Documente Academic
Documente Profesional
Documente Cultură
Statistical Tolerancing
Fritz Scholz
Spring Quarter 2007
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0
The Root Sum Square (RSS) paradigm does not work here!
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S
D
H
B
A
ideal
perturbed holes
X f (x) (density),
CDF
F(x) = P(X x) =
Z x
f (t) dt .
Z x
= X = E(X) =
Mean:
Variance:
t f (t) dt
Standard Deviation:
Z x
(t )2 f (t) dt
p
= var(X)
5
q
Y = a21var(X1) + . . . + a2k var(Xk )
6
0,
as
Y = 1 + . . . + n
and
Y2 = 21 + . . . + 2n .
7
CLT:
Example 1
uniform population on (0,1)
0.8
0.0
0.0
0.4
0.6
0.8
Weibull population
Density
4
3
2
0.5
1.0
x3
1.5
1.0
a lognormal population
5
x2
1
0.0
0.2
x1
Density
0.4
Density
0.2
0.0
Density
0.4
1.2
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
x4
CLT:
Example 2
0.20
0.15
0.10
0.05
0.00
Density
0.25
0.30
x1 + x2 + x3 + x4
CLT:
Example 3
0.0
0.2
0.4
0.6
x1
x2
a lognormal population
Weibull population
0.8
1.0
0.4
0.0
Density
0.8
Density
0.6
0.0
0.2
Density
0.4
1.2
0.0
Density
0.0
0.5
1.0
1.5
x3
0.0
0.5
1.0
1.5
2.0
2.5
3.0
x4
0.4
0.0
Density
0.8
Weibull population
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
x5
10
CLT:
Example 4
Density
x1 + x2 + x3 + x4
Density
x2 + x3 + x4 + x5
11
CLT:
Example 5
uniform population on (0,1)
0.8
0.0
0.0
0.2
0.4
0.6
0.8
x1
x2
a lognormal population
Weibull population
1.0
0.4
0.0
0.0
0.2
Density
0.4
0.8
Density
0.4
Density
0.2
0.0
Density
0.4
1.2
10
x3
15
0.0
0.5
1.0
1.5
2.0
2.5
3.0
x4
12
CLT:
Example 6
0.10
0.05
0.00
Density
0.15
0.20
10
20
30
40
x1 + x2 + x3 + x4
13
CLT:
Example 7
uniform population on (0,1)
0.04
0.00
0.02
Density
0.2
0.0
Density
0.4
0.06
10
15
x1
x2
a lognormal population
Weibull population
20
0.4
Density
3
2
0.0
1
0
Density
0.8
0.0
0.5
1.0
x3
1.5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
x4
14
CLT:
Example 8
0.04
0.02
0.00
Density
0.06
0.08
20
10
10
20
30
40
x1 + x2 + x3 + x4
15
What is a Tolerance?
Tolerances recognize that part dimensions are not what they should be.
should be = nominal or exact according to engineering design
Exact dimensions allow mass production assembly using interchangeable parts
or
Simple Examples
Example 1: A disk should have thickness 1/800 with .00100 tolerance, i.e.,
the disk thickness should be in the range
Example 2: A stack of ten disks should be 1.2500 high with .0100 tolerance,
i.e., the stack height should be in the range
17
Disk Stack
1 8
= 0.125 0.001
1.25
0.01
18
worst case
low stack
.02''
worst case
high stack
.125''
1.25''
20
.0100/10 = .00100
tolerances to the individual disks (item tolerances).
End tolerances can create very tight and unrealistic item tolerances. Costly!
21
nominaltol
nominal+tol
nominal
tol
= Statistical Tolerancing
22
1
D = TOLD so that [D 3D, D + 3D] = tolerance interval
3
The normality assumption is a simplification, but is not essential.
