State-of-the-art in fixture systems for the manufacture and assembly of rigid components: A review

Abstract Basic work holding devices (e.g. vices), fixtures and jigs are used to construct a critical interface between a workpiece and an end-effector. This interface performs two main functions: location of the workpiece in the Euclidean space and preservation of the workpiece position against any loads. Despite the critical nature of the part-machine interface, limited attention has been given to work holding systems in the academic community. In this respect, the main objective of this paper is to systematically review the field of fixture design, thus allowing the classification of fixturing systems to identify research trends and niches. This review is broken into four sections: (i) basics of fixturing and work holding; (ii) fixtures for single components. The classification of these systems is based on an evolutionary trend that allows to see how the development of technologies, such as additive manufacture, sensing technologies and actuation systems, affects fixture design; (iii) fixtures for multi-parts (both for batch production and assembly operations), with an emphasis on the unique challenges that arise from the assembling process; and (iv) conclusions, denoting various research trends/opportunities in the areas of fixture design and fixture instrumentation. Examples of these prospects includes the integration of fixtures with sensing technology (incentivise by the growth of industry 4.0) and the construction of truly new multi-part fixturing systems, rather than just the expansion of single component fixtures.

[1]  Svetan Ratchev,et al.  Towards an intelligent fixturing system with rapid reconfiguration and part positioning , 2008 .

[2]  Christian Brecher,et al.  Thermal issues in machine tools , 2012 .

[3]  Wutthigrai Boonsuk,et al.  Automated fixture design for a rapid machining process , 2009 .

[4]  Kaufui Wong,et al.  A Review of Additive Manufacturing , 2012 .

[5]  B. Benhabib,et al.  A reconfigurable modular fixturing system for thin-walled flexible objects , 1997 .

[6]  D F Walczyk,et al.  Fixtureless assembly of sheet metal parts for the aircraft industry , 2000 .

[7]  José F. Hurtado,et al.  A model for synthesis of the fixturing configuration in pin-array type flexible machining fixtures , 2002 .

[8]  Daniel F. Walczyk,et al.  Fixturing of compliant parts using a matrix of reconfigurable pins , 2000 .

[9]  Henrik Kihlman,et al.  Reconfigurable Flexible Tooling for Aerospace Wing Assembly , 2009 .

[10]  Xiaoli Li,et al.  A brief review: acoustic emission method for tool wear monitoring during turning , 2002 .

[11]  Jeries Abou-Hanna,et al.  Dynamic behavior and creep characteristics of flexible particulate bed fixtures , 1993 .

[12]  David Z. Zhang,et al.  Additive manufacturing: A framework for implementation , 2014 .

[13]  Andrew Y. C. Nee,et al.  An Advanced Treatise On Fixture Design And Planning , 2004 .

[14]  Matteo Zoppi,et al.  Fixture layout optimization for flexible aerospace parts based on self-reconfigurable swarm intelligent fixture system , 2013 .

[15]  Yiming Rong,et al.  Advanced Computer-Aided Fixture Design , 2005 .

[16]  Kwan Hee Han,et al.  Manufacturing cycle time reduction for batch production in a shared worker environment , 2013 .

[17]  Jody Muelaner,et al.  A new paradigm in large-scale assembly—research priorities in measurement assisted assembly , 2014 .

[18]  Svetan Ratchev,et al.  Fixture control by hydraulic actuation using a reduced workpiece model , 2009 .

[19]  Thomas Papastathis,et al.  Modelling and design methodology for fully-active fixtures , 2011 .

[20]  Bijan Shirinzadeh Flexible and automated workholding systems , 1995 .

[21]  Aun-Neow Poo,et al.  Error compensation in machine tools — a review: Part II: thermal errors , 2000 .

[22]  Yoke San Wong,et al.  A model-based online control of optimal fixturing process , 1997, Proceedings of International Conference on Robotics and Automation.

[23]  D. E. Dimla,et al.  Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods , 2000 .

[24]  Y. Rong,et al.  Flexible Fixturing with Phase-Change Materials. Part 1. Experimental Study on Magnetorheological Fluids , 2000 .

