Failures can occur in brushless alternators due to interferences between the moving and stationary parts, called “rub.” Improper design of component target dimensions and tolerances can result in interferences. A method was developed to evaluate the component tolerances that can create interference in a brushless alternator. Mathematic models were created to relate target dimensions to the interferences. Monte Carlo simulation was utilized to statistically evaluate the effects of tolerances on failure rate. This method allows a designer to avoid potential rub failures while still in the design phase. It can also be used to analyze rotary machines of similar designs.

Issue Section:
Technical Papers
Keywords:
alternators, Monte Carlo methods, production engineering computing, tolerance analysis, failure analysis, design, production equipment
Topics:
Algorithms, Failure, Machinery, Stators, Dimensions, Design, Manufacturing, Rotors, Computer simulation
1.
Lee
,
J.
, and
Johnson
,
G. E.
, 1993, “
Optimal Tolerance Allotment Using Genetic Algorithm and Truncated Monte Carlo Simulation
,”
Comput.-Aided Des.
0010-4485,
25
(
9
), pp.
601
–
611
.
Crossref
Search ADS
 
2.
Lin
,
C-Y.
,
Huang
,
W-H.
,
Jeng
,
M-C.
, and
Dong
,
J-L.
, 1997, “
Study of an Assembly Tolerance Allocation Model Based on Monte Carlo Simulation
,”
J. Mater. Process. Technol.
0924-0136
70
, pp.
9
–
16
.
Crossref
Search ADS
 
3.
Chen
,
M-S.
, 1995, “
Optimizing Tolerance Allocation for a Mechanical Assembly With Nonlinear Multiple Constraints
,”
J. Chin. Soc. Mech. Eng.
0257-9731,
16
(
4
), pp.
349
–
361
.
4.
Zhou
,
Z.
,
Huang
,
W.
, and
Zhang
,
L.
, 2001, “
Sequential Algorithm Based on Number Theoretic Method for Statistical Tolerance Analysis and Synthesis
,”
Trans. ASME
,
123
, pp.
490
–
493
.
5.
Gadallah
,
M. H.
, and
Eimaraghy
,
H. A.
, 1994, “
The Tolerance Optimization Problem, Using a System of Experimental Design
,”
Design Automation Conference (ASME)
,
169
(
1
), pp.
251
–
265
.
6.
Schmeiser
,
B.
, 2004, “
Simulation Output Analysis: a Tutorial Based on one Research Thread
,”
Proceedings of the Winter Simulation Conference
,
IEEE
, Piscataway, N.J.
7.
Montgomery
,
D.
, and
Runger
,
G.
, 2003,
Applied Statistics and Probability for Engineers
, 3rd ed.,
Wiley
, New York.
Copyright © 2005
 by American Society of Mechanical Engineers
You do not currently have access to this content.