23
1200
99.73%
.135%
600
400
200
18
Density
800
1000
.135%
0.1235
16
0.1240
0.1245
0.1250
0.1255
0.1260
0.1265
disk thickness
24
2
2
S = D1 + . . . + D10 = 10 D = 10 .00100/3 = .0010500
thus S ranges over
00
00
00
1.25 3 10 .001 /3 = 1.25 10 .00100 = 1.2500 .0031600
.0031600 =
200
100
0
Density
300
400
1.240
1.245
1.250
1.255
1.260
28
S =
we have
q
var(D1 + . . . + D10) = 2D1 + . . . + 2D10
q
q
TOLS = 3S = 3 2D1 + . . . + 2D10 = (3D1 )2 + . . . + (3D10 )2
q
2
2
TOL1 + . . . + TOL10 = 10 TOLD
=
S 3S contains 99.73% of the S values, because S N (S , 2S ).
This is referred to as the Root Sum Square (RSS) Method of tolerance stacking.
Contrast with arithmetic or worst case tolerance stacking
Numerically TOLi = TOL?i are the same, they are just different in what they
represent: statistical variation range versus worst case variation range.
Again, TOLS and TOL?S represent statistical and worst case variation ranges,
but they are not the same since
q
q
TOL21 + . . . + TOL210 = (TOL?1)2 + . . . + (TOL?10)2 TOL?1 + . . . + TOL?10
We get = only in the trivial cases when
when
n>1
and
n=1
or
TOL1 = . . . = TOLn = 0.
30
31
1
TOLS = n TOLD or TOLD = TOLS
n
As opposed to the worst case tolerancing relationships
TOL?S = n TOL?D
or
1
?
TOLD = TOL?S
n
More generally when the TOLDi are not all the same
TOLS =
TOL21 + . . . + TOL2n
Reverse engineering
or
TOLS TOLDi or
not so obvious.
Reduce the largest TOLDi to get greatest impact on TOLS . TOL?D ???
i
32
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....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
.......
T3
T2
q
T12 + T22 + T32
T1
T1 + T2 + T3 >
33
Benderizing
As much as RSS gives advantages over worst case or arithmetic tolerancing
it was found that the RSS tolerance buildup was often optimistic in practice.
A simple remedy was proposed by Bender (1962) and it was called Benderizing.
It consists in multiplying the RSS expression by 1.5, i.e., use
q
TOLS = 1.5 TOL21 + . . . + TOL2n
This still only grows on the order of n, but provides a safety cushion.
The motivation? When shop mechanics were asked about the dimension accuracy
they could maintain, they would respond based on experience memory.
It was reasoned that a mechanics experience covers mainly a 2 range.
To adjust TOLi = 2i to TOLi = 3i the factor 3/2 = 1.5 was applied.
34
and
Z +TOL
D
1
(t )2 dt
substituting (t )/TOLD = x
TOLD 2TOLD
Z 1
1 2
= TOL2D
x dx
with dt/TOLD = dx
1 2
"
#1
!
2
3
3 (1)3
TOL
x
1
D
= TOL2D
= TOL2D
=
6
6
6
3
1
35
TOLS = 3S =
S =
(3D1 )2 + . . . + (3Dn )2
3 = 1.732.
Density
0.2
0.3
0.4
0.0
0.1
0.2
0.0
Density
0.4
0.5
0.6
0.6
0.7
0.8
0.0
0.5
1.0
1.5
U1 + U2 + U3
2.0
2.5
3.0
0.5
1.0
1.5
2.0
2.5
3.0
U1 + + U4
37
3.5
or
TOL?S = n TOL?D,
TOLS = 3 n TOLD < TOL?S = n TOL?D
when 3 < n.
38
Motivating the
3 cT
Link
= 3 = cT .
uniform density
normal density
c = 1.225
c = 1.369
trapezoidal density: k = .5
triangular density
c = 1.5
elliptical density
c = 1.732
c = 1.306
40
c = 1
Student t density:
df = 4
Student t density:
df = 10
= = 3
c = 2.023
c = 1.134
beta density
= = 2
= = .6
beta density
p = .7 ,
c = 1.342
g = .4
c = 1.512
41
cuniform = 3,
ctrapezoidal =
ctriangular = 1.5,
1 8/2
p
for |z| g,
2g
1p
for g < |z| 1
f (z) =
2(1g)
0
else
cDIN =
i TOLi, i = 1, . . . , n
q
S = 1 + . . . + n and S = 21 + . . . + 2n
By way of 3i = ciTOLi we get for S the tolerance range S TOLS , where
q
q
TOLS = 3S = (31)2 + . . . + (3n)2 = (c1TOL1)2 + . . . + (cnTOLn)2
44
Calculate the resulting critical assembly dimension, i.e., draw ten thicknesses
from a distribution of thicknesses and compute the stack height (sum).
