MADE Module User Manual — Functional Modeling & Failure Definition

This manual (Version 3.9.1) provides the information and steps required to create a basic functional model and conduct failure analyses in the MADE module. Its aim is to familiarize the user with the MADE interface, functional and failure taxonomies, workflows for building system models and failure diagrams, and conducting model-based analyses to produce relevant outputs.

1 Nomenclature

Term/Acronym	Definition
CAD	Computer Aided Design
CIL	Critical Item List
FBD	Functional Block Diagram
FCM	Fuzzy Cognitive Mapping
FFM	Functional Failure Modes
FMEA	Failure Modes & Effects Analysis
FMECA	Failure Modes, Effects & Criticality Analysis
FTA	Fault Tree Analysis
LOI	Level of Indenture
LRU	Line Replaceable Unit
MADE	Maintenance Aware Design Ecosystem
MIL-STD	Military Standard
MTTR	Mean Time to Repair
MUX	Multiplex
NASA	National Aeronautics & Space Administration
RAM	Reliability, Availability & Maintainability
RCM	Reliability Centered Maintenance
PDF	Portable Document Format
PHM	Prognostics & Health Monitoring
SRA	Safety & Risk Assessment
SRU	Shop Replaceable Unit
STEP	Standard for the Exchange of Product model data

2 Introduction

2.1 Functional Modeling

This MADE Module User Manual provides the information and steps required to create a basic functional model and conduct failure analyses. Its aim is to familiarize the user with the MADE interface, functional and failure taxonomies, workflows for building system models and failure diagrams, and conducting model-based analyses to produce relevant outputs.

2.2 Objectives

The main objective is for the user to understand how to use the MADE module for creating a Functional Block Diagram (FBD) of a Vehicle System and investigating flow perturbations and observing flow responses in the system.

2.3 System Information

The examples and figures used in this manual are based on the Vehicle System in the MADE Example Systems Library. Appendix A at the end of this manual provides system information about the model and is used to aid in modelling. Appendix B includes the components' functions to assist in component creation. Appendix C contains Item Failure Data for all items in the Power Generation Subsystem. Note: The model used is intended for training purposes only.

2.4 System Example (MADE Example Systems)

The Vehicle System is available within the MADE software from the Library viewer. Expanding the categories MADE Example Systems → Mechanical → Vehicle System and dragging this item into the System Model editor will show the Vehicle System FBD. Alternatively, typing Vehicle System into the search field at the top of the Library viewer will filter out and display the Power Generation Subsystem.

2.5 User Workflows & Simulation Types

The user workflows below explain steps required to build a functional block diagram in MADE to conduct specific types of simulation. There are two main types of simulations used in MADE: Fuzzy Cognitive Mapping (FCM) and Bond Graph modelling. Either simulation requires specific types of information e.g. Bond Graph requires users to specify the Bond Group of an item whereas FCM does not. Conversely, FCM enables the user to set polarities and filters on a flow property connection whereas Bond Graph simulation does not require these settings.

Figures 1 & 2 show the workflows for the construction of a Functional Block Diagram (FBD) model for FCM and Bond simulation respectively. Workflow parameter pages are found in Appendix D of this document (not included in the extracted PDF pages).

WF03: Create FBD Model for Bond Simulations (Figure 1)

Pre-requisites:

• A. MADE Project: a configured project.
• B. Bill of Materials (BOM): establishes the system configuration to build the functional block diagram (FBD) model.

Workflow steps:

1. Create Model Item — Create model items with 'New Item' options under 'Modeling' in the main menu bar or via the right-click context menu opened on the system canvas.
2. Define Model Item Details (General Properties, Advanced Properties, Product Characteristics) — Define General details in the Properties viewer, which overlaps with Advanced details accessed by 'Advanced Properties' via the right-click context menu opened on the model item. Also define Product Characteristics, if necessary.
3. Define Function(s) — Define function(s) in the Functions Editor, accessed by 'Functions' via the context menu opened on the model item. Click and drag relevant function from the Function taxonomy list onto the canvas.
4. Define Functional Flows — Click and drag the relevant functional flows from the Functional Flow taxonomy list and place within the relevant function. Functional Flows are required for both in- and out-puts. Connect Flow Properties by clicking and dragging a connector from input Flow Property to output Flow Property.
5. Decision: Creating Bond Model? — Continue if a Bond Graph model is being created. If no, an FCM model is being created. Go to WF04.
6. Define Bond Properties (Bond Type, Passive Variables) — Define the Bond Properties for the item by selecting the item in either the Project Explorer or on the System Canvas. Find the Bond tab within the Properties window and define a Bond Type and any further settings.
7. Decision: All Model Items Created? — Continue creating all model items, defined with Functional Flows and Bond Properties.
8. Connect Functional Flows — Connect functional flows between model items by clicking and dragging from the output of one item, to the input of the other item. Only same functional flows will connect.
9. Verify Bond Graph Model — Access the Bond Model with 'Bond Graph' under 'Modeling' in the main menu bar. Select 'Verify Controllability' via the context menu opened in the bond graph canvas, to verify controllability.
10. Decision: Bond Graph Model Verified? — If bond graph model fails to verify causality and controllability, alter it until successful, including creating model items.
11. Review Bond Response Simulations — To review bond response simulations, generate via the context menu opened on the target location and select the target bond response in 'Response Simulation'. Select additional bond responses to overlay on the graph.
12. Decision: Responses Acceptable? — If bond responses are unacceptable, alter the bond graph model until acceptable, including creating model items.
13. FBD Model for Bond Created.

Outputs:

• i. Bond Graph Model: representation of the FBD modelled for bond, exportable as a .png file.
• ii. Bond Graph Equations: set of equations derived from the bond graph model.
• iii. Bond Response Graphs: visual representation of the functional energy flow response simulations over time steps, exportable as .png files.

WF04: Create FBD Model for FCM Simulations (Figure 2)

Pre-requisites:

• A. MADE Project: a configured project.
• B. Bill of Materials (BOM): establishes the system configuration to build the functional block diagram (FBD) model.

Workflow steps:

1. Create Model Item — Create model items with 'New Item' options under 'Modeling' in the main menu bar or via the context menu opened on the system model viewer canvas.
2. Define Function(s) — Define function(s) in the Functions Editor, accessed by 'Functions' via the right-click context menu opened on the model item. Click and drag the relevant function from the Function taxonomy and place on the canvas.
3. Define Functional Flows — Click and drag the relevant functional flows from the Functional Flow taxonomy list onto the relevant in- or out-put. Connect Flow Properties clicking and dragging from Flows to Out Flows.
4. Decision: All Model Items Created? — Continue creating model items, defined with functions and functional flows.
5. Connect Functional Flows — Connect functional flows between model items by clicking and dragging from the output of one item, to the input of the other. Only same functional flows will connect.
6. Define Model Item Details (General Properties, Advanced Properties, Product Characteristics) — Select a model item and define General details in the Properties viewer, which overlaps with Advanced details accessed by 'Advanced Properties' via the context menu opened on the model item. Also define Product Characteristics, if necessary.
7. Define Flow Property General Details (Display Name, Unit, Initial Value, Internal Damping) — Access Functions Editor and select a functional flow property to define General details in the Properties viewer.
8. Define Functional Flow Causality Details (Polarity, Response Filter, Acausality, Causal Strength) — Select a functional flow connection between flow properties to define causality details in the Properties viewer.
9. Decision: All Model Items Defined? — Select another model item, repeating previous steps until all are defined with the necessary details for FCM simulation.
10. Review FCM Response Simulations — Execute 'Propagate All' in the context menu opened on the system model viewer canvas, 'Select all' to view all functional flows and then 'Propagate', to review FCM response simulations.
11. Decision: Responses Acceptable? — Following review of FCM response simulations in the Propagation Table viewer deems responses unacceptable, alter functional flow connections until acceptable, including creating model items.
12. FBD Model For FCM Created.

Outputs:

• i. Propagation Table: tabulated results of failure propagations throughout system model for FCM response simulations, exportable as a .csv file.