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Industrial Case Study - tolerance stack design
Excerpt of Process Capable Tolerancing (PCT) article written by Don Day, Tec-Ease Inc, USA, Martin Raines and Ken Swift, CapraTechnology Ltd, UK

The case study reports on the analysis of the tolerance stack for a Smart Solenoid End Assembly (see Fig. 13). In carrying out the study the stack failure severity can be taken as S = 4 and the customer required a 'worst case' analysis. The primary design requirement was to control the plunger displacement to 0.8 ± 0.2 mm.

Fig. 13 Smart Solenoid tolerance stack
The analysis of the components in the tolerance stack using the TCE software is tabulated below in Table 1. 

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