Repeat the above many times, Nsim = 1000 (or Nsim 1000) times.
Form the histogram of the 1000 (or more) critical dimensions.
or Y = X1 + . . . + Xn
For example,
Call
Xi.
Y = 16 + 3 X1 + 2 X2 + 7 X3 + (2) X4
output dimension.
47
L2
L3
L5
L4
L6
G = L1 L2 L3 L4 L5 L6 = L1 (L2 + . . . + L6)
48
X1
...
Xn
Y = f (X1, . . . , Xn)
............................................................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
........................................................................
....................................
Y = f (X1, . . . , Xn)
Smooth Functions f
When the output Y varies smoothly with small changes in the Xi, then
Y a0 + a1 X1 + . . . + an Xn
for all small perturbations in X1, . . . , Xn around 1, . . . , n.
i=1
(Xi i)
using
n f ( , . . . , )
f (1, . . . , n)
n
1
ai =
and a0 = f (1, . . . , n)
i
i
i
i=1
50
51
1.0
1.2
1.4
1.6
x
1.8
2.0
52
1.0
1.5
2.0
x
2.5
53
1.0
1.5
2.0
2.5
x
3.0
3.5
4.0
and
2a0 = 0 .
Y2 = 2a0+a1X1+...+anXn
2
2
2
2
2
= a0 + a1X1 + . . . + anXn = a1X1 + . . . + anXn
54
3 Xi = ci TXi
2
(3Y )2 =
3 a1 X1 + . . . + 3 an Xn
2
2
a1c1TX1 + . . . + ancnTXn
=
CLT = Y N (Y , Y2 ),
2
q
TOLY = 3Y =
a1c1TOLX1
2
+ . . . + ancnTOLXn
2
q
TOLY = 3Y = TOL21 + . . . + TOL2n
regardless of the ai and ci.
56
max 21, . . . , 2n
21 + . . . + 2n
0 ,
as
max a2121, . . . , a2n2n
a2121 + . . . + a2n2n
0 ,
as
Mean Shifts
58
In either case combine this in worst case fashion or arithmetically with the
RSS part variation stack.
The reason for the last worst case stacking step is that the mean shifts
represent persistent effects that do not get played out independently and
repeatedly for each produced part dimension.
59
probability density
part dimension X2
part dimension X3
0.6
assembly stack
Y = X1 + X2 + X3
0.4
0.2
0.0
0.2
0.4
0.6
60
probability density
part dimension X2
part dimension X3
0.6
assembly stack
Y = X1 + X2 + X3
in RSS fashion
0.4
0.2
0.0
0.2
0.4
0.6
61
For the part variation to stay within tolerance there has to be a tradeoff
between variability and mean shift.
62
However, this does not control the mean shift. We could have U and
C pk = 1. Then all part dimensions would be near U = worst case stacking.
63
0 i 1 .
But maintain C pk 1
iTi + 3i Ti = 3i (1 i)Ti
64
1 = . . . = n = 0 = RSS stacking.
1 = . . . = n = 1 = Worst case arithmetical stacking.
65
TOLY =
21c21a21TOL2X1 + . . . + 2nc2na2nTOLXn 2
q
+ (1 1)2a21c21TOL2X1 + . . . + (1 n)2a2nc2nTOL2Xn
The ci are the penalty factors for the distributions governing the mean shifts.
