7

A BRIEF REVIEW OF FIXTURE DESIGN

AND AUTOMATION

Djordje VUKELIC
Branko TADIC
Janko HODOLIC
Nenad SIMEUNOVIC


Abstract: The problem of fixture design, as one of the
pivotal elements which significantly influence the quality
of process planning in manufacturing engineering,
remains topical, especially in a highly automated, flexible
manufacturing environments. Computer-aided fixture
design has, for a number of years now been in the focus of
a large number of researchers. The results of this
research have allowed a systematized knowledge of the
possibilities offered by computer-aided fixture design.
Emphasized in this paper is the importance of automation
in fixture design. Characteristic approaches to fixture
design automation are reviewed and analyzed. Basic
features, advantages and disadvantages of particular
approaches are examined. The paper concludes with
future directions of research.

Key words: fixture, design, automation, CAFD


1. INTRODUCTION

During the last couple of decades the computers have
been increasingly used to assist design activities. The
beginnings of their application date back to the sixties of
the last century, when they were first successfully used to
control machine tools. This was followed by an expansion
of their application in various domains of manufacturing
engineering. The concepts of flexible manufacturing
system (FMS) and computer aided manufacturing (CIM)
have evolved since. Today, the emphasis is placed on the
intelligent manufacturing systems which are able to solve
problems without the use of an explicit and detailed
algorithm or a mathematical interpretation of the problem.
Various CAx (Computer Aided Everything) systems are
used to assist product design and manufacture in order to
shorten the time and related costs. Numerous systems
have been developed which allow automation at particular
stages of design and manufacture. Computer technologies
have revolutionized modern manufacturing. From the
standalone CAD/CAM applications, to PDM/ERP
(Product Data Management/Enterprise Resource
Planning) systems, the computer technologies have
fulfilled the dreams of every manufacturer shorter
product development time, higher quality, and lower
costs. Computer-aided fixture design (CAFD) has become
reality as part of this revolution by integrating the fixture
design know-how and CAD platforms. With the aim to
reduce fixturing costs, over the years, various CAFD
systems have been developed to assist fixture designers.
Although numerous research efforts have been aimed at
development of fixture design systems, there is still a
need for development of a method which would assist the
designer at fixture elements level, where the basic task
would be to identify the required structure of fixture i.e.
the optimal number and arrangement of elements
according to predefined criteria. Though the primary
function of a fixture is allow precise location and
clamping of workpiece, there are a lot of other criteria to
be satisfied, which most often pertain to ergonomic
issues. Finally, one of the most important aspects of
fixtures is their impact on manufacturing costs through
assembly time, materials, costs of fixture manufacture,
etc. Another interesting feature of fixture design is the
fact that the various requirements to be met are usually
opposed to one another. Fixture design and manufacture
costs can account for up to 10-20% of the total
manufacturing costs [30]. These costs not only pertain to
fixture material, manufacture and assembly, but also
encompass the costs of fixture design. Lowering of fixture
design costs induces significant economic effects. There
are two approaches to this goal. One is focused on the
development of flexible fixtures, while the other relies on
the simplification of fixture design through computer
application.

2. GENERAL CHARACTERISTICS OF
SYSTEMS FOR AUTOMATED FIXTURE
DESIGN

Computer-aided fixture design is a more recent way of
design (the first attempts at fixture design automation date
back to the eighties of the last century). This approach
evolved as an attempt to overcome the negative aspects of
the conventional design paradigm.
CAFD uses computer to automate the steps in fixture
design. The goal is to generate an adequate fixture
solution within an acceptable time frame, while at the
same time minimizing the subjective influence and effort
of the designer. The most important assumptions for
efficient application of computers in the process of fixture
design are the 'translation' of designer's knowledge and
experience into a computer-usable form, the development
of a logic used in selection and decision-making, etc [27].
In essence, the systems for automated design are based on
information technologies (IT), while their structure and
principle of functioning make them specialized IT
systems. Regardless of methodology applied in the
development of a system for automated fixture design, the
constituent parts of every system are: module for defining
of input information, module for generation of output
information, and a data base [28].
8
Considering the systems for automated fixture design, the
input information can be broken down into three larger
categories: workpiece information (shape, geometry,
dimensions, etc.), technological information (machine
tools, cutting tools, cutting regimes, etc.), production
organization and management information (time of
design, time of manufacture, etc.).
Output information contain all the required data for
successful assembly and exploitation of fixtures. They are
always adjusted to end-users individual needs. The
necessary output information include: assembly drawing
of fixture and bill of materials (BoM). Very often, part
drawings are also required (regardless of whether the
parts are standard or not), while among the other
information are: weights of particular fixture elements,
total fixture weight, position in storage, etc.
The data base is fundamental to software support. Its
basic task is to provide system efficiency through quality
and effective functioning. Its primary functions are data
acquisition, storage, keeping, searching, and updating.
The data base must contain all the data necessary for a
successful functioning of the software support. It should
contain the required information (alpha-numerical and
graphical) pertaining to existing fixture design solutions,
fixture elements, and workpieces for which the fixtures
were designed.

