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MADE Training > Session 6 > 6.3 Automated Diagnostic Analysis

Session 6.3: Automated Diagnostic Analysis

Session 6.3 Outline

  • 6.3.1: Diagnostic Analysis
  • 6.3.2: Overview/Management
  • 6.3.3: Diagnostic Analysis (Landing Page)
  • 6.3.4: Propagation Table
  • 6.3.5: Diagnostic Inclusions
  • 6.3.6: Diagnostic Exclusions
  • 6.3.7: Sensor Set Analysis
  • 6.3.8: Ambiguity Groups
  • 6.3.9: Sensor Allocation
  • 6.3.10: Sensor Parameters
  • 6.3.11: Diagnostic Sets
  • 6.3.12: Metric Optimization
  • 6.3.13: Sensor Set Comparison

Discussion 6.3.1: Diagnostic Analysis

  • Used to analyse coverage of system failures using allocated sensors
  • Two main analysis types:
    • Automated Diagnostic Analysis: Uses a proprietary algorithm to generate sensor sets that provide maximum system coverage when allocated with sensors. This analysis also captures legacy (component/subsystem test point) sensors if present.
    • User-defined Diagnostic Analysis: Provides users with the ability to freely allocate sensors throughout a selected system, or allocate sensors based on an optimized solution from the automated diagnostic analysis.

Discussion 6.3.1 (continued): Diagnostic Analyses

Recommended Sensor Analysis approach:

  1. Automated Diagnostic Analysis: Analyse effectiveness of legacy (component/subsystem test point) sensors
  2. Automated Diagnostic Analysis: Analyse potential sensor combinations and perform trade-studies for a desired performance metric. For example: a. Optimizing for Cost b. Optimizing for Weight c. Optimizing for Coverage
  3. Automated Diagnostic Analysis: Define final (optimized) sensor configuration

Exercise 6.3.1: Propagation Table Preferences

Set Propagation Table options in Application Preferences:

  1. In the menu bar, select Preferences > Application Preferences
  2. Select Propagation Table
  3. Set the following:
    • Export Propagation Table responses as numeric values: Yes
    • Use Diagnostic Groups in PHM analysis: Yes
    • Show Out Flows for Subsystems: Yes
    • Include Failure Conditions in Propagation Table: Yes
    • Show Nominal Columns: No

Exercise 6.3.1: Accessing Diagnostic Analysis Editor

To access the Diagnostic Analysis Editor:

  1. Open the System Model of the Power Generation subsystem
  2. Right-click the canvas and select Diagnostic Analysis from the menu options
  3. Alternatively, select Analyses > Diagnostic Analysis from the main menu

Discussion 6.3.2: Overview/Management

  • Used to create all new diagnostic analyses
  • Lists all diagnostic analyses conducted on the model
  • Provides summary of diagnostic details:
    • Type
    • Threshold
    • Focus
    • Coverage

    • of Sensor Sets

Exercise 6.3.2: Creating a New Diagnostic Analysis

  1. Select the create/add icon to open the Create a Diagnostic Analysis dialog
  2. Expand the Vehicle System and select the check box for the following items:
    • Vehicle System
    • Driveline
    • Power Generation
    • Diesel Engine
  3. Set the Type of Diagnostic Analysis to Automated
  4. Select proceed (Next) to continue

Exercise 6.3.2 (continued): Creating a New Diagnostic Analysis

  1. Populate the details of the Diagnostic Analysis with the following details:
    • Name: Diagnostic Analysis 1
    • Description: Analysis of sensor configuration for the System.
  2. Set the Propagation Type to FCM
  3. Select close/create to close the dialog and create the analysis

Discussion 6.3.3: Diagnostic Analysis (Landing Page)

  • Used to view basic analysis details, indenture selection & propagation focuses

Exercise 6.3.3: Diagnostic Analysis (Landing Page)

  1. Verify information in Basic Details section & Indenture dialog (from dialog):
    • Name: Diagnostic Analysis 1
    • Description: Analysis of sensor configuration for the Power Generation System.
    • Type: Automated
    • Propagation Type: FCM
    • Response State: Steady and Transient States
  2. Verify Propagation Focuses: None selected (By default meaning all flow types are considered)

Discussion 6.3.4: Propagation Table

  • Shows item failures (rows) vs item responses to those failures (header)
  • Failure responses (high), (low) & (nominal) at intersections show for connected items
    • Example: Lift Pump failing Low will cause the Injector Pump to show a Low response
  • Table is configured based on system model and diagnostic analysis page (propagation focuses, LOI)

