RobustDesign PDF

Robust Design
1
Introduction
2
Engineering Design
3
Axiomatic Design
4
Robust Design
5
Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Mar. 8, 2010 82 / 113
Robust Design
Robust Design
References
1
Taguchi, G., On Robust Technology Development. Bringing
Quality Engineering Upstream, 1993 (ASME Press, New York)
2
Caro, S., Bennis, F. and Wenger, P., Tolerance Synthesis of
Mechanisms: a Robust Design Approach, ASME Journal of
Mechanical Design, 127, pp. 8694
3
Caro, S., 2004, Conception Robuste de M ecanismes, Th` ese de
doctorat, Ecole Centrale de Nantes, Universit e de Nantes, Nantes,
France
Robust Design
Robust Design
References
1
2
3
France
Robust Design
Robust Design
References
1
2
3
France
Robust Design
Robust Design
References
1
2
3
France
Robust Design
Robust Design
The roots of poor quality in goods or services are to be found in
the sensitivity of these to variations in operation conditions
(Taguchi, 78).
The design of a mechanism is robust when its performance is as
little sensitive to variations in design variables and design
environment parameters as possible (Caro, 03).
Robust Design
Robust Design
The roots of poor quality in goods or services are to be found in
the sensitivity of these to variations in operation conditions
(Taguchi, 78).
The design of a mechanism is robust when its performance is as
little sensitive to variations in design variables and design
environment parameters as possible (Caro, 03).
Robust Design
Robust Design (Contd)
Principles due to G. Taguchi (1987):
Minimum loss function;
minimum sensitivity of the designed object to variations in the
design environment.
Robust Design
Principles due to G. Taguchi (1987):
Minimum loss function;
minimum sensitivity of the designed object to variations in the
design environment.
Robust Design
Taguchis philosophy is based on two concepts
The loss function: measures the quality loss for the customer due to a
bad product design;
Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=
S
N
= log
10
(18)
: mean of the performance function
: standard deviation in the performance function
Robust Design
bad product design;
=
S
N
= log
10
(18)
Robust Design
bad product design;
=
S
N
= log
10
(18)
Robust Design
bad product design;
=
S
N
= log
10
(18)
Robust Design
bad product design;
=
S
N
= log
10
(18)
Robust Design
Taguchis Example
Quality levels of Sony color TV sets made in Japan and San Diego
Robust Design
Example (Contd)
Process capability index
C
p
=
Tolerance
6 Standard deviation
(19)
C
p
(Japan) 1 (20)
C
p
(San Diego) =
Tolerance
6
Tolerance
12
= 0.577 (21)
Robust Design
Example (Contd)
C
p
=
Tolerance
(19)
C
p
(Japan) 1 (20)
C
p
(San Diego) =
Tolerance
6
Tolerance
12
= 0.577 (21)
Robust Design
Example (Contd)
C
p
=
Tolerance
(19)
C
p
(Japan) 1 (20)
C
p
(San Diego) =
Tolerance
6
Tolerance
12
= 0.577 (21)
Robust Design
When an objective characteristic y deviates from its target value m,
some nancial loss will occur.
Loss function
y m L(y) = L(m) = 0 (22)
L
(m) = 0 (23)
by means of a Taylor series expansion of L around m
L(y) = L(m) +
L
(m)
1!
(y m) +
L
(m)
2!
(y m)
2
+ (24)
L(y) =
L
(m)
2!
(y m)
2
+ (25)
Robust Design
Loss function
y m L(y) = L(m) = 0 (22)
L
(m) = 0 (23)
L(y) = L(m) +
