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This study aims to monitor and guide the assembly process. The operators need to change the assembly process according to the products’ specifications during manual assembly of mass customized production. Traditional information inquiry and display methods, such as manual lookup of assembly drawings or electronic manuals, are inefficient and error-prone.

This paper proposes a projection-based augmented reality system (PBARS) for assembly guidance and monitoring. The system includes a projection method based on viewpoint tracking, in which the position of the operator’s head is tracked and the projection images are changed correspondingly. The assembly monitoring phase applies a method for parts recognition. First, the pixel local binary pattern (PX-LBP) operator is achieved by merging the classical LBP operator with the pixel classification process. Afterward, the PX-LBP features of the depth images are extracted and the randomized decision forests classifier is used to get the pixel classification prediction image (PCPI). Parts recognition and assembly monitoring is performed by PCPI analysis.

The projection image changes with the viewpoint of the human body, hence the operators always perceive the three-dimensional guiding scene from different viewpoints, improving the human-computer interaction. Part recognition and assembly monitoring were achieved by comparing the PCPIs, in which missing and erroneous assembly can be detected online.

This paper designed the PBARS to monitor and guide the assembly process simultaneously, with potential applications in mass customized production. The parts recognition and assembly monitoring based on pixels classification provides a novel method for assembly monitoring.

Automobile development needs more and more collaborative work involving geographical dispersed designers, that brings difficulty for model verification, conception review and assembly process evaluation, so a collaborative virtual environment for automobile based on network is required. In this kind of environment, designers can do interactive assembly operations collaboratively, such as grasp, move, release, collision detection (CD), assembly evaluation report generation, etc. Furthermore, automobile structure becomes more complicated, how to process this large real‐time data effectively in real‐time interactive virtual environment is a great challenge. The purpose of this paper is focus on this.

A distributed parallel virtual assembly environment (DPVAE) is developed. In this environment, the mechanism of event synchronization based on high‐level architecture/run‐time infrastructure) is applied to realize multi‐user collaboratively interactive operation. To meet the large data set real‐time processing demand, a creative parallel processing approach supported by a single supercomputer or a parallel processing environment composed of common personal computer in a high‐speed local area network is developed. The technologies such as real‐time CD, multiple interactive operation modals are applied in DPVAE and several auxiliary tools are provide to help achieving whole scheme review, component model verification and assembly evaluation.

This paper finds that DPVAE system is an available and efficient tool to support automobile collaborative assembly design.

Designers can discuss and verify the assembly scheme to realize the previous design scenario in DPVAE, so it is useful for reducing costs, improving quality and shortening the time to market, especially for new type automobile development.

A combination of distributed technology and parallel computing technology is applied in product virtual assembly, solving the problems including collaborative work of multi‐user and large data real‐time processing successfully, that provides a useful tool for automobile development.

Presents an integrated approach to assembly planning for manufacturing printed circuit boards (PCBs). The integrated manufacturing assembly planning system (IMAPS) is a system that incorporates knowledge‐based techniques to assist process engineers with the development of assembly plans for building PCBs. IMAPS has been developed in a two‐year project with a multinational telecommunications manufacturer and the Alberta Research Council of Canada. The scope of IMAPS is to develop an integrated environment that takes full advantage of electronic information for assembly planning of PCBs. Several functions in the company can be integrated with IMAPS, including product design, detailed assembly planning, line balancing and generation of shop floor drawings. Information stored in the manufacturing and design databases of the corporation, about a PCB to be assembled, is employed by a knowledge‐based module to generate assembly plans to build the PCB. A line balancing procedure is employed to select the most adequate assembly plan of those generated by the knowledge‐based module. The final assembly plan is then presented to the operators as a diagram with instructions for the assembly of the PCB. IMAPS has increased the speed to generate assembly plans from 120 hours to four hours. The final computer‐aided assembly planning system implemented in the company has taken the concepts developed in IMAPS; they have been implemented in C and C++. Lessons and experiences learned while developing and implementing IMAPS are presented.

Virtual assembly (VA) based on virtual reality (VR) is a key technique of virtual manufacturing. It provides not only an intuitive and interactive interface for virtual product design, but also an efficient method to analyze or verify assembly performance of these products. Preliminary investigations of constructing a VA system were implemented in this paper. There were three key techniques in constructing a VA system, which were data transformation from CAD system to VA system, collision detection, and virtual manipulation with a virtual hand. These key techniques were analyzed further and their concrete algorithms were given. At last an experimental VA system was set‐up to verify these algorithms. It is proved that the transformed data are sufficient, which can satisfy the VA system's requirement; the collision detection algorithm is efficient as it assures the system to be real time; and the virtual manipulation algorithm guarantees the system's reality and maneuverability.

Haptics can significantly enhance the user's sense of immersion and interactivity. Especially in an assembly task, haptic feedback can help designers to have a better understanding of virtual objects and to increase task efficiency. The purpose of this paper is to investigate the design and implementation of a haptic‐based virtual assembly system (HVAS).

A multi‐thread system structure was designed, an automatic data integration interface was developed to transfer geometry, topology, assembly and physics information from a computer‐aided design system to virtual reality application, and a hierarchical constraint‐based data model and scene graph structure was designed to construct the virtual assembly environment. Unlike traditional virtual assembly systems based on collision detection or geometry constraint only, a physics‐based modeling approach combining with haptic feedback and geometry constraint was undertaken to realize and guide the realistic assembly process. When two parts collide into each other, the force and torque can be computed and provide feedback, and a spring‐mass model is used to prevent penetration and simulate dynamic behaviour. When two parts are close enough to each other and the assembly simulation state is activated, a geometry constraint can be captured, an attractive force can be generated to guide the user to assemble the part along the correct position, and the repulsive force can also be generated to realize the mating process as natural and realistic as in real life.

