 Identify functional limits and failure
modes
 Identify critical features and critical
parameters that drive functional
performance
 Optimize critical parameters to reliably
deliver performance
 Determine critical parameter tolerance
limits required to maintain performance

11. Steering
Systems
Powertrain
(Gearboxes)
Pedal
Systems
Engines
Switches
Connectors
Door
Mechanisms
Seating
Mechanisms
Roof
Sliding
Systems
Brake
Systems
AUTOMOTIVE CUSTOMERS
Automotive Industries – Clients

12. Alan Smith
Director, New & Emerging Markets
alan.smith@enventive.com
+44 (0)7791 024092
www.enventive.com