L
(m)
1!
(y m) +
L
(m)
2!
(y m)
2
+ (24)
L(y) =
L
(m)
2!
(y m)
2
+ (25)
Robust Design
Loss function
y m L(y) = L(m) = 0 (22)
L
(m) = 0 (23)
L(y) = L(m) +
L
(m)
1!
(y m) +
L
(m)
2!
(y m)
2
+ (24)
L(y) =
L
(m)
2!
(y m)
2
+ (25)
Robust Design
Loss function
y m L(y) = L(m) = 0 (22)
L
(m) = 0 (23)
L(y) = L(m) +
L
(m)
1!
(y m) +
L
(m)
2!
(y m)
2
+ (24)
L(y) =
L
(m)
2!
(y m)
2
+ (25)
Robust Design
Loss function
L(y) = k(y m)
2
(26)
with
k =
Cost of a defective product
Tolerance
2
=
A
2
(27)
Robust Design
Solution
Let the adjustment cost be: A = $6
k =
6
5
2
= $0.24 (28)
with
L = $0.24(y m)
2
(29)
Robust Design
Solution
Robust Design
Robust Design Problem Formulation
Design Variables (DVs)
Nominal values are controllable;
the real values are uncertain due to manufacturing errors, wear...
x = [x
1
, x
2
, . . . x
l
]
T
(30)
Design Environmental Parameters (DEPs)
are not controllable
Examples: ambient temperature and pressure, behavior of the
user of the good under design
p = [p
1
, p
2
, . . . p
m
]
T
(31)
Robust Design
Robust Design Problem Formulation
Design Variables (DVs)
Nominal values are controllable;
the real values are uncertain due to manufacturing errors, wear...
x = [x
1
, x
2
, . . . x
l
]
T
(30)
Design Environmental Parameters (DEPs)
are not controllable
Examples: ambient temperature and pressure, behavior of the
user of the good under design
p = [p
1
, p
2
, . . . p
m
]
T
(31)
Robust Design
Robust Design Problem Formulation (Contd)
Performance Functions (PFs)
depend on DVs and DEPs
f = [f
1
, f
2
, . . . f
n
]
T
(32)
f = f (x, p) (33)
Robust Design
Performance Functions (PFs)
depend on DVs and DEPs
f = [f
1
, f
2
, . . . f
n
]
T
(32)
f = f (x, p) (33)
Robust Design
Rocker-Crank Mechanism
x = [l
c
, l
r
, e]
T
p = [f
p
, ]
T
f = N
Objective:
min(f,
f
)
Robust Design
x = [l
c
, l
r
, e]
T
p = [f
p
, ]
T
f = N
Objective:
min(f,
f
)
Robust Design
x = [l
c
, l
r
, e]
T
p = [f
p
, ]
T
f = N
Objective:
min(f,
f
)
Robust Design
x = [l
c
, l
r
, e]
T
p = [f
p
, ]
T
f = N
Objective:
min(f,
f
)
Robust Design
x = [l
c
, l
r
, e]
T
p = [f
p
, ]
T
f = N
Objective:
min(f,
f
)
Robust Design
Optimization Problem
Minimize f(x) = {f
1
, . . . , f
m
}
Subject to: h
j
(x) = 0, j = 1, . . . , p
g
k
(x) 0, k = 1, . . . , q
x
l
l
x
l
x
u
l
, l = 1. . . , n
Robust Design
Robust Optimization Problem
Statistical formulation
Minimize

f
i
(x, p),
f
i
(x, p)
, i = 1, . . . , n
Subject to:
g
i
(x, p) +k
g
i
(x, p) 0, j = 1, . . . , r
Knowing: p,
p
,
x
Robust Design
Robust Optimization Problem
Statistical formulation
Minimize

f
i
(x, p),
f
i
(x, p)
, i = 1, . . . , n
Subject to:
g
i
(x, p) +k
g
i
(x, p) 0, j = 1, . . . , r
Knowing: p,
p
,
x
Robust Design
Robust Optimum Solution
Robust Design
Robustness Index
Robust Design
Sensitivity Jacobian Matrix
Robust Design
Design Sensitivity
Robust Design
Design sensitivity Hyper-ellipsod
Robust Design
Robustness Index
Robust Design
Robustness Index (Contd)
Robust Design
Robustness Indices Comparison
Robust Design
Selection of the Robustness Index
Robust Design
Tolerance Synthesis Method
Robust Design
Case Study: 3R manipulator
Robust Design
Case Study: 3R manipulator (Contd)
Robust Design
Conclusion

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