Online quality assurance is crucial for elevating product quality and boosting process productivity in advanced manufacturing. However, the inherent complexity of advanced manufacturing, including nonlinear process dynamics, multiple process attributes, and low signal/noise ratio, poses severe challenges for both maintaining stable process operations and establishing efficacious online quality assurance schemes. To address these challenges, four different advanced manufacturing processes, namely, fused filament fabrication (FFF), binder jetting, chemical mechanical planarization (CMP), and the slicing process in wafer production, are investigated in this dissertation for applications of online quality assurance, with utilization of various sensors, such as thermocouples, infrared temperature sensors, accelerometers, etc. The overarching goal of this dissertation is to develop innovative integrated methodologies tailored for these individual manufacturing processes but addressing their common challenges to achieve satisfying performance in online quality assurance based on heterogeneous sensor data. Specifically, three new methodologies are created and validated using actual sensor data, namely, (1) Real-time process monitoring methods using Dirichlet process (DP) mixture model for timely detection of process changes and identification of different process states for FFF and CMP. The proposed methodology is capable of tackling non-Gaussian data from heterogeneous sensors in these advanced manufacturing processes for successful online quality assurance. (2) Spatial Dirichlet process (SDP) for modeling complex multimodal wafer thickness profiles and exploring their clustering effects. The SDP-based statistical control scheme can effectively detect out-of-control wafers and achieve wafer thickness quality assurance for the slicing process with high accuracy. (3) Augmented spatiotemporal log Gaussian Cox process (AST-LGCP) quantifying the spatiotemporal evolution of porosity in binder jetting parts, capable of predicting high-risk areas on consecutive layers. This work fills the long-standing research gap of lacking rigorous layer-wise porosity quantification for parts made by additive manufacturing (AM), and provides the basis for facilitating corrective actions for product quality improvements in a prognostic way. These developed methodologies surmount some common challenges of advanced manufacturing which paralyze traditional methods in online quality assurance, and embody key components for implementing effective online quality assurance with various sensor data. There is a promising potential to extend them to other manufacturing processes in the future. / Ph. D.

Cette thèse aborde principalement trois grands aspects tels que la systématisation et l'analyse structurale, la modélisation géométrique et cinématique et les stratégies de contrôle. La première partie de la thèse est consacrée à l'élaboration d'une approche pour la systématisation des mécanismes reconfigurables selon leurs paramètres structuraux tels que la mobilité, la connectivité, la redondance et l’hyperstatisme. Ces paramètres nous permettent de comprendre les mécanismes et de les systématiser selon leur type de mouvement ; le mécanisme peut être isostatique ou hyperstatique, redondant ou non-redondant, avec ou sans mobilités internes, etc. Afin de résoudre les problèmes pratiques de modélisation, contrôle, simulation et développement du robot, les paramètres structuraux sont nécessaires. Différents types de singularités sont systématisés et analysés en tenant compte de paramètres structuraux. En plus, pour connaître les positions et les orientations relatives des membres du robot, nous avons besoin de calculer le modèle géométrique. Nous utilisons la méthode du Système de Coordonnées Voyageur pour déterminer la position et l'orientation des membres à chaque instant. Pour connaître les vitesses linéaires et angulaires des membres, nous devons formuler les équations cinématiques pour le robot étudié. La partie contrôle est dédiée à l'élaboration de stratégies de génération de trajectoire et de contrôle, sur la base de la redondance d’actionnement. La difficulté dans la commande est de développer une loi de contrôle avancée pour la synchronisation de plusieurs actionneurs afin d'avoir une transition fluide d'un mode d'assemblage à un autre, ceci sans endommager le robot. Le choix des liaisons actionnées joue également un rôle essentiel en garantissant une haute performance et la contrôlabilité du mécanisme au passage par les configurations singulières. Dans cette thèse, nous nous concentrons sur le mécanisme à une seule boucle fermée de type 8-bar afin d’illustrer les développements réalisés dans les trois parties mentionnées ci-dessus. Il a été démontré que ce mécanisme présente une capacité intéressante de reconfiguration. Il dispose de deux degrés de mobilité dans une configuration générale, mais a besoin d'au moins cinq moteurs pour être entièrement contrôlés dans toutes les configurations singulières. / This thesis mainly addresses three major aspects such as systematization and structural analysis, geometric and kinematic formulation and control strategies. The first part of the thesis is dedicated to the development of a systematization approach for reconfigurable mechanisms with respect to their structural parameters such as mobility, connectivity, redundancy and number of overconstraints. These parameters help us to understand the mechanism and to systematize it according to type of motion, whether the mechanism is overconstrained or non-overconstraint, redundant or non-redundant, with/without internal mobilites, etc. To resolve the practical problems of modeling, control, simulation and development of the robot, the structural parameters are required. Various types of singularities are also systematized and analyzed by taking into account the structural parameters. Further to know the relative location of robot links, we need to compute the geometric model. We use Travel Coordinate System method to determine the position and orientation of links at each instant. To find out the linear and angular velocities of links, we need to formulate the kinematic equations for the robot under consideration. The control part is dedicated to the development of trajectory generation and control strategies, based on actuation redundancy. The challenging task is to develop an advanced control law in order to synchronize several actuators to have a smooth transition from one assembly mode to another without causing wear and tear to the robot. Choice of actuated joints also plays a vital role in ensuring high performance and controllability of the mechanism when crossing singular configurations. In this thesis we focus on the 8-bar single loop mechanism to illustrate the developments achieved in the three parts mentioned above. It has been shown that, this mechanism exhibits an interesting capacity to reconfigure. It has two degrees of mobility in a general configuration but needs at least five motors to be fully controlled in all singular configurations.