Virtual Assembly Sequencing Using Ray-Cast Escape Directions

The patent uses virtual copies (digital twins) of physical components and assemblies to simulate and analyze assembly/disassembly processes. Virtual models replicate geometric and physical properties of real components, allowing automated plan generation in the virtual domain without affecting physical operations. This copying approach enables high-speed automated planning while maintaining flexibility through virtual experimentation.

The patent replaces manual mechanical analysis methods with computational algorithms that automatically analyze virtual models. Ray-casting algorithms and collision detection computations substitute for manual inspection and planning, enabling automated generation of assembly and disassembly sequences. This substitution dramatically increases productivity while maintaining adaptability through software-based control.

The patent creates a universal virtual modeling framework that handles multiple assembly/disassembly scenarios using the same core algorithms. The ray-casting and collision detection systems serve multiple functions: analyzing component interference, determining assembly sequences, identifying disassembly paths, and detecting potential conflicts. This multi-functionality reduces overall system complexity despite the automated nature of the process.

The virtual model acts as an intermediary between physical components and automated planning algorithms. Rather than directly controlling physical assembly operations, the system first analyzes virtual representations and translates results into actionable plans. This intermediary layer simplifies the automated system by decoupling the complexity of physical manipulation from the computational planning process.

The patent segments the virtual assembly model into individual components and hierarchical subassemblies, allowing ray-casting operations to be performed on smaller, manageable units. By dividing the overall assembly into discrete parts with defined boundaries, the system achieves high precision in constraint identification while reducing computational load compared to analyzing the entire assembly as a single unit.

The patent applies ray-casting algorithms selectively to identify critical interference conditions rather than performing exhaustive analysis of all possible component interactions. The system casts rays from key feature points and surfaces to detect assembly constraints, using just enough computational effort to achieve accurate results without unnecessary processing of non-critical areas.