An introduction to smart assemblies for robust design

Research conducted over the past decade has resulted in a suite of methods for robust design which can be applied during different design stages. These methods focus on reducing the sensitivity of the design to variation without removing its causes. In this paper we propose an additional and very powerful means for achieving robustness that complements other methods developed to date. We have called this approach smart assemblies. A smart assembly has features, not otherwise required by the function of the design, which allow the design to absorb or cancel out the effects of variation. This paper provides an introduction to smart assemblies. Specifically, we define passive and active smart assemblies and provide examples of each. We discuss the close connection between smart assembly design and exactly constrained design. We present an example from industry illustrating the benefits of exactly constrained smart assemblies. We discuss a design methodology for smart assembly design and present the beginnings of a classification system for 2D smart features.