Virtual Shell Ray-Casting for Assembly and Disassembly Planning

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Solution Overview

Problem

Existing methods for generating assembly and disassembly plans are inefficient and lack automation, particularly in identifying optimal disassembly and assembly sequences for complex assemblies without prior knowledge of component functions or purposes.

Innovation Solution

A method involving virtual assembly models is employed to generate assembly and disassembly plans by defining virtual shells, generating constellations of rays, and identifying unrestricted and restricted escape directions for virtual components, allowing for the construction of automated disassembly and assembly sequences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If existing methods are used to generate assembly and disassembly plans, then manual planning can be performed, but the process is inefficient and lacks automation especially for complex assemblies

Engineering Contradiction:

Improveautomation of assembly plan generationVSAvoidefficiency of plan generation

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The system performs self-analysis by automatically examining the 3D CAD model of the assembly, identifying components, constraints, and disassembly sequences without requiring manual input or expert knowledge. The algorithm independently determines escape directions, component relationships, and assembly/disassembly plans through computational geometry analysis.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical planning processes with an automated computational system. Instead of engineers manually analyzing assembly structures, the system uses ray-casting algorithms, virtual shell generation, and constraint satisfaction methods to automatically determine disassembly sequences and component relationships.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated methods are implemented, then efficiency improves, but device complexity increases due to virtual shells, rays, and guards

Engineering Contradiction:

Improvespeed of plan generationVSAvoidcomplexity of virtual assembly model

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the complex problem of assembly planning into distinct computational components: virtual shell generation, ray-casting operations, guard identification, constraint analysis, and sequence determination. Each component handles a specific aspect of the analysis, making the overall system more manageable and implementable despite the complexity of the complete solution.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If virtual shells and rays are used to identify escape directions, then disassembly sequences are accurately determined, but computational time and processing complexity increase

Engineering Contradiction:

Improveaccuracy of escape direction identificationVSAvoidcomputation time for plan generation

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system generates a constellation of rays that extends beyond the immediate boundaries of components to ensure all possible escape directions are captured. By using more rays than the absolute minimum and extending them sufficiently far, the system guarantees complete coverage of feasible disassembly paths, accepting the computational cost as necessary for accuracy.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20250322115A1Method for automatically generating assembly and disassembly plans

Publication Date: 2025.10.16 C-INFINITY INC

AI summary

One variation of a method includes: accessing a virtual assembly; for a virtual component in a set of virtual components within the virtual assembly, generating a constellation of rays emanating from an inset surface of the virtual component; traversing the virtual component along a first ray, in the constellation of rays, in a first direction; in response to the virtual component colliding with another virtual component along the first ray, identifying a restricted escape direction; traversing the virtual component along a second ray, in the constellation of rays, in a second direction; in response to the virtual shell avoiding collision with another virtual component along the second ray, identifying an unrestricted escape direction; and generating a virtual assembly sequence specifying installation of the virtual component, opposite the second direction, prior to installation of another virtual component, based on the unrestricted escape direction.