The ci are the penalty factors for the distributions governing part variation.
c = 1
c = 1.225
c = 1.5
c = 1.732
c = 1.369
c = 1.306
67
c = 1
c = 1
df = 4
df = 10
= = .6
= = 3
c = 2.023
c = 1.134
= = 2
p = .7 ,
c = 1.342
g = .4
c = 1.512
68
Other Variants
Rather than dividing up TOL into mean shift and a 3 range (by squeezing
down 3 to maintain C pk 1) we can increase TOL to the sum of the original
Actuator
Ao
TA
Ro
TR
B+
B-
min,o
max,o
B
70
A0 TA and R0 TR?
72
Geometric Considerations
Given A, R and 0 the length of the (neutral position) actuator length is
q
B = B(A, R) = A2 + R2 2AR cos(0) .
Extending/contracting the actuator by x = from the neutral position
s
=
x = 2 arctan
(sx A)(sx R)
,
sx(sx Bx)
max = max(A, R)
and
min = min(A, R) .
73
0 = 55
1.0
2.0
0.0
Density
3.0
max,, 0 0 = 15.325o
15.0
15.2
15.4
15.6
15.8
2.5
min,, 0 0 = 15.999o
2.0
0 = 55
T2 = 0.467o
0.5
1.0
1.5
0.0
Density
max 0
16.6
16.4
16.2
16.0
min 0
15.8
15.6
15.4
75
and
q
T2 = a2min,A TA2 + a2min,R TR2 ,
where
amax,A =
max
,
A
amax,R =
max
,
R
amin,A =
min
,
A
and amin,R =
min
R
All derivatives are evaluated at the nominal values (A0, R0) of (A, R).
These RSS formulae come from the linearization of x (A, R) near (A0, R0), i.e.,
x
x
x(A, R) = x(A0, R0) + (A A0)
+ (R R0)
,
A A=A0,R=R0
R A=A0,R=R0
which is then taken as an approximation for x (A, R) near (A, R) = (A0, R0).
76
Approximation Quality
77
The Derivatives
1
x
=
A 1 + (sxA)(sxR) A
s (s B )
x x
(sx A)(sx R)
sx(sx Bx)
and
x
1
=
R 1 + (sxA)(sxR) R
s (s B )
x x
(sx A)(sx R)
.
sx(sx Bx)
Next we have
s
1
(sx A)(sx R)
(sx A)(sx R)
(sx A)(sx R)
= 2
sx(sx Bx)
sx(sx Bx) A sx(sx Bx)
and
s
1
(sx A)(sx R)
(sx A)(sx R)
(sx A)(sx R)
= 2
.
sx(sx Bx)
sx(sx Bx)
R sx(sx Bx)
78
More Derivatives
We also have the following list of derivative expressions
Bx
A R cos(0)
=q
A
A2 + R2 2AR cos(0)
and
Bx
R A cos(0)
=q
R
A2 + R2 2AR cos(0)
(sx A) 1 A R cos(0)
(sx R) 1 A R cos(0)
=
1
and
=
+1
A
2
B
A
2
B
(sx A) 1 R A cos(0)
(sx R) 1 R A cos(0)
=
+1
and
=
1
R
2
B
R
2
B
sx 1 A R cos(0)
sx 1 R A cos(0)
=
+1
and
=
+1
A 2
B
R 2
B
A R cos(0)
(sx Bx) 1
R A cos(0)
(sx Bx) 1
1
and
1
.
=
=
A
2
B
R
2
B
79
(s
R)
= 2
(s
A)
+
(s
A)
(sx R) sx(sx Bx)
x
x
x
2
A
A
sx (sx Bx)
= 2
(s
R)
(s
A)
+
(s
A)
(sx R) sx(sx Bx)
x
x
x
2
R
R
sx (sx Bx)
(sx R)
R
x
(sx Bx)
(sx R)
R
x
A
x
(sx Bx)
A
x
sx + sx (sx Bx) = [1 + cos(0)] [R A cos(0)] .
R
R
2
2B
81
RSS Calculations
The R function deriv.theta produced the following derivatives for A0 = 12.8,
R0 = 6, 0 = 55, and = 1.6
max
= .00006636499
A
and
min
= .004038650
A
and
max
= 0.04473785
R
min
and
= 0.05810921 .
