If you place the Pack & Go assembly in the same location as your original assembly, there's no way to avoid the conflicts, until you rename files as you found.
The best method is to use Vault Workgroup or Professional, which have a very capable Copy Design tool; next best is to use Vault Basic (included with Inventor subscription), which has a somewhat less capable Copy Design tool; next after that (in my opinion) is Design Assistant, which is an Inventor tool that operates outside Inventor. I'm not going to give the whole tutorial here, but it's pretty easily found on the Autodesk Knowledge Network. The very basic procedure: in Windows File Explorer, copy your top level assembly to a new name, then right click on the new file and select Design Assistant. When the app opens, select Manage on the left side. Now you see your assembly at the top and all its components. Select all the files except the top assembly, and right click in the Action column and choose Copy. One by one, rename all the components, then click Save. All will be copied to the new names/locations you specified, and all the links maintained (separate from the originals). In a big assembly this can get incredibly tedious and put you at risk for repetitive stress injury. But it's still much better than manually renaming, then resolving all the files.
Sam B
Inventor Pro 2021.2.1 | Windows 10 Home 2004
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