Diagnosability Analysis of Multi-Station Manufacturing Processes

Variation propagation in a multi-station manufacturing process (MMP) is described by the theory of "Stream of Variation." Given that the measurements are obtained via certain sensor distribution scheme, the problem of whether the stream of variation of an MMP is diagnosable is of great interest to both academia and industry. We present a comprehensive study of the diagnosability of MMPs in this paper. It is based on the state space model and is parallel to the concept of observability in control theory. Analogous to the observability matrix and index, the diagnosability matrix and index are first defined and then derived for MMP systems. The result of diagnosability study is applied to the evaluation of sensor distribution strategy. It can also be used as the basis to develop an optimal sensor distribution algorithm. An example of a three-station assembly process with multi-fixture layouts is presented to illustrate the methodology.

[1]  Darek Ceglarek,et al.  Dimensional variation reduction for automotive body assembly , 1995 .

[2]  Daniel W. Apley,et al.  Diagnosis of Multiple Fixture Faults in Panel Assembly , 1996, Manufacturing Science and Engineering.

[3]  Rolf Isermann,et al.  Process fault detection based on modeling and estimation methods - A survey , 1984, Autom..

[4]  Yu Ding,et al.  Fault Diagnosis of Multistage Manufacturing Processes by Using State Space Approach , 2002 .

[5]  Michael Yu Wang,et al.  Locator and Sensor Placement for Automated Coordinate Checking Fixtures , 1998, Manufacturing Science and Engineering.

[6]  David C. Gossard,et al.  Modeling the assembly of compliant, non-ideal parts , 1997, Comput. Aided Des..

[7]  Yoram Koren,et al.  Stream-of-Variation Theory for Automotive Body Assembly , 1997 .

[8]  Darek Ceglarek,et al.  Fixture Failure Diagnosis for Autobody Assembly Using Pattern Recognition , 1996 .

[9]  Yu Ding,et al.  MODELING AND DIAGNOSIS OF MULTISTAGE MANUFACTURING PROCESSES: PART I - STATE SPACE MODEL , 2000 .

[10]  Q. Rong,et al.  Adjusted Least Squares Approach for Diagnosis of Ill-Conditioned Compliant Assemblies , 2001 .

[11]  Jionghua Jin,et al.  State Space Modeling of Sheet Metal Assembly for Dimensional Control , 1999 .

[12]  Douglas C. Montgomery,et al.  Introduction to Statistical Quality Control , 1986 .

[13]  Darek Ceglarek,et al.  Sensor optimization for fault diagnosis in single fixture systems : A methodology , 1999 .

[14]  Darek Ceglarek,et al.  A Knowledge-Based Diagnostic Approach for the Launch of the Auto-Body Assembly Process , 1994 .

[15]  Daniel E. Whitney,et al.  Modeling and controlling variation propagation in mechanical assemblies using state transition models , 1999, IEEE Trans. Robotics Autom..

[16]  J. A. Robinson,et al.  Analysis of Variation Transmission in Manufacturing Processes—Part I , 1999 .