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TECHNICAL PAPERS

Sensor Optimization for Fault Diagnosis in Multi-Fixture Assembly Systems With Distributed Sensing

[+] Author and Article Information
A. Khan, D. Ceglarek

S. M. Wu Manufacturing Research Center, The University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 122(1), 215-226 (Jul 01, 1998) (12 pages) doi:10.1115/1.538917 History: Received December 01, 1997; Revised July 01, 1998
Copyright © 2000 by ASME
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References

Ceglarek,  D., Shi,  J., and Wu,  S. M., 1994, “A Knowledge-based Diagnosis Approach For The Launch Of The Auto-body Assembly Process,” ASME J. Eng. Ind., 116, No. 4, pp. 491–499.
de Kleer,  J., and Williams,  B. C., 1987, “Diagnosing Multiple Faults,” Artif. Intel., 32, pp. 97–130.
Reiter,  R., 1987, “A Theory Of Diagnosis From First Principles,” Artif. Intel., 32, pp. 57–96.
Wu,  T. D., 1991, “Problem Decomposition Method For Efficient Diagnosis And Interpretation Of Multiple Disorders,” Comput. Methods Programs Biomed., 35, No. 4, pp. 239–250.
Ceglarek,  D., and Shi,  J., 1996, “Fixture Failure Diagnosis For Autobody Assembly Using Pattern Recognition,” ASME J. Manuf. Sci. Eng., 118, No. 1, pp. 55–66.
Genesereth,  M. R., 1984, “The Use Of Design Descriptions In Automated Diagnosis,” Artif. Intel., 24, pp. 411–436.
Khan,  A. M., Ceglarek,  D., Shi,  J., Ni,  J., and Woo,  T. C., 1999, “Sensor Optimization For Fault Diagnosis In Single Fixture Systems: A Methodology,” ASME J. Manuf. Sci. Eng., 121, No. 1, pp. 109–117.
De Fazio,  T. L., and Whitney,  D. E., 1987, “Simplified Generation Of All Mechanical Assembly Sequences,” IEEE J. Robotics Automation, 3, pp. 640–705; and 1998, Corrections, IEEE J. Robotics Automation, 4, pp. 705–708.
Homem de Mello,  L. S., and Sanderson,  A. C., 1991, “Representation Of Mechanical Assembly Sequences,” IEEE Trans. Robotics Automation, 7, pp. 211–227.
Khan,  A. M., Ceglarek,  D., and Ni,  J., 1998, “Sensor Location Optimization For Fault Diagnosis in Multi-Fixture Assembly Systems,” ASME J. Manuf. Sci. Eng., 120, No. 4, pp. 781–792.
Zeigler, B. P., 1992, “Systems Formulation of a Theory of Diagnosis from First Principles,” IEEE Trans. Reliab., 41 , No. 1.
Ceglarek,  D., and Shi,  J., 1998, “Design Evaluation of Sheet Metal Joints for Dimensional Integrity,” ASME J. Manuf. Sci. Eng. 120, No. 2, 452–460.
Matlab: Optimization Toolbox User’s Guide, The MathWorks, Inc.

Figures

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Sensing approaches: (a) end-of-line sensing, (b) distributed sensing
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Generic 3-2-1 fixture layout and corresponding failure mode fault manifestations
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Assembly representation for optimization for (a) the example four-part widget assembly (S1,S2,S3 represent assembly stations), (b) state-transition representation (for each level l,{{Θ}} is a partition representing assembly state, with element {θl} representing a subassembly or part)
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Optimization implementation sequence: (a) bottom-up, (b) top-down approaches
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Assembly part fixturing schematics for (a) station S3, (b) station S2, (c) station S1 (M1 are candidate sensor locations)
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Bottom-up approach: (a) results of first step optimization, (b) graphical representation (linearized) of station sensing performance with 3, 2, and 1 sensors
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Bottom-up approach: results of second step optimization
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Bottom-up approach—overall sensing distribution: (a) station S3, (b) station S2, and (c) station S1
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Top-down approach: (a) results of the first step optimization, (b) graphical representation (linearized) of station sensing performance with 3, 2, and 1 sensors
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Top-down approach—second step optimization: Inherent-to-station allocation results
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Top-down approach—second step optimization: (a) combinations for part A allotment computation, (b) combinations for part B allotment computation, and (c) compensatory station allocation results
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Top-down approach—overall sensing distribution (a) station S3, (b) station S2, and (c) station S1

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