Exercise 6.3.4: Propagation Table

  1. Verify that when Fuel Tank static pressure decreases it causes Diesel Engine torque to show a Low failure
    • This shows that there is one or more flow connections/downstream impact

Exercise 6.3.4 (continued): Propagation Table

  1. Verify that Control Unit flow rate decreases will have a nominal effect on Air Filter mass flow rate
    • This shows that there is no flow connection/downstream impact

Discussion 6.3.5: Diagnostic Inclusions

  • Enables user to specify sensor locations that must be included in generated sensor sets
  • Specify failures that must be covered by any generated sensor sets

Exercise 6.3.5: Diagnostic Inclusions

To include failure detection in the diagnostic analysis, in the Inclusions tab:

  1. Under the Must Detect Failures section, select the add icon
  2. From the dialog box select Air Filter to include in the analysis
  3. Select the move icon to move the item to the Included Failure Modes table
  4. Select OK
  5. Ensure the Must Cover checkbox is selected

Exercise 6.3.5 (continued): Diagnostic Inclusions

In the Must Use Sensor Locations section:

  1. Select the add icon and select Fuel Tank
  2. Select the move icon to move the item to the Must Use Sensor Locations
  3. Select OK

Exercise 6.3.5 (continued): Diagnostic Inclusions

In the Legacy Sensor Set Section:

  1. Select Use TP sensors and locations check box to include the Legacy Test Point sensors in the analysis

Discussion 6.3.6: Diagnostic Exclusions

  • Enables user to threshold (exclude) sensor locations based on criticality, flow property type or item
  • Exclusions are not considered in Sensor Set Analysis

Exercise 6.3.6: Diagnostic Exclusions

To assign an exclusion to the diagnostic analysis, in the Detectable Cause Exclusions Section:

  1. Select the add icon and select Secondary Fuel Filter
  2. Select the move icon to move the item to the Excluded Failure Modes table
  3. Select OK

Exercise 6.3.6 (continued): Diagnostic Exclusions

  • Sensor Location Exclusion Selection indicates where sensors are not feasible
  • For the purpose of this demonstration we will not exclude any failure modes

Discussion 6.3.7: Sensor Set Analysis

  • Main page to analyse the propagation table then calculates and generates possible sensor sets
  • User sets the analysis parameters:
    • No restrictions = maximum coverage with least number of sensor locations
    • Defines the minimal failure coverage
    • The Include Legacy Sensor Set checkbox allows the display of the Legacy Sensors as a set
    • Test point number limiting within a defined range
    • Number of unique sensor sets generated
    • Optimization level of analyses

Exercise 6.3.7: Sensor Set Analysis

To generate a Sensor Set analysis:

  1. Select the Sensor Set Analysis tab
  2. Set Number of Sets to 10
  3. Set Depth of Analysis to High
  4. Select the generate icon to generate the diagnostic sets

Exercise 6.3.7 (continued): Sensor Set Analysis

  1. Review Sensor Sets Table
  2. Select Set 1 and select the save/advance icon to save and advance the workflow status for the set
    • Comment: Sensor set is feasible and is saved for further analysis.

Discussion 6.3.8: Ambiguity Groups

  • Shows failures from each sensor set that cannot be distinguished by currently allocated sensors
    • Example: Legacy Sensor Set has two Ambiguity Groups
  • Failures are resolved by exclusion or reconfiguring the system

Exercise 6.3.8: Ambiguity Groups

To view the Ambiguities Groups of the generated diagnostic sets:

  1. Select the Ambiguity Group tab
  2. Select Analysis 1 — Set 1, Ambiguity Group 2
    • Identify ambiguities between 7 items that have ambiguous failures

Discussion 6.3.9: Sensor Allocation

  • Used to identify item functional flows i.e. sensor locations
  • Sections: Sensor Library, Recently Used Sensors, Sensor Allocation & Items
  • Shows sensor libraries & sensors — these can be filtered based on flow type selected

Exercise 6.3.9: Sensor Allocation

To allocate sensors to the system:

  1. Select the Sensor Allocations tab
  2. Select Coupling in Items list
  3. Expand User Sensor Library and drag Rotary Transformer sensor to Mechanical — rotational Torque

Exercise 6.3.9 (continued): Sensor Allocation

Allocate sensors in the first indenture according to the table below.

