In existing automated docking assembly solutions for aerospace products, segmented docking surfaces suffer from machining errors and deformation, making assembly difficult. The aim of this study was to reduce the internal stresses in cabin assembly and maintain sufficient assembly accuracy. A cabin assembly optimization method was developed based on force–position coordination analysis. To address the interference problem of the cabin flange surface, a penalty-function-based reweighting iterative approximation method was constructed based on the square-hole characteristics of the docking. In the assembly verification, mechanism calibration and measurement field iterative compensation optimized the mechanism pose, and the accuracy of the pose adjustment component and the cabin assembly stress were tested. The experimental results show that the method proposed can reduce the interference problem during the assembly of a flange face and optimize the assembly stress while achieving assembly accuracy. The results for accuracy and interference force after flange face assembly were obtained; however, no feedback on the analytical method was obtained through the experimental results. Therefore, it is necessary to test further the propositions investigated. The preassembly analysis method for large cabin assemblies proposed optimizes the cabin assembly accuracy and internal stress under the deformation state of the assembly surface.
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