Diagnosis of Multiple Fixture Faults in Multiple-Station Manufacturing Processes Based on State Space Approach

Dimensional quality is one of the most critical challenges in industries, which uses the multistage manufacturing process (MMP) such as assembly and machining for automotive and aerospace industries.According to investigations, fixture faults accounted for 72% of all the dimensional faults. Previous studies focused on only one fault or multiple faults occurred in one station or one fault in multiple stations, but these cases rarely appear in the real manufacturing. This paper presents a method for diagnosis of multiple fixture faults in the multi-station manufacturing process. The proposed method is based on the state space model of the MMP processes, which carries the information of the fixture layout geometry and sensor position. To identify the root cause, three continuous steps were used: a) development of the state space model and the construction of the statistics variables on offline mode, b) measurement of the coordinate measuring machines data on online mode and calculation of the statistics variables, and c) diagnostic algorithm for identifying the root cause. The presented paper integrates the state space model of the manufacturing processes and hypothesis test considering the impact of the measure noises. A case study verifies the proposed method.     

面向过程的多工位薄板装配公差综合

针对多工位薄板装配过程,建立了一种新的公差综合方法.通过分析夹具定位偏差与公差的关系,利用偏差流传递的状态空间模型建立了公差综合的约束函数,以制造成本为目标函数,利用Matlab实现了优化的公差综合方法,同时研究了过程损失对产品质量的影响.结果表明,该方法在确保装配质量的前提下,显著降低了制造成本.