Adaptive Quality Control in Tolerancing and Production Strategies for the Economic Production of High Precision Products

激励复杂产品的关键功能往往只有通过精密零部件的使用才能实现。因此，生产商面临着高质量要求、成本压力和越来越多的产品变种。特别是，通常公差小于5μm的微型元件具有挑战性。在制造零件时避免技术上的固有工艺偏差，随时满足质量要求。成本效益高的精密产品的实现往往是开发、制造和装配过程中的目标冲突，一方面在较高偏差下以高产量节省生产成本，另一方面防止大量具有箭头公差的刮伤单元，以确保产品在较高性能下的功能。甚至达到了制造过程的技术极限，生产出了尖端产品。一般来说，有两种方法来应对这一挑战：由产品设计者自适应地分配公差或由生产计划者自适应地选择生产策略。这两种方法都为生产商在市场竞争中生产尚未系统分析的经济型精密产品提供了基本的概念。将制定一种新的整体容差分配方法和适应性生产战略，评估产品的技术和经济价值。该方法将工程设计要求、产品性能指标、概率制造、半偏差和检验不确定性结合在一个公共模型中，可以定量地评估自适应公差和自适应生产策略对设计、制造、装配和产品功能性能的影响。自适应公差用于在整体技术和经济方面分配最优的特征公差。自适应生产策略在网络物理生产系统中使用单独的实时评估，通过相关组件的过度完成来补偿组件偏差。因此，可以实现更窄的公差裕度，满足质量要求。功能性产品模型的开发使详细的产品知识能够融入上述战略。包含对影响产品功能实现的制造偏差的定量依赖，以评估所引入的技术和经济方面的战略。通过一个典型的工业应用，对所开发的方法在质量提高和成本效益方面进行了结果证明。牙科仪器的微型齿轮就是一个典型的例子，包括许多高质量的要求和复杂的特征相互作用。因此，所开发的方法在进一步的用例上的可转移性和普遍适用性得到了保证。

Motivation Key functions of complex products often can only berealized by precision component use. Thus, producers are confrontedwith high quality requirements, cost pressure and a rising number ofproduct variants. Especially, micro components, which often havetolerances of less than 5 μm, are challenging. Technologicalimmanent process deviations obviate to manufacture components,meeting quality requirements at any time. Often cost-efficientrealization of precision products is a conflict of objectives in thedevelopment, manufacturing and assembly process, savingproduction cost with high throughput under higher deviations on theone hand and preventing high number of scraped units with morenarrow tolerances assuring the products functionality under highercapabili-ties on the other one. Even technological limits of themanufacturing processes are reached, produc-ing cutting-edgeproducts. In general, there are two approaches to cope with thischallenge: an adap-tive allocation of the tolerances by the productdesigner or an adaptive choice of the production strategy by theproduction planner. Both approaches provide fundamental conceptsfor producers in the market competition of producing economic qualityprecision products, which have not been sys-tematically analysed incombination. Approach A new holistic approach of tolerance allocationand adaptive production strategies will be developed, assessingtechnical and economic valuation of the product. The approach bringsthe en-gineering design requirements, product performanceindicators, probabilistic manufacturing and as-sembly deviations andinspection uncertainties together in a common model, where theeffects of adaptive tolerancing and adaptive production strategies ondesign, manufacturing, assembly and product function performancescan be evaluated quantitatively. Adaptive tolerancing serves toallocate optimal characteristic tolerances under holistic technical andeconomic aspects. Adaptive production strategies take use ofindividual real-time assessment in cyber-physical production systems,compensating component deviations with over-fulfilment of anassociated component. Thus, more narrow tolerance margins can berealized, meeting the quality requirements. The development of afunctional product model enables detailed product knowledgeintegration into the aforementioned strategies. Quantitativedependencies on manufacturing deviations affecting the productsfunctional fulfilment are contained to assess the introduced strategieson technical and eco-nomic aspects. Result Proof on the developedmethodology in quality increase and cost-efficiency will be conductedon an exemplarily industrial application. Micro gears for dentalinstruments serve as an exemplarily demonstration, includingnumerous high quality requirements and complex characteristicinteractions. Thus, the transferability and general applicability ofdeveloped methodologies on further use cases is assured.