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Robotic in-line quality inspection for changeable zero defect manufacturing
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation. Mälardalen Industrial Technology Center (MITC). (Product Realisation (PR))
2021 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The growing customer demands for product variety have put unprecedented pressure on the manufacturing companies. To maintain their competitiveness, manufacturing companies need to frequently and efficiently adapt their processes while providing high-quality products. Different advanced manufacturing technologies, such as industrial robotics, have seen a drastic usage increase. Nevertheless, traditional quality methods, such as quality inspection, suffer from significant limitations in highly customised small batch production. For quality inspection to remain fundamental for zero-defect manufacturing and Industry 4.0, an increase in flexibility, speed, availability and decision upon conformance reliability is needed. If robots could perform in-line quality inspection, defective components might be prevented from continuing to the next production stage. Recent developments in robot cognition and sensor systems have enabled the robot to carry out perception tasks they were previously unable to do. The purpose of this thesis is to explore the usage of robotic in-line quality inspection during changeable zero-defect manufacturing. To fulfil this aim, this thesis adopts a mixed-methods research approach to qualitative and quantitative studies, as well as theoretical and empirical ones. The foundation for this thesis is an extensive literature review and two case studies that have been performed in close collaboration with manufacturing companies to investigate how in-line quality inspection is perceived and utilised to enhance industrial robots. The empirical studies also aimed at identifying and describing what opportunities arise from having robotic in-line quality inspection systems. The result of this thesis is a synthesis of literature and empirical findings. From the literature review/study, the need for enhancing quality inspection was identified and a multi-layer quality inspection framework suitable for the digital transformation was proposed. The framework is built on the assumption that data (used and collected) needs to be validated, holistic, and online, i.e. when needed, for the system to effectively decide upon conformity to surpass the challenges of reliability, flexibility and autonomy. Empirical studies show that industrial robotic applications can be improved in precision and flexibility using the in-line quality inspection system as measurement-assisted. Nevertheless, this methodological changes and robot application face the hurdle of previous and current management decisions when passing from one industrial paradigm to another (e.g. mass production to flexible production). A discussion on equipment design and manufacturing process harmony and how in-line quality inspection and management can harmonise such a system was provided.

Place, publisher, year, edition, pages
Eskilstuna: Mälardalen University , 2021.
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 312
Keywords [en]
industrial robot, in-line quality inspection, industry 4.0, changeable manufacturing, zero-defect manufacturing
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Innovation and Design
Identifiers
URN: urn:nbn:se:mdh:diva-56193ISBN: 978-91-7485-530-2 (print)OAI: oai:DiVA.org:mdh-56193DiVA, id: diva2:1602822
Presentation
2021-11-12, A1-068, Mälardalens högskola, Eskilstuna, 13:15 (English)
Opponent
Supervisors
Funder
Knowledge Foundation, 16484Available from: 2021-10-14 Created: 2021-10-13 Last updated: 2023-11-01Bibliographically approved
List of papers
1. Multi-Layer Quality Inspection System Framework for Industry 4.0
Open this publication in new window or tab >>Multi-Layer Quality Inspection System Framework for Industry 4.0
2021 (English)In: International Journal of Automation Technology, ISSN 1881-7629, E-ISSN 1883-8022, Vol. 15, no 5, p. 641-650Article in journal (Refereed) Published
Abstract [en]

In the era of market globalisation, the quality of products has become a key factor for success in the manufacturing industry. The growing demand for customised products requires a corresponding adjustment of processes, leading to frequent and necessary changes in production control. Quality inspection has been historically used by the manufacturing industry to detect defects before customer delivery of the end product. However, traditional quality methods, such as quality inspection, suffer from large limitations in highly customised small batch production. Frameworks for quality inspection have been proposed in the current literature. Nevertheless, full exploitation of the Industry 4.0 context for quality inspection purpose remains an open field. Vice-versa, for quality inspection to be suitable for Industry 4.0, it needs to become fast, accurate, reliable, flexible, and holistic. This paper addresses these challenges by developing a multi-layer quality inspection framework built on previous research on quality inspection in the realm of Industry 4.0. In the proposed framework, the quality inspection system consists of (a) the work piece to be inspected, (b) the measurement instrument, (c) the actuator that manipulates the measurement instrument and possibly the work-piece, (d) an intelligent control system, and (e) a cloud-connected database to the previous resources; that interact with each other in five different layers, i.e., resources, actions, and data in both the cyber and physical world. The framework is built on the assumption that data (used and collected) need to be validated, holistic and on-line, i.e., when needed, for the system to effectively decide upon conformity to surpass the presented challenges. Future research will focus on implementing and validating the proposed framework in an industrial case study.

Place, publisher, year, edition, pages
FUJI TECHNOLOGY PRESS LTD, 2021
Keywords
quality inspection, Industry 4.0, cyber-physical systems, zero-defect manufacturing, CAD/CAM/CAE
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:mdh:diva-55962 (URN)10.20965/ijat.2021.p0641 (DOI)000693411200009 ()2-s2.0-85115102684 (Scopus ID)
Available from: 2021-09-23 Created: 2021-09-23 Last updated: 2023-10-23Bibliographically approved
2. Towards fixtureless robotic in-line measurement assisted assembly, a case study
Open this publication in new window or tab >>Towards fixtureless robotic in-line measurement assisted assembly, a case study
2021 (English)In: 2021 IEEE International Workshop on Metrology for Industry 4.0 and IoT, MetroInd 4.0 and IoT 2021 - Proceedings, Institute of Electrical and Electronics Engineers Inc. , 2021, p. 636-641Conference paper, Published paper (Refereed)
Abstract [en]

In the realm of Industry 4.0, measurement systems play an important role in adapting industrial robots to dynamic environments. Real-time control techniques such as Measurement Assisted Assembly (MAA) can exploit the digital measurements for operation process corrections. Likewise, the propagation of defects can be avoided with in-line measurement conditions. The purpose of this paper is to first understand the capability of robotic in-line measurement assisted assembly in the industrial case of peg-in-hole assembly and second, record the encountered challenges and their enablers. A proof of concept - formed by two 6DoF industrial robots, an in-line Linear Laser (LL), and an on-machine force sensor - have been designed and tested in a lab environment. The experimental results show that robotic in-line measurement assisted assembly can be performed within the tight tolerances of (i) 0, 071 ° to 0, 154° angular deviation between X and Y axes, (ii) applying minimum (near 0) Newton forces in X and Y axes when performing the peg-in-hole robotic assembly of two parts with only 50μm clearance, and (iii) within the company's cycle time. Further, for the effectiveness and practicality of robotic measurement assisted assembly systems, we recorded the encountered challenges and key enablers. 

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers Inc., 2021
Keywords
Force sensor, In-line, Industrial robot, Linear laser, Measurement assisted assembly, Peg-in-hole, Position and orientation, Dielectric losses, Industrial robots, Industry 4.0, Internet of things, Real time control, Robotics, Angular deviations, Digital measurement, Dynamic environments, In-line measurements, Measurement system, Operation process, Peg-in-hole assembly, Proof of concept, Robotic assembly
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:mdh:diva-55630 (URN)10.1109/MetroInd4.0IoT51437.2021.9488551 (DOI)000709093600118 ()2-s2.0-85112088748 (Scopus ID)9781665419802 (ISBN)
Conference
2021 IEEE International Workshop on Metrology for Industry 4.0 and IoT, MetroInd 4.0 and IoT 2021, Virtual, Online, 7 June 2021 - 9 June 2021
Available from: 2021-08-19 Created: 2021-08-19 Last updated: 2023-10-23Bibliographically approved

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