The implementation details and application examples demonstrate that haptic‐based virtual assembly is a valuable tool for assembly design and process planning.

The paper presents an HVAS.

The ever‐increasing demand for rationalization of manufacturing activities requires closer co‐operation and integration between design and production planning. Since the impact on the overall cost of production of designing a product for ease of assembly was realized, feedback from assembly planning to the design process has become important for improving the design. Traditionally, planning for assembly takes place after the design of the product has been completed. Often it proves necessary to modify a design, because some aspect is not particularly convenient or efficient under the available assembly facilities. However, considerable time and cost savings can be made by making assembly‐planning information available to design engineers, so that they can take account of assembly factors when designing a product.

Aiming at presenting an interaction-free assembly assistance tool, the purpose of this paper is to propose a synchronous augmented reality (AR) assembly assistance and monitoring system. The system monitors operator’s hands activity and process completeness to recognize the assembly state, then display the AR contents contextually.

An assembly behavior recognition method is proposed based on gesture recognition. An assembly completeness inspection method is proposed based on SURF feature matching. Assembly state and AR display state are solved by a novel sequential hybrid AR display control strategy. A synchronous multi-channel AR view output strategy is proposed based on QR matrix decomposition.

A prototype system has been developed, and case study is performed on an industrial product. Experiments are performed to verify the feasibility, efficiency and recognition accuracy of the proposed methods.

The proposed system assists users to perform assembly tasks with automatic visual guidance and vision monitoring, avoiding distractions caused by redundant human–computer interactions.

All methods are integrated to work on only one head-worn device, making the proposed system portable and cheaper. The vision processing pipelines and the view output channels are reconfigurable for customization.

This paper proposes an interaction-free AR assembly assistance and monitoring system. Assembly behavior recognition and assembly completeness inspection methods are integrated to monitor the assembly state. A sequential hybrid AR display control strategy is proposed to contextually update the AR contents. A synchronous multi-channel AR view output strategy is proposed to fulfill different visualization needs.

Existing models of product assembly scheme design often ignore the constraint relations among design thinking. In order to grasp the functions of each part and the constraint relations among them in product assembly system macroscopically, further design and variation of product assembly system should be made according to design thinking. This paper seeks to address these issues.

Through analyzing the similarity between biological organization system and product system and taking biology knowledge for reference, product assembly system was expressed as product function gene, product constraint gene, product function protein, product constraint protein and product cell and so on in this paper. The product gene model composed of product function gene groups and constraint genes was established and a modeling method based on it was proposed.

The author applied this method to model the 5‐DOF manipulator of complex diamond manufacturing special equipment with good results which proved the effectiveness of this modeling method.

By identifying constraint relations and design thinking in the gene model, the system makes the modification process which is conducted by the designers automatically identified and varied to achieve computer‐aided design and assembly.

The paper aims to present the processing pipeline of an assembly immersive simulation application which can manage the interaction between the virtual scene and user using stereoscopic display and haptic devices. A new set of elements are integrated in a Collaborative Virtual Environment (CVE) and validated using an approach based on subjective and objective users’ performance criteria. The developed application is intended for Assembly/Disassembly (A/D) analysis, planning and training.

A mobility module based on contact information is used to handle the assembly components’ movements through real-time management of collision detection and kinematically constraint guidance. Information on CVE architecture, modules and application configuration process are presented. Impact of device type (3 degrees of freedom (DoFs) vs 6 DoFs) over user’s experience is evaluated. Parameters (number of assembled components and components assembly time) are measured for each user and each haptic device, and results are compared and discussed.

Test results proved the efficiency of using a mobility module based on predefined kinematic constraints for reducing the complexity of collision detection algorithms in real-time assembly haptic simulations. Also, experiments showed that, generally, users performed better with 3 DoFs haptic device compared to 6 DoFs haptic equipment.

The proposed immersive application automates the kinematical joints inference from 3D computer-aided design (CAD) assembly models and integrates it within a haptic-based virtual environment, for increasing the efficiency of A/D process simulations.

Owing to the numerous part models and massive datasets used in automobile assembly design, virtual assembly software cannot simulate a whole vehicle smoothly in real time. For this reason, implementing a new virtual assembly environment for massive complex datasets would be a significant achievement. The paper aims to focus on this problem.

A new system named “Grid‐enabled collaborative virtual assembly environment” (GCVAE) is proposed in the paper, and it comprises three parts: a private grid‐based support platform running on an inner network of enterprise; a service‐based parallel rendering framework with a sort‐last structure; and a multi‐user collaborative virtual assembly environment. These components would aggregate the idle resources in an enterprise to support assembly simulation with a large complex scene of whole vehicle.

The system prototype proposed in the paper has been implemented. The following simulations show that it can support a complex scene in a real‐time mode by using existing hardware and software, and can promote the efficient usage of enterprise resources.

Using the GCVAE, it is possible to aggregate the idle resources in an enterprise to run assembly simulations of a whole automobile with massively complex scenes, thus observably reducing fault occurrence rates in future manufacturing.

The paper introduces a new grid‐enabled methodology into research on collaborative virtual assembly system which can make the best use of idle resources in the enterprise to support assembly simulations with massively complex product models. A video‐stream‐based method was used to implement the system; this enables designers to participate ubiquitously in the simulation to evaluate the assembly of the whole automobile without hardware limitations.