[25]  Yasuhiro Kakinuma,et al.  Application of the Electro-rheological Gel to Fixture Devices for Micro Milling Processes , 2007 .

[26]  Matteo Zoppi,et al.  Reconfigurable swarm fixtures , 2009, 2009 ASME/IFToMM International Conference on Reconfigurable Mechanisms and Robots.

[27]  Kamal Youcef-Toumi,et al.  Design and implementation of robot-operated adaptable and modular fixtures , 1989 .

[28]  Mukesh V. Gandhi,et al.  Workpiece-fixture interactions in a compacted fluidized-bed fixture under various loading conditions , 1989 .

[29]  Vojislav Petrovic,et al.  Additive layered manufacturing: sectors of industrial application shown through case studies , 2011 .

[30]  Andrew Y. C. Nee,et al.  Advanced Fixture Design for FMS , 1995 .

[31]  Abe Zeid,et al.  Investigating the design and development of truly agile flexible fixtures based on electrorheological fluids , 2009 .

[32]  Sara Eastwood,et al.  Automated aerostructure assembly , 2005, Ind. Robot.

[33]  Tojiro Aoyama Development of Gel Structured Electrorheological Fluids and their Application for the Precision Clamping Mechanism of Aerostatic Sliders , 2004 .

[34]  Benoît Marguet,et al.  Measurement-Assisted Assembly Applications on Airbus Final Assembly Lines , 2003 .

[35]  Shui-Shong Lu,et al.  Development of a novel coordinate transposing fixture system , 1997 .

[36]  Grier C. I. Lin,et al.  An approach to enhancing the intelligence of a three-fingered automated flexible fixturing system by using adaptive control theory , 1999 .

[37]  Malte Brettel,et al.  How Virtualization, Decentralization and Network Building Change the Manufacturing Landscape: An Industry 4.0 Perspective , 2014 .

[38]  Matteo Zoppi,et al.  Development and Analysis of a Shape-Conformable Supporting Head for a Self-Reconfigurable Intelligent Swarm Fixture System , 2010, ISR/ROBOTIK.

[39]  Héctor R. Siller,et al.  Experimental and numerical study of a fixturing system for complex geometry and low stiffness components. , 2017 .

[40]  Paul G. Maropoulos,et al.  Review of the application of flexible, measurement-assisted assembly technology in aircraft manufacturing , 2014 .

[41]  Sarah Sharples,et al.  Manufacturing in the cloud: A human factors perspective , 2016 .

[42]  Jaime A. Camelio,et al.  Damage detection in assembly fixtures using non-destructive electromechanical impedance sensors and multivariate statistics , 2009 .

[43]  Dazhong Wu,et al.  Cloud manufacturing: Strategic vision and state-of-the-art☆ , 2013 .

[44]  K. Tuffentsammer,et al.  Automatic Loading of Machining Systems and Automatic Clamping of Workpieces , 1981 .

[45]  Mark L. Nagurka,et al.  Toward an intelligent machine tool for flexible manufacturing , 1989 .

[46]  and Lucian L. Haas Colvin,et al.  JIGS AND FIXTURES , 1948 .

[47]  Elmer C. Lee,et al.  Development of an encapsulation process for use in a universal automated fixturing system , 1999 .

[48]  Edward C. De Meter,et al.  Light Activated Adhesive Gripper (LAAG) Workholding Technology and Process , 2004 .

[49]  Andrew Y. C. Nee,et al.  An intelligent fixture with a dynamic clamping scheme , 2000 .

[50]  Edward C. De Meter,et al.  Part location algorithms for an Intelligent Fixturing System Part 2: algorithm testing and evaluation , 2001 .

[51]  Daniel F. Walczyk,et al.  Modeling and Analysis of an Active Reconfigurable Fixturing Device Using a Bed of Pins Lowered on a Moving Platen , 2009 .

[52]  X. Tang,et al.  Flexible Fixture Device with Magneto-Rheological Fluids , 1999 .

