Paul Drake

9.1 Introduction

Tolerance analysis is the process of taking known tolerances and analyzing the combination of these

tolerances at an assembly level. This chapter will define the process for analyzing tolerance stacks. It
will

show how to set up a loop diagram to determine a nominal performance/assembly value and four
techniques

to calculate variation from nominal.

The most important goal of this chapter is for the reader to understand the assumptions and risks
that

go along with each tolerance analysis method.

9.2 Analyzing Tolerance Stacks

Fig. 9-1 describes the tolerance analysis process.

9.2.1 Establishing Performance/Assembly Requirements

The first step in the process is to identify the requirements for the system. These are usually
requirements

that determine the “performance” and/or “assembly” of the system. The system requirements will,
either

directly, or indirectly, flow down requirements to the mechanical subassemblies. These

requirements

usually determine what needs to be analyzed. In general, a requirement that applies for most
mechanical

subassemblies is that parts must fit together. Fig. 9-2 shows a cross section of a motor assembly. In
this

example, there are several requirements.

• Requirement 1. The gap between the shaft and the inner bearing cap must always be greater than
zero

to ensure that the rotor is clamped and the bearings are preloaded.

• Requirement 2. The gap between the housing cap and the housing must always be greater than
zero to

ensure that the stator is clamped.