tolerance allocation for kinematic systems

154 Pages·2016·1.35 MB·English

by  Mathieu Barraja

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University of Kentucky Master's Theses Graduate School
2004
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Mathieu Barraja
University of Kentucky, [email protected]
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Barraja, Mathieu, "TOLERANCE ALLOCATION FOR KINEMATIC SYSTEMS" (2004). University of Kentucky
Master's Theses. 315.
https://uknowledge.uky.edu/gradschool_theses/315
This Thesis is brought to you for free and open access by the Graduate School at UKnowledge. It has been
accepted for inclusion in University of Kentucky Master's Theses by an authorized administrator of UKnowledge.
For more information, please contact [email protected].
TCARTSBA FOSISEHT

ECNARE LNOOTITACOLLA ROF CITAMENIKSMETSYS

A dohtem rof gnitacolla secnarelot ot yltcaxe deniartsnoc seilbmessa s i
.depoleved ehT erudecorp si dehsilbatse sa na noitazimitpo tcejbus ot .stniartsnoc e hT
evitcejbo si ot eziminim ehtam nufacturing cost of the assembly while respecting an
elbatpecca level fo .ecnamrofrep sihT dohtem si ylralucitrap gnitseretni rofy ltcaxe
s tdtnlaeu h nodteohebpssnmsioaacmrtsnoc - produced.
sihT siseht stneserp eht tnereffid stpecnoc desu ot poleved eht .dohtem t I
sebircsed tcaxe tniartsnoc ,yroeht gnirutcafunam ,snoitairav noitazimitpo ,stpecnocd na
the related mathematical tools. Then it explains how to relate these different topics in
.noita ceo cl mnlrraae o rdofaertrloeopt
ehT depoleved dohtem sia pplied on two relevant exactly constrained examples:
itlum - fiber connectors, and kinematic coupling. Every time a mathematical model of the
metsys dna sti gnidnopserroc gnirutcafunam snoitairav si .dehsilbatse nehT n a
optimization procedure uses this mode l to minimize the manufacturing cost of the system
while respecting its functional requirements. The results of the tolerance allocation are
.dne oih ifte tiitoarwnlleoruvMamCis

KEYWORDS: Tolerance Allocation, Manufacturing Variation, Kinematic Design
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ECN ANROEILTOATCOLLA ROF CITAMENSIMKETSYS

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Unpublished theses submitted for the Master’s degree and deposited in the University of
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NO IET CARNCOAOFRLEELNLAIOKT MATIC SYSTEMS

THESIS

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ACKNOWLEDGEMENTS

tsriF fo lla I dluow ekil ot knaht .rM segroeG yrehcreV dna .rM m arhahS
hedazzaviA rof gnivig em eht ytinutroppo ot retne a s’retsaM eerged margorp tae ht
nU ytisrevi fo .ykcutneK I epoh yeht redisnoc siht yrev tsrif KU siseht nettirw ybn a
naitasi as the result of their hard work for establishing an academic partnership between
UK and ISAT Nevers. For the same reason, I would like to thank Dr. G.T. Lineberry
ohw detpecca ym noitacilppa rof eht ytisrevinU fo .ykcutneK dnA I t’nac tegrofs siM
enitsirhC ,zelaznoG ohw dluoc emocrevo lla eht evitartsinimda seitluciffid tahte rew
gn in .moneriilatiwa fscyimlppa
,txeN I dluow ekil ot sserpxe ym tsepeed edutitargt o ym ,rosivda .rD .Rn ayR
.ecnallaV I ylluf ezilaer taht ym ecneirepxe ni KU dluow ton evah neeb os gnihcirne fi I
t’ndah tem .mih I tonnac enigami na rosivda erom detacided ot sih stneduts dnae rom
lufthguoht ot rieht .sehcraeser I erimda mih rof siho gnidnatstu gnireenigne ,egdelwonk
.seit ito nlusr taablosamuafieuqhrhg
I ma osla yllaer lufknaht sdrawot elpoep ni SCT rof gnivah nevig em e ht
opportunity to work on an exciting project. I would like to thank John Lehman, Burke
,rekasnuH dnayllaicepse .rD rhepeS .inaiK ev’yehT syawla detroppus ym ,hcraeser dna
I epoh eht tluser fo ym krow nac eb lauqe ot eht edutitarg I dluow ekil ot wohs .meht I
.t mn m eratoehaorvtelfalh
Finally, I would like to thank Dr. Stephens and Dr. Mengüç as my examining
c ommittees. I wish the results of my project might find some application in their
;sehcraeser gniwonk taht yeht dluow dnif hcus na tseretni ni ym skrow dluow eba
lano.sdrreapwer

