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The paper introduces a complete offline programming toolbox for remote laser welding (RLW) which provides a semi-automated method for computing close-to-optimal robot programs. A workflow is proposed for the complete planning process, and new models and algorithms are presented for solving the optimisation problems related to each step of the workflow: the sequencing of the welding tasks, path planning, workpiece placement, calculation of inverse kinematics and the robot trajectory, as well as for generating the robot program code. The paper summarises the results of an industrial case study on the assembly of a car door using RLW technology, which illustrates the feasibility and the efficiency of the proposed approach

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The paper proposes a generic approach to assembly planning where individual tasks, with detailed technological content specified by features, must be combined into an optimal assembly plan subject to technological and geometric constraints. To cope with the complexity and variety of the constraints that refer to the overall assembly process, Benders decomposition is applied. The macro-level master problem looks for the optimal sequencing and resource assignment of the tasks, while sub-problem modules ensure plan feasibility on the micro-level from aspects of technology, fixturing, tooling, and collision. Constraints are also dynamically generated for the master problem. The approach is demonstrated in automotive assembly.

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