3. CHARACTERISTIC APPROACHES TO
FIXTURE DESIGN

During the past two decades a number of researchers have
put in effort to solving the problem of rationalization, i.e.
automation of fixture design. There are numerous
examples of developed systems to confirm that claim.
Based on available references and consultations with
professionals and scientists from that area, it can be
concluded that the so far fixture design automation has
been developing through three main approaches: expert
systems, Case Based Reasoning, and Artificial Neural
Networks.

3.1. Application of expert systems in fixture
design

Operation of the majority of expert systems for fixture
design is based on symbolical representation and
processing of built-in knowledge. The knowledge is
represented using formal symbols and other appropriate
data structures presented in a formal language, while the
problems are solved by deriving conclusions through
manipulation of these symbols and data structures.
Expert systems whose knowledge is formalized through
rules are often termed rule-based systems. The rules can
be understood as the elements of knowledge, i.e. the
quantum of knowledge pertaining to a particular domain
of fixture design [15].
A rule represents a logic relation, and can be expressed
as:
If X Then Y

meaning: "if assumption X holds true, then Y is inferred"
or "If situation is X Then action Y is in order". For
instance: if "the base surface is a hole" then "the locating
element is a long pin" [23].
In other words, a rule is a logical If-Then loop meaning: if
a premise holds (or a set thereof), then an inference can be
made (or a set thereof) or an action can be undertaken (or
a sequence of actions). Such way of formalizing
knowledge is very natural and is suitable for modular
representation. It also allows easy modifications of the
knowledge, for the new rules can be added independently
from the existing ones, while the system is transparent,
i.e. its inference in easy to follow. Due to their form,
production rules are suitable for representing the logic-
based knowledge [21,22].
The inferences are made through comparison of a set of
rules with the set of facts pertaining to a given situation. If
the "If" part of the rule holds true, then the action defined
by "Then" is executed. When this happens it is usually
said that the rule has fired. For instance:
If (Premise)
Machining operation =drilling (and),
Batch size =single (and),
Machine tool =vertical milling machine (and),
Machine tool type =conventional (and),
No. of machining surfaces =one (and),
No. of cutting tools =one (and),
Drilling diameter =three (and)
Then (Inference)
Guiding element =fixed bush

Such or similar production rules have been developed
mostly for locating and/or clamping elements [2,6,7,9,12].
The elements are selected by re-iterating rules until
satisfactory elements have been found in the data base.
Should a larger number of eligible candidates be found,
the designer decides upon the one, based on his/hers
experience. Elements are selected based on their function.
Since there are several elements with identical functions,
they are grouped together. When applying the rules, the
function of each element is checked.
The beginnings of application of expert systems in fixture
design is attributed to the works of Markus et al. [20] and
Gandhi and Thompson [13]. Larger part of these
researches was theoretical while pointing out at some
possible ways of practical application. They marked the
onset of intensive development of expert systems in the
domain of fixture design. Darvishi and Gill [10], and
Ferreira, et al. [11] proposed a general model for
knowledge representation within an expert system. They
placed emphasis on the representation of declarative
knowledge. However, the rules which describe mutual
relationships and functions of elements were not
developed. Besides, the geometry of workpiece, its
dimensions and tolerances were also disregarded.
Procedural knowledge is vital to expert system operation,
and for its representation production rules are most often
used. Decision trees and rules networks were used to
define production rules. Decision trees were first
introduced by Bugtai and Young [4], and Dai, et al. [8]
and they are clear and comprehensible for the user. As
their main feature, they require a hierarchy of knowledge
in a particular domain. When representing knowledge
using rule networks, strict hierarchy is not required but,
on the other hand, they are less comprehensible. Fixture
design is, by nature, much closer to this way of
representing knowledge.
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Fig. 1. Fixture designed using an expert system [31]