iii
TABLE OF CONTENTS
CA STNEMEGDELWONK ................................ ................................ ................................ ................... iii
SELBA TF OTSIL ................................ ................................ ................................ ................................ iiv
TGFSIOIFL SERU ................................ ................................ ................................ ............................. iiiv
TFSOFIL I SEL ................................ ................................ ................................ ................................ ...... x
:R1ETPAHC E HD TNNAOITCUDORTNI WEIVRE VSOIS ................................ ...................... 1
.1.1 B ACKGROUNTDTO H E T HESIS ................................ ................................ ................................ ........ 1
.2.1 P RIOR W ORK AND L ITERATURE R EVIEW ................................ ................................ ......................... 2
.1.2.1 smet sdyeSniarts nyolCtcaxE ................................ ................................ .............................. 2
.2.2.1 snoitai rlaaVnoisnemiD ................................ ................................ ................................ ..... 3
.3.2.1 noitacollA ecnareloT tsoC tsaeL ................................ ................................ ......................... 4
.4.2.1 scitamehtaM scitsitatS dna ................................ ................................ ................................ . 4
.3.1 T SISEH O VERVIEW ................................ ................................ ................................ ......................... 5
.1.3.1 sisehtopyH ................................ ................................ ................................ ......................... 5
.2.3.1 oC weivr etvnOetn ................................ ................................ ................................ .............. 5
:R2ETPAHC EH TN IDES USTPECNOC DOHTEM ................................ ................................ .. 6
.1.2 E XACTLY C ONSTRAINED S YSTEMS ................................ ................................ ................................ . 6
.1.1.2 yroehT ................................ ................................ ................................ ............................... 6
.2.1.2 noitcenno Cf osepyT ................................ ................................ ................................ ........... 7
.3.1.2 eldnip Scitameni Kf oelpmaxE ................................ ................................ .......................... 10
.2.2 M ANUFACTURING V ARIATIONS ................................ ................................ ................................ .... 14
.1.2.2 noitatneserP ................................ ................................ ................................ .................... 14
.1.1.2.2 noitcudortnI ................................ ................................ ................................ ............. 14
.2.1.2.2 snoitai rsfaeoVcruoS ................................ ................................ ............................... 15
.2.2.2 noitatneserpeR lacitamehtaM ................................ ................................ ........................... 16
.1.2.2.2 Dim selbair amVodn assRanoisne ................................ ................................ ............. 16
.2.2.2.2 snoitacific ecpiSrtem o eelfhGeot dloaMcitamehtaM ................................ ................ 17
.3.2.2 oitaira Veh tezylan Ao tsdohteM sn ................................ ................................ ................... 19
.1.3.2.2 noitalu moilS reatCnoM ................................ ................................ ........................... 19
.2.3.2.2 le dloaMcitylanA ................................ ................................ ................................ ...... 20
.3.3.2.2 sisyl arnoA rertEairavitluM ................................ ................................ ...................... 21
.4.3.2.2 sdoht ee MhfntoosirapmoC ................................ ................................ ...................... 22
.3.2 L EAST C OST T OLERANCE A LLOCATION ................................ ................................ ........................ 23
.1.3.2 noitcudortnI ................................ ................................ ................................ ..................... 23
.2.3.2 noitazim i ntyopbiOtaco lelcAnareloT ................................ ................................ .............. 24
.3.3.2 Cost / snoita leecRnareloT ................................ ................................ ............................... 25
.4.2 C HAPTER S UMMARY ................................ ................................ ................................ .................... 27
:R3ETPAHC CITP OO TNOITACILPPA SROTCENN ORCEB ILFA ................................ ..... 30
.1.3 I NTRODUCTION ................................ ................................ ................................ ............................ 30
.1.1.3 noitatneserP ................................ ................................ ................................ .................... 30
.1.1.1.3 sci trpeObiF ................................ ................................ ................................ ............. 30
.2.1.1.3 ses snooLissimsnarT ................................ ................................ ................................ . 31
.3.1.1.3 srotcen nroeC bliaFcitpO ................................ ................................ .......................... 33
.2.1.3 k rrooW i drdnPnauorgkcaB ................................ ................................ ............................ 34
.3.1.3 noitaco lelcAnareloT ................................ ................................ ................................ ........ 35
.2.3 M ATHEMATICAL M ODEL ................................ ................................ ................................ .............. 38
.1.2.3 Ex rotcenn oeC hntiht isWtniartsn otCca ................................ ................................ ........... 38
vi
.2.2.3 rotcenno Ceh tn istnenopmo Ceh tf oledo McirtemaraP ................................ .................... 40
.1.2.2.3 noitatneserP ................................ ................................ ................................ ............. 40
.2.2.2.3 sgnidd arleC b disnFnaiP ................................ ................................ .......................... 42
.3.2.2.3 sre bsfieoFroC ................................ ................................ ................................ ......... 43
.4.2.2.3 F selurre ................................ ................................ ................................ .................... 44
.5.2.2.3 selbair ae VhfttosiL ................................ ................................ ................................ . 45
.3.2.3 led ocMirtemo eeG h ftnooitpircs ecDitamehtaM ................................ .............................. 46
