Conrad Toepfer

Tolerance management 1.0
Tolerance management, initially started in the Anglo/American Engineering community as “Dimensional Management”, is a Methodology that takes care of the robust layout of mechanical assembly processes to insure dimensional quality. It defines the measurement and documents the datum scheme to insure a proper definition and exchangeable information. The “language” of Tolerance management is GD&T – Geometric Dimensioning & Tolerancing. That language has different “dialects” such as ISO, ANSI and DIN and various versions. A proper definition and the reference to the applied standard is obligatory to insure the correct definitions and support the Design for Assembly.

Tolerance management as a methodology is supported by 2-D / 3-D simulation Software since the 90th of the last Century. TTC3 GmbH – part of the EnginSoft group – has access to all state of the art software products and proven project experience in various applications out of leading players in different industry sectors for about 20 years.

Tolerance management 2.0
The Focus of Dimensional Management – TM 1.0 - is set to the process capabilities and quality of assembly processes – Automotive Industry used it mainly to optimize Gap and Flush in a body in white structure. Mechanic and Mechatronic Systems cannot be designed and managed only by the dimensional quality but have also to be monitored also with respect to the physical effects – such as forces, Moments, friction, Moments of inertia, magnetism? (hall effects). On top of the proper topology – supported by TM 1.0 – TM 2.0 “catches the physics” to support a Robust Design strategy and drive the product quality from the very early design phase. It usually starts with feasibility studies by supporting sketches /skeleton and helps identifying the critical parameters of the functional layout.

Tolerancemanagement 3.0
The Complexity of the products and the “in built intelligence” of controllers and software require a multi-disciplinary strategy to manage and achieve a long term product Quality. Trends in automotive - such as Autonomous driving – require reliable systems for braking, steering and identification of actual valid boundary conditions to take the proper decisions for a safe transportation. The quality of a signal as input for a decision is influenced by the proper Mechanical layout and Mechatronic effects. If a proper signal quality is not supported, there is additional time (next loop) required to achieve the output data of an input signal. This will have a serious impact to reliability and safety due to lack of system performance.

The actual software solutions for technical simulations are usually based on nominal geometry.

Tolerance effects – no matter if sourced in production or from wear out in use – have to be identified and qualified with respect to the functional capabilities in the full product life cycle. This goal can only be achieved with a multi-disciplinary optimization to manage the cross border functions that might implicit parasitic effects. ModeFRONTIER provides a workbench to consolidate the functional requirements - and support the Systems Engineering approach - to manage future technical requirements and drive Quality.

EnginSoft Germany in cooperation with TTC3 GmbH is incubating that next step technology together with market leaders to support their competitive advantage for the future.