This paper presents a nonlinear kinematic tolerance analysis algorithm for higher pairs based on configuration space construction. The input is a pair of planar parts whose profiles consist of line and circle segments. Each part translates along a planar axis or rotates around an orthogonal axis. The part shapes and motion axes are parameterized by a vector of tolerance parameters with range limits. The algorithm constructs a generalized configuration space, called a contact zone, that bounds the worst-case kinematic variation over the tolerance parameter range. The zone specifies the variation of the pair at every configuration and in every operating mode. It reveals qualitative changes in kinematic function, such as jamming, that can be caused by parameter variations. Case studies show that the algorithm is more accurate and detects more failure modes than a prior algorithm that computes a linear approximation of the contact zone.

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