The reason for application of expert systems is to place
the available knowledge on fixture design at disposal
through various application software. Expert systems
cannot entirely replace fixture design experts, especially
when it comes to creativity and general knowledge.
However, their advantage over humans lies in the
permanence of their knowledge, i.e. it does not depend on
repeated use. Expert systems use existing rules for fixture
design and can function relatively well as initial solutions.
Nevertheless, they lack flexibility, are difficult to adjust
and self-improve. In addition, there is no formalism to
allow detection of possible conflicts among production
rules when updating the database with new rules. For
these reasons, expert systems are recommended to
production systems with a well established and permanent
production program.

3.2. Case-Based Reasoning in fixture design

Case Based Reasoning (CBR) is one of the approaches to
intelligent database search. Every new search is based on
previous similar cases, thus utilizing some sort of
experience. This approach has been widely used in fixture
design. CBR is a concept which comes up with new
fixture solutions based on the existing ones, applying
modifications where necessary. The process of reasoning
can be described as follows. There is a new problem to be
solved, i.e. new workpiece for which a fixture must be
designed. The designer searches the knowledge base in
order to find similar design solutions. The next step is to
adapt the existing solution to new requirements and to
generate a new working solution. Should the same
problem be solvable using two solutions (all the
parameters are identical or close enough), the solution
that better solves the problem is stored in the knowledge
base. Knowledge representation in such fixture design
systems is performed based on cases. Every case contains
criteria which are classified as input and output. The input
criteria store information required for proper fixture
design, while the output criteria store information with
complete fixture design solutions. A subset of criteria
which allow the knowledge base to be searched are the
indices. Each case consists of the so called indexed and
non-indexed criteria.
The indexed criteria allow the search of the knowledge
base. Kumar and Nee [16] performed indexing using
numbers as attributes which describe the workpiece for
which a fixture is designed. Liqing and Kumar [19]
developed their cases from indexed criteria in the Internet
environment based on XML technology. In this way they
allowed exchange of information with other CAD/CAM
systems.
Non-indexed criteria do not allow comparison of cases
(they are not normalized), but are the carriers of semantic
information which are not suitable for normalization. The
indices, i.e. search criteria, are essential to proper system
functioning. Sun and Chen [25] developed the cases from
both indexed and non-indexed criteria. To simplify the
problem, he also developed a system for concept fixture
design. The inference process was based on cases which
define required locating elements for prismatic
workpieces using the 3-2-1 locating method. The criteria
were represented in a tree form.
After a case is structured, it is necessary to reduce all data
to a form which allows efficient manipulation and
management. Normalization requires all the cases to be
organized in a way which allows efficient comparison of
all values. Most often used for this purpose are the well
known metrics-based normalizations. Normalization is to
be viewed upon as the process in which a particular set of
data is allotted a common attribute in order to facilitate its
management. The so far research has efficiently tackled
the problem of normalization based on classifiers. Vukelic
et al. [29] approached normalization by adding a system
for unification of elements within complete fixture design
solutions.
Once normalization is completed, it is possible to perform
aggregation (synthesis) of data. With the case-based
fixture design systems a concept of similarity was used to
calculate the difference between the existing and required
fixture design solutions. Aggregation is required to
generate a single value from several indices (results
column) which is subsequently used to select - and, in the
case of several similar solutions - sort the existing fixture
design solutions.
Sun and Chen [25] applied the nearest neighbour method
which determines the similarity between the existing and
the novel fixture solution based on a weighted sum of
indices.
Vukelic et al. [29] were using the induction method. The
induction algorithm was used to form a decision tree,
which was subsequently used to measure similarity based
on If-Then rules.
Boyle et al. [3] applied the knowledge guided induction
method which is based on an expert system. It involves a
series of questions set by the system, which have to be
answered by the designer in order to narrow the domain
of feasible solutions.
However, the indexing remains an issue here. There are
no formal methods which could be used to define those
indices, thus the use of indices still relies on designer's
experience. Poor understanding of design requests is
causes inadequate indexing. If the design requests can be
adequately formalized, then the chances are greater that
those requests shall be used to generate indices, either
directly or as general guidelines. It is worth noting that
there exist some techniques for automated indexing, such
as the criterial learning method, inductive learning
method, method based on differences, method based on
similarities, etc.
In majority of cases, aggregation of data is solved by the
nearest neighbour method. The largest problem with this
design method is determination of significance and slow
10
search of the required solution. Fastness of this method is
directly linearly proportional to the number of cases
stored in the knowledge base. Thus, this method is more
useful in the case of a relatively small knowledge base,
which is rather unlikely in fixture design where quality
fixture solutions demand large number of cases.
Analysis of selected solutions is also at the hands of
designer and his experience. There is no possibility to
revise previous stages or improve the selected solution
without repeating the whole fixture design procedure
from scratch. Li et al. [17] proposed a solution for this
problem introducing an arbitration of conflicts between
dimensions and functions of fixture elements which could
be reviewed in the form of intermediate results at any
moment throughout the design process. Nevertheless, this
solution proved inadequate.


