A new method for automatic synthesis of tolerances for complex assemblies based on polychromatic sets

In computer-aided tolerance design (CAT), integrated design of dimensional and geometric tolerances is still one of the research hotspots. Polychromatic sets theory (PST) is a new mathematic tool, which is especially suitable for formal hierarchical structure models. Based on PST, in this article, a new hierarchical representation model for tolerance synthesis is presented to realise integrated design of dimensional and geometric tolerances. According to the inference relations between unified and individual colours of PST, the synthesis matrices of variational geometric constraints (VGC) are established in the VGC tier of the model, and the synthesis matrices of tolerance types are established in the tolerance type tier of the model. On this basis, the synthesis processes from the feature tier to the VGC tier and from the VGC tier to the tolerance type tier can be realised. VGCs, which are achieved by the synthesis matrices of VGCs, can be combined together to establish a well-constrained VGC network (VGCN). Tolerance types, which are achieved by the synthesis matrices of tolerance types, can be added to the well-constrained VGCN to construct a well-constrained tolerance network. An application example is given in the article to illustrate the synthesis steps.