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Session 2.2: Failure Simulation

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Session 2.2: Failure Simulation

SESSION 2.2 OUTLINE

2.2.1 Introduction to Failure Simulation in MADE 2.2.2 FCM Simulation Parameters 2.2.3 FCM Simulation 2.2.4 FCM Step Table 2.2.5 Response Simulation Viewer 2.2.6 FCM Simulation Threshold Types 2.2.7 Bond Graph Simulation 2.2.8 Bond Graph Model 2.2.9 Bond Graph Response Simulation

Session 2.2: Failure Simulation

DISCUSSION 2.2.1 INTRODUCTION TO FAILURE SIMULATION IN MADE

Failure simulation involves editing simulation-specific properties in the model

   E.g. Causal Strength, Initial Value, Internal Damping for FCM Simulation
   E.g. Bond Types & Passive Variables for Bond Simulation

These properties are used to simulate the effects and failure propagation in the system model

Session 2.2: Failure Simulation

DISCUSSION 2.2.1 INTRODUCTION TO FAILURE SIMULATION IN MADE

MADE utilises two response simulation methods that allow analysis of failures and performance: Fuzzy Cognitive Maps (FCM)

  • Uni-directional flow of information (failure is propagated downstream only)
  • Signal, material, and energy flows incorporated into model

Power bond modeling (Bond)

  • Bi-directional flow of information (failure is propagated both upstream and downstream of an item)
  • Energy (power) flows incorporated into model

Session 2.2: Failure Simulation

DISCUSSION 2.2.1 INTRODUCTION TO FAILURE SIMULATION IN MADE

Which simulations should be used for a system model? Questions to ask include:

   What type of system behaviour is being represented?

      - Bond graphs model bi-directional information exchange typical of energy relationships
      - FCM model unidirectional information exchange typical of signal relationships

   What is/are the engineering domains in the system?

         - Bond allows multiple energy domains to be analyzed and integrated into the same model
                - E.g. Power transfer between energy flow types such as mechanical, electrical, hydraulic etc.

         - FCM allows different flow domains to be analysed
                - E.g. Energy, Material & Signal flow types

   What is the analysis being undertaken?

         - FCM is ideal for FMEA / FMECA reports or as the basis for reliability analysis
         - Bond is ideal when undertaking PHM analysis

Session 2.2: Failure Simulation

DISCUSSION 2.2.2 FCM SIMULATION PARAMETERS

Fuzzy Cognitive Mapping (FCM) uses causal strength & polarity to define causality between two items FCM is used to define the relationship between input and output of an item

   E.g. A drop in Fuel flow rate inflow affecting the fuel flow rate output of an item

Note: For more information refer to FCM Simulation & Theory Guide in MADE Help

Session 2.2: Failure Simulation

DISCUSSION 2.2.2 FCM SIMULATION PARAMETERS

To perform an FCM analysis, FCM parameters need to be edited in the MADE model

FCM parameters are accessed from several locations:

Causal connection between input and output flow properties (Functions Editor)
Output Flow Properties (Functions Editor)
Right-click menu in the system model

FCM Parameter Location in MADE Description Initial Value Output Flow Property Augments the nominal value of a flow during a simulation Internal Damping Output Flow Property Internal feedback of an item (Resistance, damping, friction) Polarity Causal Connection Relationship between a cause and effect (in and out flow) Causal Strength Causal Connection The likelihood that an input flow perturbs the connected output flow Response Filter Causal Connection A filter applied to internal flow perturbations Perturbation/Failure Injection Item (Right-click menu) An introduced failure response (high or low) from the nominal state

Session 2.2: Failure Simulation

EXERCISE 2.2.2 FCM SIMULATION PARAMETERS

To edit FCM Parameters:

Open the Power Generation' system model Open the Diesel Engine' system model Open the Functions editor of `Coupling 1' Select the causal connection between

Torque & Angular Velocity Add a Block Positive response filter in the

Properties Viewer

Session 2.2: Failure Simulation

EXERCISE 2.2.2 FCM SIMULATION PARAMETERS (CONTINUED)

Open the Control Unit' Functions editor (Power Generation' subsystem)

