Optimal design of controlled multibody dynamic systems for performance, robustness and tolerancing

The multidisciplinary design approach has gained increasing popularity in recent years due to its ability to deal with conflicting design requirements imposed by discipline-specific objectives. The traditional design process involving multiple disciplines is typically a sequential process where the design objectives are met one at a time in a sequence of designs. However, in doing so, unnecessary limitations are imposed on the design parameters and the final design is far from being optimal. The effectiveness of integrated design methodology has been proven and such designs are being obtained in many applications. However, most of the work in this area has been problem and/or system specific and does not address important manufacturing considerations, such as tolerance allocation, robustness with respect to machining tolerances, etc. The results presented in this paper are intended to contribution towards filling these gaps. In particular, the new approach will help designers avoid a common known pitfall of performance optimization, i.e. the fact that designs that are optimized for performance alone are notoriously sensitive to deviations from the nominal design. Thus, optimizing for performance alone leads to designs that fall below acceptable standards of robustness; they are also expensive to manufacture because the tolerances must be kept very tight to ensure acceptable performance. The approach presented here will allow the user to systematically tradeoff performance versus robustness and tolerancing concerns. A proof-of-concept example that was solved to evaluate this methodology is also presented in this paper. This example provides a convincing demonstration of the fact that small sacrifices in performance can yield huge benefits in the other areas, provided a methodology is available for making these tradeoffs in a systematic way. This especially can be used by designers in various fields such as automotive, aerospace, deployable structures, machine tools (including hexapods), robotic systems, precision machinery, etc.