Tolerance Distribution Optimization for Multi-Part Assembly Cost
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Solution Overview
Problem
Existing process design technologies fail to consider assembly processes and facilities for structures composed of multiple parts, leading to inefficiencies in product design optimization and increased investment costs for assembly facility maintenance.
Innovation Solution
A product design and process design device that includes a storage unit for design specifications, tolerance distribution processing, and facility planning, which generates proposed tolerance distributions and calculates manufacturing and investment costs to optimize production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing process design technology is used, then product design can be completed, but assembly processes and facilities are not considered leading to rework and increased investment costs
Solution Approach 1:
The patent applies preliminary action by integrating assembly process and facility considerations into the product design phase itself. The system evaluates multiple candidate products not only on design accuracy but also on assembly efficiency and facility requirements, making preliminary assessments that prevent rework later in the manufacturing process.
Solution Approach 2:
The patent implements feedback mechanisms by using evaluation indexes that incorporate assembly process feedback and facility maintenance cost information. This feedback loop allows the system to iteratively optimize product designs based on assembly efficiency metrics and facility investment requirements, ensuring that design decisions account for downstream manufacturing considerations.
2Ease of manufacture
If tolerance distribution is optimized for part manufacturing, then manufacturing cost is reduced, but assembly facility error and maintenance investment are not considered
Solution Approach 1:
The patent merges part manufacturing cost optimization with assembly facility maintenance investment consideration into a unified evaluation framework. The system simultaneously evaluates both manufacturing costs and facility maintenance requirements, integrating these previously separate considerations into a single comprehensive product selection and optimization process.
Solution Approach 2:
The patent applies parameter changes by introducing new evaluation parameters that capture the relationship between tolerance distribution and facility maintenance investment. The system modifies the evaluation criteria to include facility error rates and maintenance costs as variables that change based on selected product designs and tolerance specifications.
3Reliability
If multiple candidate products are evaluated, then optimal product selection is achieved, but evaluation time and computational resources increase
Solution Approach 1:
The patent applies partial action by implementing a staged evaluation process where candidate products are assessed using progressively refined criteria. The system performs preliminary evaluations using key metrics first, then applies more comprehensive assessment only to promising candidates, reducing overall evaluation time while maintaining selection optimality.
Solution Approach 2:
The patent uses preliminary action by pre-establishing evaluation frameworks, data structures, and computational models before the actual product selection process. This preliminary preparation includes setting up the evaluation index system and organizing manufacturing cost and facility maintenance data, which accelerates the subsequent product evaluation and selection process.
Data Source
AI summary
A product design and process design device includes: a storage unit that stores design specification information containing the tolerance of a dimensional variation at any site of an assembly product, part dimension error information, assembly facility error information, assembly tolerance information, the part dimension error information, and the assembly facility error information, part manufacturing cost information, and facility investment cost information with respect to the assembly facility error information; a tolerance distribution processing unit that uses the assembly tolerance information to generate proposed tolerance distributions that differ in distributional combination with respect to each error, and calculates part manufacturing costs and facility investment costs; a facility planning processing unit that determines a proposed tolerance distribution, with, as an evaluation index, total production costs respectively including the sums of the part manufacturing costs and the facility investment costs calculated; and an output unit that outputs the proposed tolerance distribution.