Abstract
The auto body process monitoring and the root cause diagnosis based on data-driven approaches are vital ways to improve the dimension quality of sheet metal assemblies. However, during the launch time of the process mass production with an off-line measurement strategy, the traditional statistical methods are difficult to perform process control effectively. Based on the powerful abilities in information fusion, a systematic Bayesian based quality control approach is presented to solve the quality problems in condition of incomplete dataset. For the process monitoring, a Bayesian estimation method is used to give out-of-control signals in the process. With the abnormal evidence, the Bayesian network (BN) approach is employed to identify the fixture root causes. A novel BN structure and the conditional probability training methods based on process knowledge representation are proposed to obtain the diagnostic model. Furthermore, based on the diagnostic performance analysis, a case study is used to evaluate the effectiveness of the proposed approach. Results show that the Bayesian based method has a better diagnostic performance for multi-fault cases.
Similar content being viewed by others
References
CEGLAREK D, SHI J. Fixture failure diagnosis for autobody assembly using pattern recognition [J]. Journal of Engineering for Industry, 1996, 118(1): 55–66.
LIU Y G, HU S J. Assembly fixture fault diagnosis using designated component analysis [J]. Journal of Manufacturing Science and Engineering, 2005, 127(2): 358–368.
DU S, LÜ J, XI L. A robust approach for root causes identification in machining processes using hybrid learning algorithm and engineering knowledge [J]. Journal of Intelligent Manufacturing, 2012, 23(5): 1833–1841.
APLEY D W, SHI J. Diagnosis of multiple fixture faults in panel assembly [J]. Journal of Manufacturing Science and Engineering, 1998, 120(4): 793–801.
LIU S C, HU S J. Variation simulation for deformable sheet metal assemblies using finite element methods [J]. Journal of Manufacturing Science and Engineering, 1997, 119(3): 368–374.
CAMELIO J A, HU S J, YIM H. Sensor placement for effective diagnosis of multiple faults in fixturing of compliant parts [J]. Journal of Manufacturing Science and Engineering, 2005, 127(1): 68–74.
YU K G, JIN S, LAI X M. Fixture variation diagnosis of compliant assembly using sensitivity matrix [J]. Journal of Shanghai Jiaotong University (Science), 2009, 14(6): 707–712.
DING Y, CEGLAREK D, SHI J. Fault diagnosis of multistage manufacturing processes by using state space approach [J]. Journal of Manufacturing Science and Engineering, 2002, 124(2): 313–322.
ZHOU S, CHEN Y, SHI J. Statistical estimation and testing for variation root-cause determination of multistage manufacturing processes [J]. IEEE Transactions on Automation Science and Engineering, 2004, 1(1): 73–83.
DEY S, SRORI J A. A Bayesian network approach to root cause diagnosis of process variations [J]. International Journal of Machine Tools & Manufacture, 2005, 45(1): 75–91.
JIN S, LIU Y, LIN Z. A Bayesian network approach for fixture fault diagnosis in launch of the assembly process [J]. International Journal of Production Research, 2012, 50(23): 6655–6666.
LAURITZEN S L. The EM algorithm for graphical association models with missing data [J]. Computational Statistics & Data Analysis, 1995, 19(2): 191–201.
Author information
Authors and Affiliations
Corresponding author
Additional information
Foundation item: the National Natural Science Foundation of China (Nos. 51405299 and 51175340), and the Natural Science Foundation of Shanghai (No. 14ZR1428700)
Rights and permissions
About this article
Cite this article
Liu, Y., Ye, X. & Jin, S. A bayesian based process monitoring and fixture fault diagnosis approach in the auto body assembly process. J. Shanghai Jiaotong Univ. (Sci.) 21, 164–172 (2016). https://doi.org/10.1007/s12204-016-1708-1
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12204-016-1708-1