Research Papers

A Simplified Method for Optimal Sensor Distribution for Process Fault Diagnosis in Multistation Assembly Processes

[+] Author and Article Information
Lai Xinmin

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 20030, P.R.C.xmlai@sjtu.edu.cn

Tian Zhaoqing

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 20030, P.R.C.zhmaxp@yahoo.com.cn

Lin Zhongqin

School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 20030, P.R.C.zqlin@sjtu.edu.cn

J. Manuf. Sci. Eng 130(5), 051002 (Aug 14, 2008) (13 pages) doi:10.1115/1.2951943 History: Received January 20, 2006; Revised May 08, 2008; Published August 14, 2008

The fault diagnosis plays an important role for product quality improvement in the multistation assembly processes (MAPs) and the efficiency of diagnosis significantly depends on the sensor distribution strategy, such as the number and location of the sensor. The diagnosis-oriented sensor distribution optimization in MAP has been studied for the purpose of a full diagnosis of the process faults with the minimum sensing stations number as well as the minimum sensor number. However, the existing studies are time consuming with the complex analysis and calculation processes, and no intuitive principles are given directly according to the process configuration. In this paper, a simplified method for the optimal sensor distribution is presented for a fully diagnosis of the process faults. First, two different types of assembly modes are defined and the variation transmissibility ratios for these two assembly modes are discussed based on the process configuration. Then, the conditions for between-station diagnosability and within-station diagnosability are analyzed, respectively. Based on the results, the optimal sensor distribution method is derived finally. After comparing with the former methods, the optimal sensor distribution in this paper is based only on the process configuration without using for model-based matrix computation. Therefore, the proposed method greatly simplified the process.

Copyright © 2008 by American Society of Mechanical Engineers
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Figure 1

Flowchart of former optimal sensor distribution strategy

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Figure 2

Layout of 3-2-1 fixture illustration

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Figure 3

Variation transimission in TP-assembly process

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Figure 4

Variation transimission in MTP-assembly process

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Figure 5

Dimensions on the final product

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Figure 6

Assembly process and optimal sensors distribution in MMP

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Figure 7

The growth of diagnosability ratio μ at different stations

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Figure 8

Assembly process at TP-assembly station

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Figure 9

Assembly process at MTP-assembly station



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