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The purpose of this paper is to focus on optimal sensor placement for the fixture variation diagnosis of compliant sheet metal assembly process. Fixture variations are the main sources for complex automotive body dimensional failures. An effective measurement strategy can help exactly and timely diagnose these fixture variations. Research on sensor placement strategy of compliant sheet metal assembly process is not much stated formerly.

The impact principle of fixture variations is analyzed to set up the relationship between the assembly variation and fixture variations applying the method of influence coefficients and the effective independence (EI) method is used to find the optimal sensor positions based on the impact principle analysis of fixture variations.

The obtained fixture variation sensitivity matrix describes the influence of fixture variations to compliant sheet metal assembly variation and can be used for diagnosing fixture variations. The EI method can effectively solve the optimal sensor positions for compliant sheet metal assembly by a case demonstration.

The proposed method can solve the sensor placement of online assembly station for diagnosing fixture variations. It takes the compliant characteristics of sheet metal parts into account and the sensor information has much greater diagnosability than that from applying other methods.

Fixture failures are the main cause of the dimensional variation in the assembly process. The purpose of this paper is to focus on the optimal sensor placement of compliant sheet metal parts for the fixture fault diagnosis.

Based on the initial sensor locations and measurement data in launch time of the assembly process, the Bayesian network approach for fixture fault diagnosis is proposed to construct the diagnostic model. Furthermore, given the desired number of sensors, the diagnostic ability of the sensor set is evaluated based on the mutual information of the nodes. Thereby, a new sensor placement method is put forward and validated with a real automotive sheet metal part.

The new proposed method can be used to perform the fixture fault diagnosis and sensor placement optimization effectively, especially in a data‐rich environment. And it is robust in the presence of measurement noise.

This paper presents a novel approach for fixture fault diagnosis and optimal sensor placement in the assembly process.

Material variation is inevitable in volume production, especially the sheet metal thickness variation, which influences part stiffness characteristic. The purpose of this paper is to present a new variation model of compliant sheet metal assembly with consideration of material variation influence.

The theory of computational solid mechanics is used to obtain the relationship between part stiffness matrix and material characteristic. The method of influence coefficients is adopted to deduce the assembly variation model.

Material variation‐induced influence coefficients to assembly variation are obtained, and a variation model of compliant sheet metal assembly with sources of material variations, part geometric variations and fixture variations is presented. Analysis shows that material variation has an important influence to assembly variations.

A quantitative relationship between assembly variations and material thickness variations is firstly given and a new variation model of compliant sheet metal assembly is presented to help designers to more exactly predict the assembly variation and diagnose variation sources.

The structure stiffness is greatly affected by the fixture constraints during assembly due to the flexibility of large-scale thin-walled structures. The compliant deformation of structures is usually not consistent for the non-uniform stiffness in various clamping schemes. The purpose of this paper is to investigate the correlation between the assembly quality and the clamping schemes of structures with various initial deviations and geometrical parameters, which is based on the proposed irregular quadrilateral plate element via absolute nodal coordinate formulation (ANCF).

Two typical clamping schemes are specified for the large-scale thin-walled structures. Two typical deviation modes are defined in both free and clamping states in the corresponding clamping schemes. The new irregular quadrilateral plate element via ANCF is validated to analyze the compliant deformation of assembled structures. The quasi-static force equilibrium equations are extended considering the factors of clamping constraints and geometric deviations.

The initial deviations and geometrical parameters strongly affect the assembly deviations of structures in two clamping schemes. The variation tendencies of assembly deviations are demonstrated in details with the circumferential clamping position and axial clamping position in two clamping schemes, providing guidance to optimize the fixture configuration. The assembly quality of structures with deviations can be improved by configuration synthesis of the clamping schemes.

Typical over-constraint clamping schemes and deviation modes in clamping states are defined for large-scale thin-walled structures. The plate element via ANCF is extended to analyze the assembly deviations of thin-walled structures in various clamping schemes. Based on the proposed theoretical model, the effects of clamping schemes and initial deviations on the deformation and assembly deviation propagation of structures are investigated.