Fig. 2. An example of output results from the case-based
fixture design system [19]

Case-based reasoning can be successfully applied at the
conceptual stage of fixture design, when locating and
clamping surfaces are defined for predefined schemes.
The essential problem in the so far investigations has been
clear and systematic definition of all parameters which are
necessary for implementation of adequate modifications,
whether at the conceptual- or detailed fixture design
stage. The set of currently available design rules is still
incomplete. In addition, it is impossible to define all
design rules, since their number grows with experience.

3.3. Application of Artificial Neural Networks in
fixture design

Artificial Neural Networks (ANN) represent a transition
from symbolical to sub-symbolical level of data
processing where the rules used to transform input
information into output result - fixture design, are not
known. This approach does not require user to explicitly
formulate knowledge. ANN are trained iteratively, over a
period of time. It is important to define proper structure
and interrelations. ANN consists of an input and output
layer, and one or several hidden layers, each of them
having certain number of neurons. Unless user instructs
the system otherwise, the initial values of weight
coefficients are set on a random basis. During training,
weight coefficients are updated so that the next iteration
produces output values which are closer to the input.
Once the desired accuracy is achieved, or the predefined
maximum number of iterations is reached, the training
stops and the network is ready for the testing phase.
In their feasibility study on application of ANNs in fixture
design, Balasubramanian and Herrmann [1] give a mainly
theoretical contribution which lacks a practical case study.
The authors suggested application of ANNs to define
measures of similarity between the existing and novel
fixture design solutions as an alternative to case-based
reasoning. Their goal was to establish prerequisites for
fixture design based on existing design solutions.
Lin and Huang [18] used ANNs to generate concept
design of modular fixture for cutting-off operations based
on the principles of Group Technology (GT). GT concept
was used to classify workpieces of various shapes and
dimensions. Once a workpiece is classified using ANN
and an appropriate heuristic algorithm, concept solution is
generated. The system was developed for a particular
group of workpieces and in that respect lacks generality
(cannot be used for a broader class of workpieces).
Yuperl and Cus [32] developed a system for optimization
of clamping forces which is based on artificial neural
networks for prismatic parts, using the 3-2-1 clamping
method, and assuming that both fixture and workpiece are
rigid bodies. The 3-2-1 method requires three locating
elements on the first locating surface, two locating
elements on the second locating surface, and one on the
third. The system can define various clamping schemes,
positions of clamping elements, and magnitude of
clamping force. However, it does not allow selection of
required elements, but instead solves the problem of
clamping on a conceptual level.
Hamedi [14] also used ANNs to define positions of
clamping elements, using maximum stress and elastic
deformations of workpiece as the goal function. To
provide input data for ANN training, he used the ANSYS
CAE system. Hamedis system generated satisfactory
concept solutions of clamping schemes for prismatic parts
of simple geometry.
Subramaniam et al. [26] used ANNs to generate concept
fixture design solutions. ANN was trained to approximate
fixture productivity, and the ease with which a workpiece
is placed into and taken out of the fixture. For lack of
real-life, industrial data, to enhance the process of training
they used a performance matrix which was composed
based on their own data, which renders this study
unrealistic.
Similar contribution came from Cai et al [5]. They
developed a highly specialized system which allowed
generation of concept fixture design solutions exclusively
for locating elements, restricted to a predefined group
type of workpieces.