[53]  Beno Benhabib,et al.  A reconfigurable fixturing system for robotic assembly , 1990 .

[54]  A. Y. C. Nee,et al.  The cutting force measurement in a fixturing setup with instrumented locators , 2004 .

[55]  Yasuhiro Kakinuma,et al.  Development of Fixture Devices for Thin and Compliant Workpieces , 2005 .

[56]  B. S. Thompson,et al.  Phase change fixturing for flexible manufacturing systems , 1985 .

[57]  M. A. Mannan,et al.  A Force-Controlled Clamping Element for intelligent Fixturing , 1997 .

[58]  Xiong Li,et al.  Adaptable Fixturing Heads for Swarm Fixtures: Discussion of Two Designs , 2012 .

[59]  Brian S. Thompson,et al.  The computer-aided design of modular fixturing systems , 1987 .

[60]  S. Ohnimus,et al.  A study on the influence of clamping on welding distortion , 2009 .

[61]  Jody Muelaner,et al.  Achieving Low Cost and High Quality Aero Structure Assembly through Integrated Digital Metrology Systems , 2013 .

[62]  Liang Hou,et al.  Additive manufacturing and its societal impact: a literature review , 2013 .

[63]  H. Harry Asada,et al.  Kinematic analysis of workpart fixturing for flexible assembly with automatically reconfigurable fixtures , 1985, IEEE J. Robotics Autom..

[64]  M. Q. Dai,et al.  A Modular Programmable Fixturing System , 1991 .

[65]  Lianyu Zheng,et al.  A novel algorithm of posture best fit based on key characteristics for large components assembly , 2013 .

[66]  E. C. De Meter,et al.  The application of tool path compensation for the reduction of clampinginduced geometric errors , 1997 .

[67]  Svetan M. Ratchev,et al.  Development of a Reconfigurable Fixture for the Automated Assembly and Disassembly of High Pressure Rotors for Rolls-Royce Aero Engines , 2010, IPAS.

[68]  Fei Tao,et al.  Cloud manufacturing: a computing and service-oriented manufacturing model , 2011 .

[69]  David Stockton The Catic Modular Fixturing System , 1988 .

[70]  Marie Jonsson,et al.  Coordinate Controlled Fixturing for Affordable Reconfigurable Tooling , 2008 .

[71]  Robert M. Parkin,et al.  Experimental design and investigation of a pin-type reconfigurable clamping system for manufacturing aerospace components , 2003 .

[72]  Matteo Zoppi,et al.  SwarmItFIX: a multi-robot-based reconfigurable fixture , 2013, Ind. Robot.

[73]  Yoke San Wong,et al.  Off-line modelling and planning of optimal clamping forces for an intelligent fixturing system , 1999 .

[74]  Jeries Abou-Hanna,et al.  Sinkage characteristics of workpieces in flexible particulate bed fixtures: An experimental and numerical investigation , 1994 .

[75]  Dragos Axinte,et al.  Assessment of adhesive fixture system under static and dynamic loading conditions , 2013 .

[76]  Gideon Levy,et al.  RAPID MANUFACTURING AND RAPID TOOLING WITH LAYER MANUFACTURING (LM) TECHNOLOGIES, STATE OF THE ART AND FUTURE PERSPECTIVES , 2003 .

[77]  Svetan Ratchev,et al.  Active fixturing: literature review and future research directions , 2013 .

[78]  Wojciech Szynkiewicz,et al.  Task planning for cooperating self-reconfigurable mobile fixtures , 2013 .

[79]  Andrew Kusiak,et al.  Computer-aided fixture design : a review , 1994 .

[80]  Hans-Georg Kemper,et al.  Application-Pull and Technology-Push as Driving Forces for the Fourth Industrial Revolution , 2014 .

[81]  Gang Liu,et al.  Attractive Fixture System Based on Magnetic Field and Friction Force for Numerically Controlled Machining of Paper Honeycomb Core , 2005 .

[82]  Grier C. I. Lin,et al.  Development of an automated flexible fixture for planar objects , 1998 .