Toggle the Enabled flow properties icon Select the Voltage to Amplitude causal connection Set Polarity to Negative Set the Causal strength to 5.00

Next section will demonstrate the results of these parameters

Session 2.2: Failure Simulation

DISCUSSION 2.2.3 FCM SIMULATION

FCM Simulation looks at the propagating effects of a simulated failure due to an initiating failure introduced by the user

A failure must first be `injected' in the system model before FCM Simulation can occur

System response is observed using methods below:

   Sequentially (System Model or Step Viewer � see right)
   Graphically for all time steps (Response Simulation Viewer below)

Session 2.2: Failure Simulation

DISCUSSION 2.2.3 FCM SIMULATION

Failures in MADE are classified deviations from an item's nominal behaviour/state

   E.g. A Pump provides a flow rate for an operating mode � flow rate outside of this range is considered a failure
   Nominal behaviour/state is represented as a `zero' value

Magnitude of a deviation (per step) is calculated from 3 parameters:

   Causal Strength (Weighting Matrix, W)
   Initial Value (Initial State Vector, A0)
   Perturbation (Perturbation Vector, P)

System State Vector* is expressed as: = -1 +

                           Reference*: FCM Simulation & Theory User Guide in MADE Help

Session 2.2: Failure Simulation

EXERCISE 2.2.3 FCM SIMULATION

To inject a Failure:

Open the Diesel Engine' system model Right-click Coupling 1' Select Failure Injection Mech...Angular Velocity Down Verify Functional Perturbation is injected into the system

model with text string: Couple Mechanical � rotational Angular Velocity (Coupling 1)

Session 2.2: Failure Simulation

DISCUSSION 2.2.4 FCM STEP TABLE

Injected Failures are displayed in the system model

Item State Vectors are listed in the Step Table viewer

Step Table Icons are used to control the failure propagation

Failure Propagation `Steps' can be traced throughout the system once a failure is fully propagated

Session 2.2: Failure Simulation

EXERCISE 2.2.4 FCM STEP TABLE

To step a failure through the system:

Select to move forwards one step & repeat until system reaches equilibrium

   When last column `=` in Step Viewer is filled out

Select to go back one step Select to reset stepping to its initial state Select to run all steps automatically until system equilibrium Select to clear all steps and injected failure in system

Session 2.2: Failure Simulation

DISCUSSION 2.2.5 RESPONSE SIMULATION VIEWER

Response Simulation Graph displays the response of failure/s at each step until equilibrium Shows the change over time (steps) due to failure Graph consists of 3 parts:

1. Initial Equilibrium Region (Blue region on left)
2. Failure Activation (Vertical line) representing steps where perturbation is introduced
3. Post-Failure Response Region (White region)

Session 2.2: Failure Simulation

EXERCISE 2.2.5 RESPONSE SIMULATION VIEWER

To view response simulation of the Injector Pump component when the Coupling 1 failure occurs: Inject failure in Coupling 1 (Angular velocity Down) Right-click the Injector Pump' Select Response Simulation Liquid Dynamic pressure Verify response graph transitions from nominal (0) to a low' failure (-1.0) Select other flows to see additional graph overlays

Session 2.2: Failure Simulation

DISCUSSION 2.2.6 FCM SIMULATION THRESHOLD TYPES

FCM Simulation Thresholds are used to ensure:

   Failure simulation graphs are not divergent (unstable response)
   Amplitude detail resolution is maintained

There are currently 5 Threshold Types:

   Bivalent: Graph results range between nominal (0) and high (+1)
   Bivalent Sigmoid: Graph results range between nominal (0) and high (+1) with a sigmoid curve acting as a

     smoothing function
   Trivalent: Graph results range between nominal (0) and low (-1) to high (+1)
   Trivalent Sigmoid: Graph results range between nominal and low (-1) to high (+1) with a sigmoid curve acting as a

     smoothing function
   No Threshold: User can set a specified limit value to the graph

Session 2.2: Failure Simulation

DISCUSSION 2.2.6 FCM SIMULATION THRESHOLD TYPES (CONTINUED)