Fig. 3. An example of output results from an ANN-based
fixture design system [26]
11
Advantages of ANNs lie in their robustness to noisy input
data as well as their ability to learn. ANNs should
therefore be used for solving particular problem areas in a
highly complex matter of fixture design which is virtually
impossible to express algorithmically.
All the so far results of application of ANNs in fixture
design only allow generation of partial concept solutions.
Completion of the process from conceptual to detailed
fixture design is often time-consuming.
The basic problem of creating an adequate ANN pertains
to collecting sufficient quantity of input training data
based on systematized examples from the industry.

4. CONCLUDING REMARKS AND FUTURE
RESEARCH

Fixture design is a complex process which requires
extensive knowledge. For this reason, fixture design
automation is a very demanding undertaking and
represents one of the bottlenecks in flexible
manufacturing systems.
None of the reviewed approaches to automated fixture
design have managed to completely satisfy demands. One
of the general traits of these systems is their ability to
produce partial solutions, i.e. the locating and clamping
elements for simple prismatic workpieces. Although this
is not the only way to perform locating, the so far research
has relied on the 3-2-1 locating method, as well as on a
complete restraint of the workpiece, in spite of the fact
that this increases both costs of fixturing and the number
of constituent fixture elements. The designer is very often
left on his/her own devices when it comes to decision-
making, which many authors corroborate in their papers
claiming that 'The quality of fixture solution depends on
the designer's experience'. The influence of locating error
is completely disregarded, though it greatly contributes to
the total machining error, i.e. machining accuracy.
Although the intelligent systems have been undergoing
constant development, it is still early to talk about a
general solution for intelligent fixture design, since none
of the so far proposed systems have seen successful
industrial application. This is due to the fact that the
processes are very complex, and depend on numerous
factors which must be taken into consideration (but are, in
some cases, impossible to define). Obviously, the
artificial neural networks are an attempt to simulate the
work of the human brain. However, they are still far from
sophistication and complexity required to completely
replace humans in fixture design.
Despite the obvious advantages of automated fixture
design, there is still the problem of integration of
Computer Aided Design (CAD) and Computer Integrated
Manufacturing (CAM). In order to increase the efficiency
of the manufacturing system as a whole, there is a logical
requirement to integrate the information systems which
support design decisions, and other systems which
support enterprise management functions. The process of
fixture design is not entirely synchronized with other
design processes. In spite of numerous research efforts to
automate the methodology, there was little advancement
in the development of methods to support the design
within Concurrent Engineering (CE) environment based
on team collaboration. Future approaches to fixture design
methodology must be focused not only on CAD/CAM
integration, but more importantly, on providing support
for multidisciplinarity through concurrent engineering
paradigm.
Efficient application of the concept of virtual fixture
design would enable the development of fixture solutions
through co-operation of multidisciplinary teams which
would be in a position to understand, review, evaluate,
edit and improve a virtual fixture solution before it has
assumed any physical form.
All this supports the claims that there is still a lot of space
for potential research in the domain of automated fixture
design. It is logical to expect that the novel approaches to
automated fixture design and manufacturing automation
in general, shall be based on non-algorithmic
programming and methods of artificial intelligence.
Special efforts should be aimed towards creating systems
which are integral, universal, consistent, flexible, simple,
and intuitive.




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73-86.


CORRESPONDENCE


Djordje VUKELIC, Mgr. MSc. Eng.
University of Novi Sad
Faculty of Technical Sciences
Trg Dositeja Obradovica 6
21000 Novi Sad, Serbia
vukelic@uns.ac.rs


Branko TADIC, Prof. D.Sc. Eng.
University of Kragujevac
Faculty of Mechanical Engineering
Sestre J anjic 6
34000 Kragujevac, Serbia
btadic@kg.ac.rs


J anko HODOLIC, Prof. D.Sc. Eng.
University of Novi Sad
Faculty of Technical Sciences
Trg Dositeja Obradovica 6
21000 Novi Sad, Serbia
hodolic@uns.ac.rs


Nenad SIMEUNOVIC, Mgr. MSc. Eng.
University of Novi Sad
Faculty of Technical Sciences
Trg Dositeja Obradovica 6
21000 Novi Sad, Serbia
nsimeun@uns.ac.rs