Gradient-Based Optimization of Component Layout: Addressing Accessibility and Mounting in Assembly System Design

Abstract This article proposes novel methods for capturing and modeling critical physical assembly parameters, with a particular focus on mounting and accessibility requirements, for use in 3D assembly design optimization. The effectiveness of the proposed parameters is validated by integrating them into a gradient-based optimization framework and applying it to three increasingly complex test cases. The proposed framework simultaneously addresses essential assembly requirements: maximizing packing density, preventing part overlap, accommodating components on nonplanar mounting surfaces, maintaining proximity relationships, and ensuring accessibility for high-maintenance components. The results show that the method consistently generates densely packed, feasible layouts that satisfy all defined assembly requirements. This work establishes a strong foundation for practical assembly design optimization. Future efforts will focus on improving computational efficiency, scaling to larger and more diverse problems, and incorporating additional engineering considerations to further enhance the framework's industrial and academic utility.