5 Threshold Types Graphed:

   Bivalent

   Bivalent Sigmoid

Session 2.2: Failure Simulation

DISCUSSION 2.2.6 FCM SIMULATION THRESHOLD TYPES (CONTINUED)

   Trivalent

   Trivalent Sigmoid

   No Threshold

Session 2.2: Failure Simulation

DISCUSSION 2.2.6 FCM SIMULATION THRESHOLD TYPES (CONTINUED)

Notes on Sigmoid Charts (Bivalent & Trivalent):

Accessed from FCM Analysis page in Project Preferences by selecting Sigmoid curve is adjusted by setting the sigmoid threshold value

   Smaller Sigmoid Threshold equates to a lower returned value for input value <1

            E.g. For a Threshold of 1.1, Input Value of 1.0 gives a returned value of 0.8

   Larger Sigmoid Threshold equates to a higher returned value for input value <1

            E.g. For a Threshold of 2.0. Input Value of 1.0 gives a returned value of 0.964

Trivalent curve looks at returned value ranges between -1.0 and 1.0 Bivalent curve looks at returned value ranges between 0.0 and 1.0

Session 2.2: Failure Simulation

EXERCISE 2.2.6 FCM SIMULATION THRESHOLD TYPES

To set FCM Threshold:

Select Preferences FCM Threshold Preferences Set Threshold Type to Trivalent Sigmoid 1.0 Repeat Failure Injection for `Coupling 1'

   Clear all failure injections (Select )
   Right-click `Coupling 1'
   Select Failure Injection  Mech...Angular Velocity  Down

Right-click the `Injector Pump' Select Response Simulation Liquid Dynamic pressure

Note difference between Trivalent & Trivalent Sigmoid responses � what does this mean?

Session 2.2: Failure Simulation

DISCUSSION 2.2.7 BOND GRAPH SIMULATION

A Bond graph is an energy model of a dynamic system Bond graph modeling represents bi-directional exchange of energy Bond graph models use equations for each item to determine the net change in energy Power bonds are used to link different elements together

Session 2.2: Failure Simulation

DISCUSSION 2.2.7 BOND GRAPH SIMULATION

Bond graph analysis requires editing of Bond graph properties These are accessed from the Properties viewer when selecting an item In MADE the user needs to:

   Define the system model configuration
   Assign bond groups to items

Taxonomy for Bond Graph parameters is in the table below:

Bond Graph Parameter Location Description

Bond Type Properties Viewer Bond tab Selection of bond type and junction represented by each item

Passive Variables Properties Viewer Bond tab Contains fields for setting capacitor, inductor and resistor values & effort limits

Session 2.2: Failure Simulation

DISCUSSION 2.2.7 BOND GRAPH SIMULATION

Modeling system model items for Bond simulation is the same process for FCM simulation The only limitation is that all flows used must be energy flows

Session 2.2: Failure Simulation

EXERCISE 2.2.7 BOND GRAPH SIMULATION

There are two methods of assigning Bond Types:

Method 1:

   Open the functions editor for the `Driveshaft' component
      (in the `Driveline' subsystem)

   Select the function Support
   Select Bond tab the Properties viewer
   Select Bond type (0 � C) Compliance from drop down menu
   Verify Capacitance and Initial Value are set to 0.90 & 0.00

      respectively

Session 2.2: Failure Simulation

EXERCISE 2.2.7 BOND GRAPH SIMULATION (CONTINUED)

Method 2:

  Select the `Transmission' (in the `Driveline' subsystem)
  Navigate to the Properties viewer and select the Bond tab
  Select the function Distribute
  Select Bond Type: (1 - IR) Rotational Inertia Mass and Resistance
  Verify Values for Inductor is set to 0.90
  Verify Values for Resistor is set to 0.25
  Verify Inductor Initial Value is set to 0.00

Session 2.2: Failure Simulation

EXERCISE 2.2.7 BOND GRAPH SIMULATION (CONTINUED)

Assign the remaining components according to the table below with the appropriate Bond Type:

Item Bond Type Transmission Rotational Inertia Mass and Resistance (1-IR) Driveshaft Compliance (0-C) Differential Rotational Inertia Mass and Resistance (1-IR) Half Shaft (Front & Rear) Compliance (0-C) Planetary Gearbox (Front & Rear) Rotational Inertia Mass, Compliance and Resistance (1-IRC) Wheel (Front & Rear) Rotational Inertia Mass and Resistance (1-IR)

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL

There are 2 ways of generating the Bond Graph model:

1. Select Driveline in Project Explorer

         From main menu: Modeling  Bond Graph

2. Right-click the Driveline, then select Bond Graph

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL (CONTINUED)

Verify that there are 4 junction errors & 6 causal stroke errors due to incompatible causal strokes (bond types)

These are indicated by red lines/numbers on the Bond Graph You may also find these in the Problems window under Errors

   Causal strokes do not match the bond graph assigned to ...

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL (CONTINUED)

To fix the error, split each Wheel' component into two components: Wheel Resistance' & Wheel' by copying the Wheel' components and renaming accordingly

Set `Wheel Resistance' function: Rotate Mechanical � Rotational Angular Velocity

Set Wheel Resistance' & Wheel' Bond Types as (0 � R) & (1 � I) respectively

Re-run Bond Graph model to verify no causality errors are present

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL (CONTINUED)

The current Bond Graph model shows 3 warnings:

 1. Bond Model is not Controllable (Bond Graph editor)
 2. Vehicle system has no defined Sources (Problems viewer under Warnings)
 3. Vehicle system has no defined Sinks (Problems viewer under Warnings)

To resolve the first warning, convert both the Half Shaft Front and Half Shaft Rear components to a (0 � CR) Bond Type

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL (CONTINUED)

To resolve warning regarding sources & sinks, create two new components at the top level of indenture: Coupling' component, set as an Effort Source (SE) Bond type Vehicle' component set as an Effort Sink (SES) Bond type

Details of the component functions & flows are listed in the table below:

Component Function In Flow Out Flow Bond Type Coupling Couple Mechanical � rotational Torque Mechanical � rotational Torque Effort Source (Connect) Vehicle Connect Mechanical � rotational Angular velocity Mechanical � rotational Angular velocity Effort Sink Connect Mechanical � rotational Angular velocity Mechanical � rotational Angular velocity Effort Sink

Session 2.2: Failure Simulation

EXERCISE 2.2.8 BOND GRAPH MODEL (CONTINUED)

Connect the model as shown below

Session 2.2: Failure Simulation

DISCUSSION 2.2.9 BOND GRAPH RESPONSE SIMULATION

Bond graph response simulation is similar to FCM but only uses Bond properties Bond graph simulation provides more accuracy in terms of model behaviour due to equations and bi-

directional feedback (leading to more detailed responses) Bond graph response simulation is used to validate the Bond graph model Bond graph simulation can be tested against quantitative simulations, such as:

   AMESIM
   MATLAB Simulink

Session 2.2: Failure Simulation

EXERCISE 2.2.9 BOND GRAPH RESPONSE SIMULATION

To inject a failure in a Bond Graph model:

Right-click the `Transmission' component Select Failure Injection Torque differential Down

Session 2.2: Failure Simulation

EXERCISE 2.2.9 BOND GRAPH RESPONSE SIMULATION (CONTINUED)

In the Response Simulation viewer locate `Wheel Front' Select check box for Wheel Front Angular Velocity SES Vehicle Angular Velocity Review the graph: Wheel Angular Velocity drops momentarily as a result of Transmission loss Try other perturbations & corresponding simulation responses

Session 2.2: Failure Simulation

SESSION 2.2 SUMMARY

2.2.1 Introduction to Failure Simulation in MADE 2.2.2 FCM Simulation Parameters 2.2.3 FCM Simulation 2.2.4 FCM Step Table 2.2.5 Response Simulation Viewer 2.2.6 FCM Simulation Threshold Types 2.2.7 Bond Graph Simulation 2.2.8 Bond Graph Model 2.2.9 Bond Graph Response Simulation

Source: Local MADE 3.9.1 installation: com.phm.made.help.plugin/documents/help/pdf/MADE Training Session 2.pdf · retrieved 2026-07-09