Constraint-Based Disassembly Sequencing Algorithms for Dismantling Applications—A Comparative Study

With growing interest in automated dismantling operations for hazardous environments, automatically planning safe and efficient disassembly sequences is becoming increasingly important. When a large structure is segmented into parts, the removal order must ensure that each part can be extracted safely without destabilising the remaining structure. This paper presents a comparative study of four algorithms for solving the disassembly sequencing problem in two dimensions: First Feasible Random Search (FFRS), Greedy Search (GS), Height-Decreasing Search (HDS), and Stochastic Tree Search (STS). The present study focuses specifically on sequencing feasibility under geometric and physical constraints, namely connectivity, accessibility, and structural stability. The 2D formulation provides a simplified yet computationally efficient testbed for analysing algorithmic behaviour under varying cutting complexities, with the objective of minimising the total removal trajectory length. Results show that while STS consistently finds optimal or near-optimal solutions, its factorial runtime limits scalability. GS produces high-quality solutions efficiently but can become trapped in infeasible configurations, whereas HDS offers strong reliability and speed at the expense of solution quality. Based on these findings, a hybrid height-based backtracking algorithm is proposed as a promising future direction, combining the efficiency of greedy search with the robustness of stochastic exploration. The results provide insight into the relative strengths and limitations of different sequencing strategies and establish a foundation for future extension to more realistic dismantling scenarios, including 3D and radiologically constrained applications.