Assembly sequence planning is a combinatorial optimization problem with hig
hly nonlinear geometric constraints. Most proposed solution methodologies a
re based on graph theory and involve complex geometric and physical analyse
s. As a result, even for a simple structure, it is difficult to take all im
portant criteria into account and to find real-world solutions. This paper
proposes an adaptive genetic algorithm (AGA) for efficiently finding global
-optimal or near-global-optimal assembly sequences. The difference between
an adaptive genetic algorithm and a classical genetic algorithm is that gen
etic-operator probabilities for an adaptive genetic algorithm are varied ac
cording to certain rules, but genetic operator probabilities for a classica
l genetic algorithm are fixed. For our AGA, we build a simulation function
to pre-estimate our GA search process, use our simulation function to calcu
late optimal genetic-operator probability settings for a given structure, a
nd then use our calculated genetic-operator probability settings to dynamic
ally optimize our AGA search for an optimal assembly sequence. Experimental
results show that our adaptive genetic assembly-sequence planner solves co
mbinatorial assembly problems quickly, reliably, and accurately.