Tolerance optimisation and reliability analysis of planetary roller screws based on sensitivity analysis

Current research on planetary roller screw mechanism lacks systematic tolerance optimization under multi-error coupling. This study proposes a methodology integrating sensitivity analysis, genetic algorithm-driven tolerance design, and Halton sequence-based reliability verification. Key machining/assembly errors affecting transmission accuracy are quantified, followed by multi-objective optimization to balance performance and manufacturability. Verification confirms optimized tolerances significantly reduce operational errors, control clearance fluctuations, and enhance load distribution uniformity. Reliability assessments demonstrate marked improvements in precision compliance and deformation resistance. The framework advances planetary roller screw design for high-precision applications, ensuring robustness and extended service life.