Neue Normenkonzepte nach ISO /TR 14638 zwingen Unternehmen sich neu zu orientieren, um normgerechtes und wertschöpfendes Toleranzmanagement durchzuführen. INNEO-Produkte können dabei helfen.

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Els serveis de telecomunicacions i sistemes radar estan migrant a freqüències mil•limètriques (MMW), on es disposa d 'una major amplada de banda i conseqüentment d'una major velocitat de transmissió de dades. Aquesta migració requereix de l'ús de diferents tecnologies amb capacitat d'operar a la banda de freqüències mil•limètriques (30 a 300 Ghz), i més concretament en les bandes Ka (26,5 - 40GHz), V (50 – 75GHz) i W (75 – 110GHz). En moltes aplicacions i sobretot en aquelles on l'antena forma part d'un dispositiu mòbil, es cerca poder utilitzar antenes planes, caracteritzades per tenir unes dimensions reduïdes i un baix cost de fabricació. El conjunt de requeriments es pot resumir en obtenir una antena amb capacitat de reconfigurabilitat i amb un baix nivell de pèrdues en cada una de les bandes de freqüència. Per tal d'afrontar aquests reptes, les dimensions de les antenes mil•limètriques, juntament amb els tipus de materials, toleràncies de fabricació i la capacitat de reconfigurabilitat ens porten a l'ús de processos de microfabricació. L'objectiu d'aquesta tesis doctoral és l'anàlisi dels conceptes mencionats, tipus de materials, geometries de línia de transmissió i interruptors, en el context de les freqüències mil•limètriques, així com la seva aplicació final en dissenys d'antenes compatibles amb els processos de microfabricació. Finalment, com a demostració s'han presentat dissenys específics utilitzables en tres aplicacions a freqüències mil•limètriques: Sistemes de Comunicació per Satèl•lit (SCS) a la banda Ka, Xarxes d'àrea personal inalàmbriques (WPAN) a la banda V i sistemes radar per l'automoció a la banda W. La primera part d'aquesta tesis consisteix en l'anàlisi d'algunes tecnologies circuitals a freqüències mil•limètriques. S'han presentat els materials més utilitzats a altes freqüències (Polytetrafluoroethylene or Teflon (PTFE), Quartz, Benzocyclobuten polymer (BCB) i Low Temperature Co-fired Ceramic (LTCC)) i s'han comparat en termes de permitivitat i tangent de pèrdues. També s'inclou un estudi de pèrdues a altes freqüències en les principals línies de transmissió (microstrip, stripline i CPW). Finalment, es presenta un resum dels interruptors RF-MEMS i es comparen amb els PIN diodes i els FET. En la segona part, es presenten diferents agrupacions d'antenes amb la capacitat de reconfigurar la polarització i la direcció d'apuntament. S'han dissenyat dos elements base reconfigurables en polarització: CPW Patch antena i 4-Qdime antena. La primera antena consisteix en un element singular amb interruptors RF-MEMS, dissenyada per operar a les bandes Ka i V. La segona antena consisteix en una arquitectura composta on la reconfigurabilitat en polarització s'obté mitjançant variant la fase d'alimentació de cada un dels quatre elements lineals. La fase és controlada mitjançant interruptors RF-MEMS ubicats en la xarxa de distribució. L'antena 4-Qdime s'ha dissenyat per operar en les bandes V i W. Ambdós elements base s'han utilitzat posteriorment pel disseny de dues agrupacions d'antenes amb capacitat de reconfigurar l'apuntament del feix principal. La reconfigurabilitat es dur a terme utilitzant desfasadors de fase d'1 bit. La part final de la tesis es centra en les toleràncies de fabricació i en els processo de microfabricació d'agrupacions d'antenes mil•limètriques. Les toleràncies de fabricació s'han estudiat en funció dels error d'amplitud i fase en cada element de l'agrupació, fixant-se en les pèrdues de guany, error d'apuntament, error en l'amplada de feix, errors en el nivell de lòbul secundari i en l'error en la relació axial. El procés de microfabricació de les diferents antenes dissenyades es presenta en detall. Els dissenys de l'antena CPW Patch reconfigurable en polarització i apuntament operant a les bandes Ka i V, s'han fabricat en la sala blanca del Cornell NanoScale Science & Technology Facility (CNF). Posteriorment, s'han caracteritzat l'aïllament i el temps de resposta dels interruptors RF-MEMS, i finalment, el coeficient de reflexió, el diagrama de radiació i la relació axial s'han mesurat a les bandes Ka i V per les antenes configurades en polarització lineal (LP) i circular (CP). / Telecommunication services and radar systems are migrating to Millimeter-wave (MMW) frequencies, where wider bandwidths are available. Such migration requires the use of different technologies with the capability to operate at the MMW frequency band (30 to 300GHz), and more specifically at Ka- (26.5 to 40GHz), V- (50 to 75GHz) and W-band (75 to 110GHz). For many applications and more concretely those where the antenna is part of a mobile device, it is targeted the use of planar antennas for their low profile and low fabrication cost. A wide variety of requirements is translated into a reconfiguration capability and low losses within each application frequency bandwidth. To deal with the mentioned challenges, the MMW antenna dimensions, together with the materials, fabrication tolerances and reconfigurability capability lead to microfabrication processes. The aim of this thesis is the analysis of the mentioned concepts, materials, transmission lines geometries and switches in the MMW frequencies context and their final application in antenna designs compatible with microfabrication. Finally, specific designs are presented as a demonstration for three MMW applications: Satellite Communication Systems (SCS) at Ka-band, Wireless Personal Area Network (WPAN) at V-band and Automotive Radar at W-band. The first part of this thesis consist to analyze some MMW circuit technologies. The four most used materials at MMW frequencies (Polytetrafluoroethylene or Teflon (PTFE), Quartz, Benzocyclobuten polymer (BCB) and Low Temperature Co-fired Ceramic (LTCC)) have been presented and compared in terms of permittivity (εr) and loss tangent (tanδ). An study of the main transmission lines attenuation (microstrip, stripline and CPW) at high frequencies is included. Finally, an overview of the RF-MEMS switches is presented in comparison with PIN diodes and FETS switches. The second part presents different polarization and beam pointing reconfigurable array antennas. Two polarization-reconfigurable base-elements have been designed: CPW Patch antenna and 4-Qdime antenna. The first consists of a single reconfigurable element with integrated RF-MEMS switches, designed to operate at Ka- and V-band. The second antenna presented in this thesis has a composed architecture where the polarization reconfigurability is obtained by switching the phase feeding for each of the four linear polarized elements in the feed network with RF-MEMS switches. The 4-Qdime antenna has been designed to operate at V- and W-band. The two base-elements have been used to design two beam pointing reconfigurable antenna arrays. Using phased array techniques, beamsteering is computed and implemented with 1-bit discrete phase-shifter. The final part of the thesis is focused into the fabrication tolerances and microfabrication process of Millimeter-wave antenna arrays. The fabrication tolerances have been studied as a function of the amplitude and phase errors presented at each elements array, focusing on the gain loss, beam pointing error, Half-Power Beamwidth (HPBW) error, sidelobe level error and axial ratio error. The microfabrication process for the designed antennas is presented in detail. Polarization- and pointing- reconfigurable CPW Patch antenna operating at Ka- and V- band have been fabricated in a clean-room facility at Cornell NanoScale Science & Technology Facility (CNF). The RF-MEMS switches isolation and time response have been characterized. Finally, the reflection coefficient, radiation pattern and axial ratio have been measured at Ka- and V-band for the fabricated antennas configured in Linear Polarization (LP) and Circular Polarization (CP).