.1.3.2.3 e emVod n eaadRis nrIednil ymCod n fyaaolRbmessA -evoorG ................................ 46
.2.3.2.3 sreb i fFyoar r nAganitaerC ................................ ................................ ...................... 50
.3.3.2.3 srebi Fow TgnitaM ................................ ................................ ................................ ... 53
.3.3 T OLERANCE A LLOCATION ................................ ................................ ................................ ............ 55
.1.3.3 weivrevO ................................ ................................ ................................ ......................... 55
.2.3.3 noitagapo rrPor rfwE oae L hystbisyla nnAoitairaV ................................ ........................ 56
.3.3.3 snoitcnu Fecnarelo T/tsoC ................................ ................................ .............................. 60
.4.3.3 f ostluseR mhtiro gnloAitaco lelcAnare leohTt ................................ ................................ .. 61
.5.3.3 noitalu moilS reatC nho tMniowsirapmoC ................................ ................................ ........ 63
.4.3 M ANUFACTURING P ROCESS ................................ ................................ ................................ .......... 64
.1.4.3 noitcudortnI ................................ ................................ ................................ ..................... 64
.2.4.3 ssec o ernfhPootitpircseD ................................ ................................ ............................... 65
.3.4.3 dyuhtpSargollateM y ................................ ................................ ................................ ........ 66
.4.4.3 sevo oyfrroGtemolif osruPlytS ................................ ................................ ......................... 68
.5.4.3 snoisulcnoC ................................ ................................ ................................ ..................... 71
CH :R4ETPA MENI KO TNOITACILPPA SGNILPU OCCITA ................................ ................ 72
.1.4 I NTRODUCTION ................................ ................................ ................................ ............................ 72
.1.1.4 noitatneserP ................................ ................................ ................................ .................... 72
.2.1.4 k rrooW i drdnPnauorgkcaB ................................ ................................ ............................ 73
.3.1.4 noitaco lelcAnareloT ................................ ................................ ................................ ........ 75
.2.4 M ATHEMATICAL M ODEL ................................ ................................ ................................ .............. 78
.1.2.4 secafr ugSnitcatn o fCnooitatneserp ecRirtemaraP ................................ ........................... 78
.2.2.4 noitatneir Odn anoitiso PgnitseR ................................ ................................ ...................... 80
.3.2.4 noitacoL gnitseR ni noitairaV fo sisylanA rorrE etairavitluM ................................ ........... 83
.4.2.4 stn igonPitar entpoaOitairaV ................................ ................................ .......................... 85
.3.4 T OLERANCE A LLOCATION ................................ ................................ ................................ ............ 88
.1.3.4 secnare l dotnT sagonCirutcafunaM ................................ ................................ ................. 88
.2.3.4 noitazim i ntyopbiOtaco lelcAnareloT ................................ ................................ .............. 90
.3.3.4 noitalum ioSlr aeCtn o yMnboitacifireV ................................ ................................ ........... 94
.4.4 C ONCLUSION ................................ ................................ ................................ ............................... 95
:R5ETPAHC OISULCNOC KR OEWRUT UDF NSAN ................................ ............................. 96
.1.5 C ONCLUSIONS ................................ ................................ ................................ ............................. 96
.2.5 F UTURE W ORK ................................ ................................ ................................ ............................ 96
XIDNEPPA A: ................................ ................................ ................................ ................................ ...... 98
YTIS NYETDILIBABORP SF OMU SF ONOITCNUF SERAUQ ................................ .................... 98
:XBIDNEPPA ................................ ................................ ................................ ................................ .... 101
NI KRO FSEDO CBALTAM SGNILPU OCCITAME ................................ ................................ ...... 101
.1OB PTIMIZATION : O EVITCEJB F UNCTION ................................ ................................ ............................. 101
.2OB PTIMIZATION : C ONSTRAINT F UNCTIONS ................................ ................................ ........................ 103
.3OB PTIMIZATION : I NVOKING F ILE ................................ ................................ ................................ ....... 104
.4MB ONTE C ARLO S IMULATION ................................ ................................ ................................ ........... 105
.5SB BU - F UNCTION : KCT _ BALLGEOM ................................ ................................ ................................ .... 107
.6SB BU - F UNCTION : KCT _ CENTROID ................................ ................................ ................................ ...... 109
v
.7SB BU - FUNCTION : KCT _ ERRORS ................................ ................................ ................................ .......... 111
.8SB BU - F UNCTION : KCT _ GROOVEGEOM ................................ ................................ ............................... 115
.9SB BU - F UNCTION : KCT _ PERTURB ................................ ................................ ................................ ....... 118
.0S1B BU - F UNCTION : KCT _ REST ................................ ................................ ................................ ............ 122
.1S1B BU - F UNCTION : KCT _ SEAT ................................ ................................ ................................ ........... 125
X:ICDNEPPA ................................ ................................ ................................ ................................ .... 128
MT HEH TGNINIMRETED MORF RF MUTAD YGOLORTEM A LADIORTNE CAO TEMA
METS YESTANIDROOC ................................ ................................ ................................ .................. 128
SECNEREFER ................................ ................................ ................................ ................................ ... 133
ATIV ................................................................................. ................................................ 140
iv