R
The RSS calculation using normal variation for A and R then gives the following
values for T1 and T2 based on TA = .12 and TR = .14
T1 = 0.3588609
and
T2 = 0.4669441 ,
Numerical Differentiation
The derivation of the derivatives was quite laborious, but R code is compact.
Useful in understanding the variation propagation in the tolerance analysis.
An obvious alternative approach is numerical differentiation.
It requires the evaluation of the function x , used in the simulation anyway.
The respective derivatives are approximated numerically at (A, R) = (A0, R0) by
difference quotients for very small values of
x(A0 + , R0) x(A0, R0)
x
A A=A0,R=R0
x
x(A0, R0 + ) x(A0, R0)
.
R A=A0,R=R0
83
max
.00006636269
A A=A0,R=R0
and
min
.004038651
A A=A0,R=R0
and
max
0.04473777
R A=A0,R=R0
and
min
0.05810908 .
R A=A0,R=R0
These agree very well with the derivatives obtained previously via calculus.
84
(
max
a212X
1
,...,
a2n2Xn
a212X + . . . + a2n2Xn
a212X + . . . + a2n2Xn
1
1
i.e., none of the a2i 2i terms dominates the others.
)
is small,
q
q
TY = 3Y = a21(3X1 )2 + . . . + a2n(3Xn )2 = c21a21T12 + . . . + c2na2nTn2 .
applicable for linear approximations to smooth functions of any random inputs,
subject to above CLT condition.
The Ti should be small for linearization to be reasonable.
86
The next few slides show simulations with 0 = 55 and = 1.6 and
87
0 = 55o
Density
T1 = 0.359o
15.0
15.2
15.4
15.6
15.8
min,, 0 0 = 15.999o
T2 = 0.469o
1.0
2.0
0 = 55o
0.0
Density
3.0
max 0
16.6
16.4
16.2
16.0
15.8
15.6
15.4
min 0
88
2.0
1.0
0 = 55o
0.0
0.5
Density
1.5
max,, 0 0 = 15.325o
14.5
15.0
15.5
16.0
1.0
min,, 0 0 = 15.999o
T2 = 0.809o
0.5
0 = 55o
0.0
Density
1.5
2.0
max 0
17.0
16.5
16.0
min 0
15.5
15.0
89
2.0
1.0
0 = 55o
0.0
0.5
Density
1.5
max,, 0 0 = 15.325o
14.5
15.0
15.5
16.0
1.0
min,, 0 0 = 15.999o
T2 = 0.81o
0.5
0 = 55o
0.0
Density
1.5
2.0
max 0
17.0
16.5
16.0
min 0
15.5
15.0
90
20
10
0 = 55o
Density
15
max,, 0 0 = 15.325o
15.25
15.30
15.35
15.40
10
min,, 0 0 = 15.999o
T2 = 0.0809o
0 = 55o
Density
15
20
max 0
16.10
16.05
16.00
min 0
15.95
15.90
91
q
360
T1 = (.00006636269)2 3 .122 + (.04473777)2 3 .142
= 0.6215642
2
and
q
360
2
2
2
2
= 0.8087691
T2 = (.004038651) 3 .12 + (.05810908) 3 .14
2
using the inflation factor c = 3 and the numerical derivatives in both cases.
Reasonable agreement with the values .622 and .81 from simulation.
Not surprising when linearization is good. We are simply using the variance rules.
However, T1 and T2 do not capture the variation range of x , since the CLT fails.
Tightening the tolerances in last case = echoes the uniform distribution of R.
Linearity was not good with wider tolerances = tilted uniform.
92
theta.simUUUU
Here we let 4 inputs vary with result shown on next slide.
