Proper constraint as a design principle for assemblies

This paper's objective is to explain the concept of proper kinematic constraint to guide requirements‐driven design of mechanical assemblies and to connects proper constraint to the datum flow chain (DFC) and key characteristics (KCs).

The paper presents proper constraint as a way to support the goal of placing key parts in particular geometric relationships with respect to one another so that a DFC can deliver KCs unambiguously. Such a DFC is said to be competent. Additionally, a competent DFC is robust in the sense that the constraint relationships between parts retain their definition and effect under all allowed variations in parts.

Failure to provide proper constraint can lead to undesired consequences including locked‐in stresses and difficult or inconsistent assembly. Some designs need to be over‐constrained, and this requires very careful control and tight tolerances on the over‐constrained degrees of freedom in order to avoid or at least understand the consequences listed above.

Mathematical methods exist to test designs for proper constraint. The simplest, and occasionally unsuccessful, is the Kutzbach criterion. Screw theory is the most reliable method but its application requires extra knowledge and mathematical tools.

Most CAD software and tolerance analysis software do not test designs for their state of constraint. The engineer needs to take account of this independently and be aware of the limitations of software as a guide. Tolerance analysis software that does not take account of constraint may yield incorrect answers.

The paper reinvigorates a once‐well‐known principle and makes engineers aware of it. It also links this concept to the concepts of DFC and KCs and supports a mathematically‐based method for designing assemblies.