This thesis presents a product development process, where an existing solution on a cab door have been analysed and developed, with the aim to result in a cost-effective concept solution for handling tolerances on the door frame. The methodological approach in this thesis is based on Volvo Construction Equipment’s development model; The Global Development Process, which started with a pre-study phase where the problem formulation was established. The problem formulation in short is to find a solution for how to handle narrow tolerances in steel profiles for the door weldment on cab doors. Various solution ideas were discussed and concepts were generated with focus to design a new cab door corner that would solve the problems addressed by the project. The applied method resulted in a final concept consisting of the same steel profiles but with new dimensions, and two new concepts in each corner; one corner module that is placed inside the steel profiles and joined by welding, and a plastic shell that covers the welded corner. The concept was validated using a prototype of the proposed solution, where tests show that the requirements were achieved, besides a few deficiencies. A cost comparison between the existing and the proposed solution was made within limitations for this thesis. The result of the cost comparison shows an indication of that the proposed solution can be more cost-effective than the existing solution. Some of the recommendations after have completing the project are to make a complete cost comparison to ensure that the indication is correct and to analyse the new components to optimize and define the dimensions of them.

The need for increased product variety and improved aesthetics require the manufacturing enterprise to reduce time to market and to increase use of free-form surfaces in the form of the product. These changes lead to problems in the traditional approach for specification and verification of tolerances especially for a free form surfaces. In the case of freeform surfaces, the desired performance of a product depends on its geometry and is often controlled by intrinsic parameters such as curvature. Design intent therefore requires control on variations in these parameters. Ideally therefore, tolerances have to be applied on these parameters to prescribe allowable variations in the geometry of free-form surfaces. Since only the geometry of the product is controlled in manufacturing, tolerance specification has to ensure that the tolerances specified on the part geometry will ensure that the resulting value of the parameter of interest is within the limits prescribed by the designer. Relationship between allowable range in design parameters and that in geometry is not linear. Tolerance specification therefore becomes a trial and error process requiring considerable expertise and time. This thesis provides designers with a tool to automatically derive the corresponding tolerances to be specified to the manufacturing process to realize the final shape, such that the parameters that are used to control shape of the surface are within the prescribed variations. Automation in acquiring inspection data has brought dramatic changes in procedure for tolerance verification too. Optical scanners and similar non-contact devices provide large amount of points on the surface of the part quite rapidly. The unstructured point data are then processed to determine if the part complies with the given tolerance specifications. For freeform surfaces, current methods of verification uses minimum distance criterion between the nominal surface and unstructured point data. This ignores the correspondence between the points in the two data sets and may result in the rejection of good parts and acceptance of bad parts. There are other unresolved such as the singularity at corners of polyhedral shapes and handling datum. A new approach based on the Medial Axis Transform (MAT) has been proposed. It has been shown that reasoning on the MAT of the nominal model and the measured point set respectively enables the identification of corresponding points in the two sets. Verification of the tolerance allocated is therefore free from the problem mentioned above. MAT exhibits dimensional reduction and hence reduces verification time. It also eliminates surface fitting for detected feature. Results of implementation are provided for tolerance specification and verification using MAT.