R U (6 .15, 6 + .15)
1.0
0.4
0.6
0 = 55o
0.0
0.2
Density
0.8
T1 = 1.38o
14
15
16
17
0.6
min,, 0 0 = 15.999o
T2 = 1.59o
0.2
0.4
0 = 55o
0.0
Density
0.8
1.0
max 0
18
17
16
min 0
15
14
94
Final Comments
This actuator example has been very instructive. It showed
the effect of the CLT when sufficiently many contributing inputs are involved
Voltage Amplifier
96
Output Voltage V0
The amplified output voltage is a function of 6 variables,
2 input voltages E1, and E2 and 4 resistances R1, . . . , R4
R2
E1 1 + R
1
R3
1+R
4
E2 R2
R1
Nominal values:
The Derivatives
R2
1+R
V0
1
=
,
R
E1 1 + 3
R4
V0
R2
=
E2
R1
E1
E2
V0
R1
=
R
R2 1 + 3 R1
R4
R2 E2 R2
V0
E1
2+
=
,
R
R1
R21
1 + R3 R1
4
R2
R2
E
1
+
E
1
+
1
1
R1
R1
V0
1
V0
R3
=
,
=
2
2 2
R3
R4
R4
R3
R3
R4
1+R
1+R
4
4
98
V.amp.simN2U4(del=.1)
> V.amp.simN2U4(del=.1)
$V0
[1] 20
$delta
[1] 0.1
$derivatives
[1] 10.000000000 -10.000000000
+ -0.090909091
0.009090909
-1.909090909
0.190909091
$sigmas
[1] 0.33314890 0.33326565 1.10195837 1.10243208
+ 0.05248074 0.05246410
$nominals
[1]
1 -1
10 100
10 100
99
V.amp.simN2U4(del=.1)
0.25
0.00
0.05
0.10
Density
0.15
0.20
= 0.1
14
16
18
20
V0
22
24
26
100
V.amp.simN2U4(del=.05)
> V.amp.simN2U4(del=.05)
$V0
[1] 20
$delta
[1] 0.05
$derivatives
[1] 10.000000000 -10.000000000
+ -0.090909091
0.009090909
-1.909090909
0.190909091
$sigmas
[1] 0.16657056 0.16676230 0.55079156 0.55108759
+ 0.02627634 0.02624854
$nominals
[1]
1 -1
10 100
10 100
101
V.amp.simN2U4(del=.05)
0.5
0.0
0.1
0.2
Density
0.3
0.4
= 0.05
17
18
19
20
V0
21
22
23
102
V.amp.simU6(del=.1)
> V.amp.simU6(del=.1)
$V0
[1] 20
$delta
[1] 0.1
$derivatives
[1] 10.000000000 -10.000000000
+ -0.090909091
0.009090909
-1.909090909
0.190909091
$sigmas
[1] 0.57739282 0.57698360 1.10221137 1.10199967
+ 0.05251682 0.05253420
$nominals
[1]
1 -1
10 100
10 100
103
V.amp.simU6(del=.1)
Ei ~ U(i i , i + i ) , Ri ~ U(i i , i + i )
0.10
0.05
0.00
Density
0.15
0.20
= 0.1
14
16
18
20
22
24
26
V0
104
V.amp.simN6(del=.1)
> V.amp.simN6(del=.1)
$V0
[1] 20
$delta
[1] 0.1
$derivatives
[1] 10.000000000 -10.000000000
+ -0.090909091
0.009090909
-1.909090909
0.190909091
$sigmas
[1] 0.33348276 0.33332256 0.63653780 0.63714909
+ 0.03031808 0.03029352
$nominals
[1]
1 -1
10 100
10 100
105
V.amp.simN6(del=.1)
0.4
0.2
0.1
0.0
Density
0.3
= 0.1
16
18
20
V0
22
106
V.amp.simN6(del=.05)
> V.amp.simN6(del=.05)
$V0
[1] 20
$delta
[1] 0.05
$derivatives
[1] 10.000000000 -10.000000000
+ -0.090909091 0.009090909
-1.909090909
0.190909091
$sigmas
[1] 0.16656830 0.16669687 0.31840687 0.31774622
+ 0.01514106 0.01513453
$nominals
[1]
1 -1
10 100
10 100
107
V.amp.simN6(del=.05)
0.8
0.4
0.2
0.0
Density
0.6
= 0.05
18
19
20
21
V0
108