This paper presents a methodology for diagnostics of fixture failures in multistage manufacturing processes (MMP). The diagnostic methodology is based on the state-space model of the MMP process, which includes part fixturing layout geometry and sensor location. The state space model of the MMP characterizes the propagation of fixture fault variation along the production stream, and is used to generate a set of predetermined fault variation patterns. Fixture faults are then isolated by using mapping procedure that combines the Principal Component Analysis (PCA) with pattern recognition approach. The fault diagnosability conditions for three levels: (a) within single station, (b) between stations, and (c) for the overall process, are developed. The presented analysis integrates the state space model of the process and matrix perturbation theory to estimate the upper bound for isolationability of fault pattern vectors caused by correlated and uncorrelated noises. A case study illustrates the proposed method.

Issue Section:
Technical Papers
Keywords:
manufacturing processes, quality control, fault diagnosis, state-space methods, principal component analysis
Topics:
Manufacturing, Noise (Sound), Fault diagnosis, Fixturing
1.
Ceglarek
,
D.
, and
Shi
,
J.
,
1995
, “
Dimensional Variation Reduction for Automotive Body Assembly
,”
Manufacturing Review
,
8
, pp.
139
–
154
.
2.
Asada
,
H.
, and
By
,
B.
,
1985
, “
Kinematic Analysis of Workpart Fixturing for Flexible Assembly with Automatically Reconfigurable Fixtures
,”
IEEE J. Rob. Autom.
,
RA-1
, pp.
86
–
94
.
3.
Rong
,
Y.
, and
Bai
,
Y.
,
1996
, “
Machining Accuracy Analysis for Computer-aided Fixture Design Verification
,”
ASME J. Manuf. Sci. Eng.
,
118
, pp.
289
–
299
.
4.
Choudhuri
,
S. A.
, and
De Meter
,
E. C.
,
1999
, “
Tolerance Analysis of Machining Fixture Locators
,”
ASME J. Manuf. Sci. Eng.
,
121
, pp.
273
–
281
.
5.
Ceglarek
,
D.
, and
Shi
,
J.
,
1996
, “
Fixture Failure Diagnosis for Auto Body Assembly Using Patter Recognition
,”
ASME J. Eng. Ind.
,
118
, pp.
55
–
65
.
6.
Barton
,
R. R.
, and
Gonzalez-Barreto
,
D. R.
,
1996
, “
Process-oriented Basis Representations for Multivariate Process Diagnosis
,”
Quality Engineering
,
9
, pp.
107
–
118
.
7.
Apley
,
D. W.
, and
Shi
,
J.
,
1998
, “
Diagnosis of Multiple Fixture Faults in Panel Assembly
,”
ASME J. Manuf. Sci. Eng.
,
120
, pp.
793
–
801
.
8.
Chang
,
M.
, and
Gossard
,
D. C.
,
1998
, “
Computational Method for Diagnosis of Variation-related Assembly Problems
,”
Int. J. Prod. Res.
,
36
, pp.
2985
–
2995
.
9.
Rong
,
Q.
,
Ceglarek
,
D.
, and
Shi
,
J.
,
2000
, “
Dimensional Fault Diagnosis for Compliant Beam Structure Assemblies
,”
ASME J. Manuf. Sci. Eng.
,
122
, pp.
773
–
780
.
10.
Mantripragada
,
R.
, and
Whitney
,
D. E.
,
1999
, “
Modeling and Controlling Variation Propagation in Mechanical Assemblies Using State Transition Models
,”
IEEE Trans. Rob. Autom.
,
15
, pp.
124
–
140
.
11.
Lawless
,
J. F.
,
Mackay
,
R. J.
, and
Robinson
,
J. A.
,
1999
, “
Analysis of Variation Transmission in Manufacturing Processes-Part I
,”
J. Quality Technol.
,
31
, pp.
131
–
142
.
12.
Agrawal
,
R.
,
Lawless
,
J. F.
, and
Mackay
,
R. J.
,
1999
, “
Analysis of Variation Transmission in Manufacturing Processes-Part II
,”
J. Quality Technol.
,
31
, pp.
143
–
154
.
13.
Jin
,
J.
, and
Shi
,
J.
,
1999
, “
State Space Modeling of Sheet Metal Assembly for Dimensional Control
,”
ASME J. Manuf. Sci. Eng.
,
121
, pp.
756
–
762
.
14.
VSA, 1998, VSA-3D Release 12.5 User Manual, Variation System Analysis, Inc., 300 Maple Park Boulevard, St. Clair Shores, MI 48081.
15.
Huang, Q., Zhou, N., and Shi, J., 2000, “Stream-of-Variation Modeling and Diagnosis of Multi-station Machining Processes,” Proceedings of the 2000 ASME International Mechanical Engineering Congress and Exposition, MED-11, pp 81–88.
16.
Callier, F. M., and Desoer, C. A., 1991, Linear System Theory, Springer-Verlag, New York.
17.
Kumar, P. R., and Varaiya, P., 1986, Stochastic Systems: Estimation, Identification and Adaptive Control, Prentice-Hall, Inc., Englewood Cliffs, NJ 07632.
18.
Johnson, R. A., and Wichern, D. W., 1998, Applied Multivariate Statistical Analysis, Prentice-Hall, Upper Saddle River, NJ.
19.
Ceglarek, D., 1994, “Knowledge-based Diagnosis for Automotive Body Assembly: Methodology and Implementation,” Ph.D. Dissertation, The University of Michigan, Ann Arbor, MI, 48109.
20.
Ceglarek
,
D.
, and
Shi
,
J.
,
1999
, “
Fixture Failure Diagnosis for Sheet Metal Assembly with Consideration of Measurement Noise
,”
ASME J. Manuf. Sci. Eng.
,
121
, pp.
771
–
777
.
21.
Golub, G. H., and Van Loan, C. F., 1996, Matrix Computations, 3rd edition, The Johns Hopkins University Press, Baltimore, MD 21218.
22.
Apley
,
D. W.
, and
Shi
,
J.
,
2001
, “
A Factor Analysis Method for Diagnosis Variability in Multivariate Manufacturing Processes
,”
Technometrics
,
43
, pp.
84
–
95
.
23.
Cai
,
W.
,
Hu
,
S. J.
, and
Yuan
,
J. X.
,
1997
, “
Deformable Sheet Metal Fixturing: Principles, Algorithms, and Simulations
,”
ASME J. Manuf. Sci. Eng.
,
118
, pp.
318
–
324
.
Copyright © 2002
 by ASME
You do not currently have access to this content.