[83]  Paul K. Wright,et al.  Reference Free Part Encapsulation: A new universal fixturing concept , 1997 .

[84]  Erik K. Henriksen,et al.  Jig and Fixture Design Manual , 1973 .

[85]  Antony R Mileham,et al.  A comparison of two distributed large-volume measurement systems: The mobile spatial co-ordinate measuring system and the indoor global positioning system , 2009 .

[86]  Joshua D. Summers,et al.  A review of computer-aided fixture design with respect to information support requirements , 2008 .

[87]  Guha Manogharan,et al.  Making sense of 3-D printing: Creating a map of additive manufacturing products and services , 2014 .

[88]  Dragos Axinte,et al.  An assessment of “variation conscious” precision fixturing methodologies for the control of circularity within large multi-segment annular assemblies , 2014 .

[89]  Edward C. De Meter,et al.  Part location algorithms for an intelligent fixturing system part 1: system description and algorithm development , 2001 .

[90]  Sanjay E. Sarma,et al.  The process window for reference Free Part Encapsulation , 2002 .

[91]  Aun-Neow Poo,et al.  Error compensation in machine tools — a review: Part I: geometric, cutting-force induced and fixture-dependent errors , 2000 .

[92]  Svetan Ratchev,et al.  Dynamics model of active fixturing systems for thin-walled parts under moving loads , 2012 .

[93]  Sanjay E. Sarma,et al.  Reference free part encapsulation: Materials, machines and methods , 2007 .

[94]  Branko Tadic,et al.  NOVEL WORKPIECE CLAMPING METHOD FOR INCREASED MACHINING PERFORMANCE , 2012 .

[95]  Paul K. Wright,et al.  Reference Free Part Encapsulation (RFPE): An investigation of material properties and the role of RFPE in a taxonomy of fixturing systems , 2002 .

[96]  K. C. Chan,et al.  Development of a computer numerical control (CNC) modular fixture — Machine design of a standard multifinger module , 1996 .

[97]  Branko Tadic,et al.  Efficient workpiece clamping by indenting cone-shaped elements , 2012 .

[98]  Hua Li,et al.  Computer aided fixture design: Recent research and trends , 2010, Comput. Aided Des..

[99]  Wen-Han Qian,et al.  A 3-D modular fixture with enhanced localization accuracy and immobilization capability , 2008 .

[100]  Bijan Shirinzadeh,et al.  Issues in the design of the reconfigurable fixture modules for robotic assembly , 1993 .

[101]  Paul G. Maropoulos,et al.  Manufacturing and assembly automation by integrated metrology systems for aircraft wing fabrication , 2010 .

[102]  Juanjo Zulaika,et al.  Adaptive Fixturing System for the Smart and Flexible Positioning of Large Volume Workpieces in the Wind-power Sector , 2014 .

[103]  Jingxia Yuan,et al.  Deformable Sheet Metal Fixturing: Principles, Algorithms, and Simulations , 1996 .

[104]  Jeries Abou-Hanna,et al.  Experimental study of static and dynamic rigidities of flexible particulate bed fixtures under external vertical and torque loads , 1994 .

[105]  Z. M. Bi,et al.  Flexible fixture design and automation: Review, issues and future directions , 2001 .

[106]  Iain M. Boyle,et al.  Review: A review and analysis of current computer-aided fixture design approaches , 2011 .

[107]  Bryan Kok Ann Ngoi,et al.  Development of an automated fixture set-up system for inspection , 1997 .

[108]  J. Kong,et al.  Precision Machining for Thin Wall Spherical Shell Based on Magneto-Rheological Fluids Strengthening , 2011 .

[109]  Heinrich M. Jaeger,et al.  Universal robotic gripper based on the jamming of granular material , 2010, Proceedings of the National Academy of Sciences.

[110]  Jay Lee,et al.  Service Innovation and Smart Analytics for Industry 4.0 and Big Data Environment , 2014 .

[111]  Jonathan Corney,et al.  Cloud-based manufacturing-as-a-service environment for customized products , 2011 .