Abstract A model-based approach to the recognition of assembly process states is presented. Force information acquired in the process is interpreted using state classifiers in order to estimate the current state of the assembly process. The classifiers of the assembly process state are formulated by using the theory of polyhedral convex cones, which allows us to treat unidirectional geometric constraints in a systematic manner. We develop a systematic method for generating the classifiers automatically based on geometric models of assembly parts. Using the classifiers generated on a computer, a recognition system can determine the process state from sensory information. First, a symbolic representation of assembly processes with respect to contact states is addressed. Kinematic and static behavior of assembly parts at each contact state are then analyzed by applying the theory of polyhedral convex cones. State classifiers that discriminate contact states are formulated by using the polyhedral convex cones, which directly provide a set of discriminant functions. To reduce real-time computations, the classifiers are simplified to a minimum set by using reduction rules of polyhedral convex cones. The algorithm to generate the state classifiers is then implemented on a computer to demonstrate the usefulness of this approach.