Integrated Robust Design Method Based on Maximum Tolerance Region

Traditionally,parameter design is carried out prior to tolerance design. However, this two-step design strategy cannot guarantee optimal robustness for products' quality. The proposed integrated robust design method determined the optimal parameter and tolerance simultaneously by calculating the maximum tolerance region,thereby improving the quality of products. In addition,the proposed method did not need uncertainty analysis to obtain the maximum tolerance region,so that the calculation cost could be decreased. And the method avoided the difficulty of gaining costtolerance function as maximum tolerance region represented both demand of cost and robust. Finally,an amplifier circuit case was conducted for verification purpose. Based on the results, the proposed approach could provide robust solution with optimal maximum tolerance region.

Development of six sigma concurrent parameter and tolerance design method based on response surface methodology

Using Response Surface Methodology (RSM), an optimizing model of concurrent parameter and tolerance design is proposed where response mean equals its target in the target being best. The optimizing function of the model is the sum of quality loss and tolerance cost subjecting to the variance confidence region of which six sigma capability can be assured. An example is illustrated in order to compare the differences between the developed model and the parameter design with minimum variance. The results show that the proposed method not only achieves robustness, but also greatly reduces cost. The objectives of high quality and low cost of product and process can be achieved simultaneously by the application of six sigma concurrent parameter and tolerance design.

Optimization of Quality Consistency Problem of Electromechanical Component due to Manufacturing Uncertainties with a Novel Tolerance Design Method

The consistency problem caused by uncertainties in manufacturing process is a significant factor influencing the quality of electromechanical components. Currently, there are two approaches for reducing the influence of uncertainties. The first one is to improve the resistance capability of design scheme by using robust parameter design( RPD) method with nonlinear feature of controllable factors. The second one is to control the influence of uncertainties by using robust tolerance design( RTD) method with quality loss function,setting the optimal tolerance with the minimum total product loss as the objective. However, as for the electromechanical component, it is difficult to achieve nonlinear region owing to the restrictions of design parameters. In addition,the establishment of cost function in manufacturing process is also confronted by practical difficulties. In order to solve the quality consistency problem under the influence of manufacturing uncertainties,a novel tolerance design method was proposed for the electromechanical components. Through the experiment design and contribution rate analysis, key factors influencing the quality consistency were determined,and the tolerance allocation scheme was confirmed according to the consistency objective of quality.Then, quality distribution characteristics before and after the consistency optimization were analyzed and verified through the Monte Carlo stochastic simulation. The application result of electromagnetic relay proves the effectiveness of the method proposed in this paper.

A CAD MODEL FOR FUZZY CONCURRENT TOLERANCE

Research situation of concurrent tolerance design has been analyzed. As fuzzy factors are objective and unavoidable in concurrent tolerance design, fuzzy optimization theory is applied in the design. A new mathematical model of concurrent tolerance design is constructed.

A method of multi-objective reliability tolerance design for electronic circuits

Tolerance design plays an important role in reliability design for electronic circuits. The traditional method only focuses on the consistency of output response. It is not able to meet the needs of increasing development of electronic products. This paper researches the state of related fields and proposes a method of multi-objective reliability tolerance design. The characteristics of output response and operating stresses on critical components are both defined as design objectives. Critical components and their operating stresses are determined by failure mode and effect analysis （FMEA） and fault tree analysis （FTA）. Sensitivity analysis is carried out to determine sensitive parameters that affect the design objectives significantly. Monte Carlo and worst-case analysis are utilized to explore the tolerance levels of sensitive parameters. Design of experiment and regression analysis are applied in this method. The optimal tolerance levels are selected in accord with a quality-cost model to improve consistency of output response and reduce failure rates of critical components synchronously. The application in light-emitting diode （LED） drivers indicates details and potential. It shows that the proposed method provides a more effective way to improve performance and reliability of electronic circuits.

Design of passive fault-tolerant flight controller against actuator failures

The problem of designing passive fault-tolerant flight controller is addressed when the normal and faulty cases are prescribed. First of all, the considered fault and fault-free cases are formed by polytopes. As considering that the safety of a post-fault system is directly related to the maximum values of physical variables in the system, peak-to-peak gain is selected to represent the relationships among the amplitudes of actuator outputs, system outputs, and reference commands. Based on the parameter dependent Lyapunov and slack methods, the passive fault-tolerant flight controllers in the absence/presence of system uncertainty for actuator failure cases are designed, respectively. Case studies of an airplane under actuator failures are carried out to validate the effectiveness of the proposed approach