Assembly path planning (APP) for complex products is challenging due to the large number of parts and intricate coupling requirements. A hybrid assembly path planning method is proposed herein that reuses a priori paths to improve the efficiency and success ratio. The assembly path is initially segmented to improve its reusability. Subsequently, the planned assembly paths are employed as a priori paths to establish an a priori tree, which is expanded according to the bounding sphere of the part to create the a priori space for path searching. Three rapidly exploring random tree (RRT)-based algorithms are studied for path planning based on a priori path reuse. The RRT* algorithm establishes the new path exploration tree in the early planning stage when there is no a priori path to reuse. The static RRT* (S-RRT*) and dynamic RRT* (D-RRT*) algorithms form the connection between the exploration tree and the a priori tree with a pair of connection points after the extension of the exploration tree to a priori space. The difference between the two algorithms is that the S-RRT* algorithm directly reuses an a priori path and obtains a new path through static backtracking from the endpoint to the starting point. However, the D-RRT* algorithm further extends the exploration tree via the dynamic window approach to avoid collision between an a priori path and obstacles. The algorithm subsequently obtains a new path through dynamic and non-continuous backtracking from the endpoint to the starting point. A hybrid process combining the RRT*, S-RRT*, and D-RRT* algorithms is designed to plan the assembly path for complex products in several cases. The performances of these algorithms are compared, and simulations indicate that the S-RRT* and D-RRT* algorithms are significantly superior to the RRT* algorithm in terms of the efficiency and success ratio of APP. Therefore, hybrid path planning combining the three algorithms is helpful to improving the assembly path planning of complex products.

Assembly path planning of complex products in virtual assembly is a necessary and complicated step, which will become long and inefficient if the assembly path of each part is completely planned in the assembly space. The coincidence or partial coincidence of the assembly paths of some parts provides an opportunity to solve this problem. A path planning algorithm based on prior path reuse (PPR algorithm) is proposed in this paper, which realizes rapid planning of an assembly path by reusing the planned paths. The core of the PPR algorithm is a dual-tree fusion strategy for path reuse, which is implemented by improving the rapidly exploring random tree star (RRT *) algorithm. The dual-tree fusion strategy is used to find the nearest prior node, the prior connection node, the nearest exploring node, and the exploring connection node and to connect the exploring tree to the prior tree after the exploring tree is extended to the prior space. Then, the optimal path selection strategy is used to calculate the costs of all planned paths and select the one with the minimum cost as the optimal path. The PPR algorithm is compared with the RRT * algorithm in path planning for one start node and multiple start nodes. The results show that the total time and the number of sampling points for assembly path planning of batch parts using the PPR algorithm are far less than those using the RRT * algorithm.