Functional product validation and optimization of technical systems in motion as a part of product lifecycle oriented tolerance management

在研究项目(DFG-GZ：ME1029/16-1)的两年续展期间，将加强产品开发期间统计公差计算(公差分析和公差综合)的使用，以便能够及早验证和优化技术系统的运行行为。在此背景下，在研究项目的头两年开发了运动系统的综合容差分析。这种方法使产品开发人员能够确定系统运行中制造引起的偏差和操作引起的偏差的时间依赖效应。研究项目继续进行的第一个目标是将现有的集成公差分析方法扩展到更复杂的技术系统以及系统的完整运行时间。因此，必须考虑其他种类的偏差，包括装配引起的偏差以及与操作相关的偏差，这些偏差还没有被考虑到。由于所考虑的操作时间间隔的延长(完整的操作时间而不是仅仅一个运动周期)，还可以考虑操作相关的偏差，这些偏差通常在大得多的时间间隔中出现。例如，该系统在使用过程中部件磨损和松弛。考虑出现的偏差之间的相互作用使产品开发人员能够量化单个参数对功能关键特性的影响以及参数之间的影响。特别是在复杂程度较高的系统中，需要考虑这些相互作用。一般来说，产品开发人员更多地面临公差综合(将功能关键特性的公差适当分配给单个部件的特性)的问题，而不是公差分析。因此，为了更好地利用本项目已有的成果，必须将已开发的综合公差分析转化为综合公差综合。因此，产品开发人员将能够确定最优的公差分配/规格，通过最小化公差规格产生的成本来确保系统在整个运行时间内的任何时间点的功能。最后，所开发的关于集成公差分析和公差综合的方法必须在适当的过程中被制定和可视化。因此，产品开发人员可以使用该方法系统地进行统计公差分析和综合，从而获得重复性好、可靠性高的结果。

Within the two-year continuation of the research project (DFG-GZ: ME1029/16-1) the use of statistical tolerance calculations (tolerance analysis and tolerance synthesis) during the product development will be enhanced in order to enable the early validation and optimization of a technical system`s operational behavior. In this context, the integrated tolerance analysis of systems in motion was developed during the first two years of the research project. This approach enables the product developer to determine the time-depending effects of manufacturing-caused deviations and operation-depending deviations of a system in motion.The first aim of the research project`s continuation is the extension of the existing integrated tolerance analysis-approach towards more complex technical systems as well as the system`s complete operation time. Therefore, additional kinds of deviations have to be taken into account, including assembly-caused deviations as well as operation-depending deviations, which haven`t been considered yet. Due to the extension of the considered operation time interval (complete operation time instead of just one motion cycle) also operation-depending deviations can be taken into account which effects usually appear during much larger time intervals. Examples include wear and relaxation of parts during the system`s use. The consideration of interactions between the appearing deviations enables the product developer to quantify the effect of a single parameter on a functional key characteristic as well as the effects of the parameters among themselves. Especially in case of systems of higher complexity these interactions need to be taken into account.In general the product developer is more often faced with the problem of tolerance synthesis (the appropriate allocation of the functional key characteristic`s tolerance towards the single part`s characteristics) instead of tolerance analysis. So in order to use the achieved results of the project for this task, the developed integrated tolerance analysis should be transferred into an integrated tolerance synthesis. So the product developer will be able to determine the optimal tolerance allocation/specification, ensuring the system`s functionality at any point in time during the complete operation time by minimizing the costs resulting from the tolerance specification.Finally, the developed approaches on the integrated tolerance analysis and tolerance synthesis have to be formulated and visualized in an appropriate procedure. So the product developer can use this methodology to perform statistical tolerance analysis and synthesis systematically achieving reproducible und reliable results.