Note: Minimize the items list

Items Flow Property Sensor Name
Coupling Torque Rotary Transformer
Power Generation
Driveline Angular Velocity Angular Velocity Sensor 1
Vehicle

Exercise 6.3.9 (continued): Sensor Allocation

Expand Driveline components and allocate the following sensors:

Driveline Flow Property Sensor Name
Driveshaft Torque Rotary Transformer
Half Shaft Front
Half Shaft Rear Angular Velocity Angular Velocity Sensor 1
Wheel Resistance Rear
Planetary Gearbox Rear Amplitude Amplitude Detector
Transmission
Wheel Front
Planetary Gearbox Front
Wheel Rear
Wheel Resistance Front
Control Unit

Exercise 6.3.9 (continued): Sensor Allocation

Expand all items in Power Generation and allocate the following sensors:

Power Generation Flow Property Sensor Name
Diesel Engine Torque Rotary Transformer
Engine
Control Unit Amplitude Amplitude Detector
Coupling 1
Air Filter Mass Flow Rate (Gas) Tube Anemometer
Governor
Lift Pump Linear Velocity Optical Tracker and Velocimeter
Secondary Fuel Filter
Fuel Tank Flow Rate (Liquid) Orifice Plate
Injector Pump* Static Pressure Pressure Sensor

Note: Injector Pump is completed from the previous sections of the training documents.

Discussion 6.3.10: Sensor Parameters

  • This page enables the user to edit each sensor parameter selected
  • Sections: Allocated Sensors, Sensor Details, Parameters & Additional Sensor Information

Exercise 6.3.10: Sensor Parameters

To edit the Sensor Parameters:

Select the Rotary Transformer of the Diesel Engine and enter/modify the following sensor details:

  • Dimensions: 30.0 (H), 20.0 (W), 20.0 (D) — Estimated POD: 0.95
  • Dimension units: Millimetres — Estimated Specificity: 0.92%
  • Weight: 10.0 grams — Description: COTS sensor
  • Replacement Cost: $1500 — Detection method: Passive
  • Detection Cost: $0.01 — Signal type: Digital
  • MTTF: 200,000 hours — Operating Environment: -
  • MTTR: 1 minute — Constraints: -

Discussion 6.3.11: Diagnostic Sets

  • Page shows the failure diagnosis based on the sensor set selected
  • Shows how to diagnose an item or ambiguity group using Diagnostic Rules

Exercise 6.3.11: Diagnostic Sets

To access the Diagnostic rules:

  1. Select the Diagnostic Sets tab
  2. Select an analysis set in the Diagnostic Sets section
  3. Select the Air Filter component and read the diagnostic rule

Discussion 6.3.12: Metric Optimization

  • Lists all Sensor Sets and shows the details of sensed test points
  • Provides filters (cost, weight, coverage) for user to optimize sensor set selection

Exercise 6.3.12: Metric Optimization

To set the metric optimization for the generated sensor sets:

  1. Select the Metric Optimization tab
  2. Verify that Legacy Sensor Sets are included (check box selected)
  3. Under the Filters section:
    • Select check box for Max Cost and enter: $90,000

Discussion 6.3.13: Sensor Set Comparison

This page allows users to compare sensor sets based on criteria which includes:

  • Coverage
  • Number of Sensors
  • Cost of Sensors
  • Weight of Sensors
  • Probability of Detection
  • Cost of Detection

Multiple sensors sets can be compared. All charts can be exported.

Exercise 6.3.13: Sensor Set Comparisons

To compare sensor sets:

  1. Select the Comparisons tab
  2. Select the analysis sets to be compared
  3. The graphs can be used to visually compare the following metrics:
    • Coverage
    • LRU Coverage
    • Number of Sensors
    • Cost
    • Weight
    • Probability of Detection
    • Cost of Detection

Session 6.3 Summary

  • 6.3.1: Diagnostic Analysis
  • 6.3.2: Overview/Management
  • 6.3.3: Diagnostic Analysis (Landing Page)
  • 6.3.4: Propagation Table
  • 6.3.5: Diagnostic Inclusions
  • 6.3.6: Diagnostic Exclusions
  • 6.3.7: Sensor Set Analysis
  • 6.3.8: Ambiguity Groups
  • 6.3.9: Sensor Allocation
  • 6.3.10: Sensor Parameters
  • 6.3.11: Diagnostic Sets
  • 6.3.12: Metric Optimization
  • 6.3.13: Sensor Set Comparison

Source: Local MADE 3.9.1 installation: com.phm.made.help.plugin/documents/help/pdf/MADE Training Session 6.pdf · retrieved 2026-07-09