This paper presents a practical approach for integrating automatically designed fixtures with automated assembly planning. Product assembly problems vary widely; here the focus is on assemblies that are characterized by a single base part to which a number of smaller parts and subassemblies are attached. This method starts with three-dimension at CAD descriptions of an assembly whose assembly tasks require a fixture to hold the base part. It then combines algorithms that automatically design assembly pallets to hold the base part with algorithms that automatically generate assembly sequences. The designed fixtures rigidly constrain and locate the part, obey task constraints, are robust to part shape variations, are easy to load, and are economical to produce. The algorithm is guaranteed to find the global optimum solution that satisfies these and other pragmatic conditions. The assembly planner consists of four main elements: a user interface, a constraint system, a search engine, and an animation module. The planner expresses all constraints at a sequencing level, specifying orders and conditions on part mating operations in a number of ways. Fast replanning enables an interactive plan-view-constrain-replan cycle that aids in constrain discovery and documentation. The combined algorithms guarantee that the fixture will hold the base part without interfering with any of the assembly operations. This paper presents an overview of the planners, the integration approach, and the results of the integrated algorithms applied to several practical manufacturing problems. For these problems initial high-quality fixture designs and assembly sequences are generated in a matter of minutes with global optimum solutions identified in just over an hour.
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