Presented diploma thesis was created in cooperation with Siemens s.r.o., and deals with the analysis of the bending of aluminium sheets which are later used as a conductors of high voltage electrical energy. These parts are completed into assemblies which serves as connectors of particular segments of an electrical network. The problem occurs as a result of incorrect bend, because it is impossible to join these sections properly. The customer would like to verify if the defined tolerances of semi-finished products are sufficient for proper bend and in case they are not, the tolerances should be modified. Due to the requirement for running numerical simulation in one of the open source software, the Salome-Meca program environment was used.

During turning, the neck of a workpiece is ​three-lobed deformed due to the clamping pressure on the gripping jaws. While the workpiece is deformed, the machining tool will cut along a preprogrammed circular path. After removal from the chuck, the material returns to its original shape thus deforming the circular path. This means the processed part is no longer circular, as it should be. Typically, this type of problem is usually solved by changing the fixtures (jaws) or adjusting the clamping pressure. This thesis takes a different approach that is based on creating a compensated toolpath that follows the workpiece deformation. This can be a much faster and cheaper way to solve the problem and the technique can be applied to other cylindrical workpieces. The main results of this thesis are a methodology to address the deformation problem as well as suggested changes to the manufacturing process for the workpiece. This involves in particular a change from turning to milling in the last manufacturing stage involving fine machining.

A torque transducer or a torque sensor is a device for measuring and recording the torque on a rotating system. Torque transducers usually employ strain gauges to measure the torsional moment applied to a rotating shaft.It is to be noted that for an ideal torque transducer, it should measure only the strain that is caused by a torque. Strain due to bending load should be compensated as per the Wheatstone bridge arrangement. However, because of geometrical tolerances and assembly errors, the compensation doesn’t occur and the measured strain is a resultant of bending loads and axial loads which are undesired to measure the torque associated with the system. An analytical formulation has been developed using Matlab and this thesis gives the generalized indication of the strain due to all the associated loads. The user shall also entire the region where the strain needs to be computed and this knowledge can be useful for placing the strain gauges in the shaft accordingly. Initially, the formulation is based on a standard Torque Transducer used at Atlas Copco and then, a generalized result has been developed. The theoretical formulation is verified using the ProEngineer Mechanica software. The end user shall enter the different loads (if any) along with the geometrical tolerance values and the output will be an indication of the strain at point, strain at a region and sensitivity. The main intention of the thesis is to create a better understanding of the strain associated with the twisting, bending and axial loads and also the geometrical imperfections. The user can also make a decision on the location of strain gauges on a shaft for maximum accuracy. Finally, the differences in error from different possible configurations are compared and a conclusion has been made based on factorial design pertaining to design of experiments. / Momentgivare är små sensorer som används för att mäta och registrera vridmomentet på en roterande axel. Momentgivare baseras vanligtvis på trådtöjningsmätare för att mäta vridmomentetet kring axeln de är fixerade på. Det skall noteras att en ideal momentgivare endast bör mäta den yttöjning som uppkommer på grund av ett vridmoment. Den belastning som uppkommer på grund av axelns böjning kompenseras bort med hjälp av en Wheatstonebrygga. Men på grund av geometriska toleranser och monteringsfel kan kompensationen bli felaktig och då påverkas det uppmätta momentet även av böj och axialbelastningar vilket är oönskat. En analytisk modell har utvecklats med hjälp av Matlab och denna rapport undersöker de olika lastfallens bidrag till momentfelet. Användaren kan ange området där yttöjningen skall beräknas och utifrån de beräkningarna bestämma var trådtöjningsgivarna bör placeras. Inledningsvis är beräkningarna baserade på en av Atlas Copcos momentgivare och sedan har generaliserade resultat utvecklats. De teoretiska beräkningarna verifieras med hjälp av programmet ProEngineer Mechanica. Användaren kan ange vilka belastningar som axeln känner samt de geometriska toleransvärdena och modellen beräknar då ytspänningen för den valda regionen. Det huvudsakliga syftet med denna avhandling är att skapa en bättre förståelse av ytspänningen som uppkommer på grund av vridning, böjning och axiella belastningar och även geometriska imperfektioner. Modellen kan också användas för att göra beräkningar som visar var töjningsgivare bör placeras på axeln för maximal precision. Slutligen har de introducerade felet från de olika möjliga konfigurationerna jämförts och en slutsats har dragits baserat på faktorförsök.