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TECHNICAL PAPERS

Assembly Fixture Fault Diagnosis Using Designated Component Analysis

[+] Author and Article Information
Y. G. Liu, S. J. Hu

Department of Mechanical Engineering, The University of Michigan, Ann Arbor, MI 48109-2125

J. Manuf. Sci. Eng 127(2), 358-368 (Apr 25, 2005) (11 pages) doi:10.1115/1.1852572 History: Received February 28, 2002; Revised June 26, 2003; Online April 25, 2005
Copyright © 2005 by ASME
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References

Hu, S. J., and Wu, S. M., 1992, “Identifying Sources of Variation in Automobile Body Assembly and Using Principal Component Analysis,” Transaction of NAMRI/SME XX, pp. 311–316.
Roan, C., Hu, S. J., and Wu, S. M., 1993, “Computer Aided Identification of Root Causes of Variation in Automobile Body Assembly,” Manufacturing Science and Engineering, Vol. 64, pp. 391–400, ASME WAM, New Orleans.
Ceglarek,  D., Shi,  J., and Wu,  S. M., 1994, “A Knowledge-Based Diagnosis Approach for the Launch of the Auto-Body Assembly Processes,” ASME J. Eng. Ind., 116, pp. 491–499.
Ceglarek,  D., and Shi,  J., 1996, “Fixture Failure Diagnosis for Autobody Assembly Using Pattern Recognition,” ASME J. Eng. Ind., 118, pp. 55–66.
Apley,  D. W., and Shi,  J., 1998, “Diagnosis of Multiple Fixture Faults in Panel Assembly,” J. Manuf. Sci. Eng., 120, pp. 793–801.
Carlson, J. S., Lindkvist, L., and Söderberg, R., 2000, “Multi-Fixture Assembly System Diagnosis Based On Part and Subassembly Measurement Data,” Proceedings of 2000 ASME Design Engineering Technical Conferences, 10–13 September, 2000, Baltimore, MD, pp. 1–13.
Jackson,  J. E., 1980, “Principal Components and Factor Analysis: Part I—Principal Components,” J. Quality Technol., 12, pp. 201–213.
Jackson,  J. E., 1981, “Principal Components and Factor Analysis: Part II—Additional Topics Related to Principal Components,” J. Quality Technol., 13, pp. 46–58.
Geladi,  P., and Kowalski,  B. R., 1986, “Partial Least-Squares Regression: A Tutorial,” Anal. Chem., 185, pp. 1–17.
Barton,  R. R., and Gonzalez-Barreto,  D. R., 1996, “Process-Oriented Basis Representations for Multivariate Process Diagnostics,” Quality Eng.,9, pp. 107–118.
Apley,  D. W., and Shi,  J., 2001, “A Factor-Analysis Method for Diagnosing Variability in Multivariate Manufacturing Processes,” Technometrics, 43, pp. 84–95.
Carlson,  J. S., and Söderberg,  R., 2003, “Assembly Root Cause Analysis: A Way To Reduce Dimensional Variation In Assembled Products,” Int. J. Flexible Manuf. Syst.,15, pp. 113–150.
Camelio, J. A., Hu, S. J., and Yim, H., 2003, “Sensor Placement for Effective Diagnosis of Multiple Faults in Fixture of Compliant Parts,” Proceeding of 2003 ASME International Mechanical Engineering Congress and Exposition, Washington, DC, 16–21 November, pp. 1–8.

Figures

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A typical sheet metal joining fixture with a 3–2–1 locating scheme
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A principal component in the case of two variables
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PCA results of two orthogonal patterns with a component correlation
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Variation patterns of rigid-body motion for two groups of measurements
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The procedure of DCA of a single station sheet metal assembly process
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A fixture with 3–2–1 locating scheme and 12 measurement points
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The six possible variation patterns defined by fixture layout: P1 through P6
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An illustration of liftgate installation and measurement datum scheme
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The three designated components of rigid body motions
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The two significant deflection patterns as indicated by PCA
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Designated component values for liftgate assembly dimensions
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Four most significant eigenvectors for the liftgate assembly dimensions under functional datum

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