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

在为期两年的研究项目（DFG-GZ: ME1029/16-1）中，在产品开发期间将加强使用统计公差计算（公差分析和公差合成），以便能够对技术系统的操作行为进行早期验证和优化。在此背景下，在研究项目的头两年开发了运动系统的综合公差分析。这种方法使产品开发人员能够确定由制造引起的偏差和由运行中的系统引起的偏差的时间依赖性影响。该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，必须考虑其他类型的偏差，包括装配引起的偏差以及操作相关的偏差，这些偏差尚未被考虑在内。由于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），也可以考虑到操作依赖偏差，这些偏差通常在更大的时间间隔内出现。例子包括在系统使用过程中零件的磨损和松弛。考虑出现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。特别是在高度复杂的系统中，需要考虑到这些相互作用。一般来说，产品开发人员更多地面临的是公差综合问题（将功能关键特性的公差适当地分配给单个零件的特性），而不是公差分析问题。因此，为了将项目取得的成果用于这项任务，应将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佳公差分配/规格，通过最小化公差规格导致的成本，确保系统在整个操作时间内的任何时间点的功能。最后，发展起来的综合公差分析和公差综合的方法必须在适当的程序中具体化和可视化。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，从而获得可重复且可靠的结果。

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.