Introduction to Diagnostic Engineering

6/16/2008

Introduction to

Diagnostic Engineeringusing the ISDD Tool Suite

January 2020

Who We Are

© 2019 DSI International

MIL-HDBK-1814Integrated Diagnostics

(1991)

MIL-STD-2165Testability

(1985)IEEE 1522Testability &

Diagnosability

(2004)

MIL-M-24100BFunctionally-Oriented

Maintenance Manuals

(1974)

DSI International40 Years of Diagnostic Engineering

Logic

ModelingLOGMOD

(1978)STAT

(1988)eXpress

(1998)

STAGE

(2008)


LOGMOD (“GiB”)

(1977)

SAMA

(1981-1985)

SPIFI

(1989)

Desktop Fault

Insertion

(2005, 2016, 2018)

40 Years of Run-Time Solutions

Run-Time

Authoring Tool

(2010)


DSI Workbench

(2011)DSI Embedded

Reasoner

(2017) DSI Dynamic

Reasoner

(2018)

DiagML

(2001)

GADDS / DOKTOR

(1992)

Aerospace & Defense Government

BAE Systems U.S. Army

Boeing U.S. Navy

General Atomics • NAVAIR/NAVSEA

General Dynamics

Honeywell Commercial

Lockheed Martin GE Transportation

Northrop Grumman Thermo King

Raytheon

Sikorsky Over 500 licenses sold worldwide

Current U.S. Customers

DSI is the World’s Leading Provider of

Diagnostic Engineering Software


DSI is the World’s Leading Provider of

Diagnostic Engineering Software

Europe AsiaSPHEREA [FR / UK] Aviation Technologies (China)

MBDA [FR / UK] Dongfanghong Aircraft (China)

NEXTER (GIAT) [FR] Ishikawajima HI (Japan)

Safran (SAGEM / Zodiak) [FR] Kingswell Enterprises (China)

THALES [FR] Mitsubishi HI (Japan)

French DGA Shiji Electronics (China)

Tianwei Industry (China)

Middle East Xi’an Industries (China)

Hewlett-Packard (Israel) Yuntong Technology (China)

International Customers


New Evolution

Locomotive

Crusader

Self-Propelled

Howitzer

Space Operations

Vehicle (SOV)

X-33

VentureStar

AIM-9X Evolved

Sidewinder Missile

2nd Gen RLV Future Combat

Systems F-35 (JSF)

Eurofighter

TSAT Satellites

Fire Scout UAV

Comanche

Helicopter

CVN-76 Nimitz-Class

Supercarrier

DSI Has Extensive Experience on

Major Programs

Recent Programs That Have Used eXpress

JLENS (Raytheon) CH-53K (Sikorsky)

Predator – MTS (Raytheon)JASSM (Lockheed)

X-Band Radar

(Raytheon)Standard Missile

(Raytheon)

IBCS

(Boeing / Northrop)

GCV (BAE Systems)

Global Hawk (Northrop)

Current Programs Using eXpress

Standard Missile (Raytheon)

Triton (Northrop)

Small Diameter Bomb

SDB-II & III (Raytheon)

CVN-78 – EMALS/AAG

(General Atomics)Bradley Vehicle

(BAE Systems)

KC-767 Refueling Tanker

(Boeing)


What We Do

Four Main Goals of Diagnostic Engineering

Availability Cost of Ownership

Mission Success Safety


Subsidiary Benefits of Diagnostic Engineering

Availability Cost of Ownership

Mission Success Safety

Improved Fault Detection

Reduced False Alarms

Reduced System / Mission Aborts

Effective Isolation to

Optimum Repair Level

Unique Isolation of

Critical Failures

Reduced False Removals

Lower Maintenance Costs

FMECA / Fault Tree Analysis

Probabilistic Risk Assessment

Lower MTTI / MTTR

Improved MTBF


Fault Detection & Isolation in eXpress


Simulation-based Analysis in STAGE


Fault Detection in STAGE

Detected Failures

Non-Detected Failures


Fault Isolation in STAGE

Isolation to a Single LRU

Isolation to Multiple LRUs


False Alarms in STAGE

Operational

(True) Alarms

Isolated

Diagnostic Alarms

Diagnostic

False Alarms

Non-Alarm Faults


System/Mission Aborts in STAGE

False System/Mission Aborts

True System/Mission Aborts


Item A Item B

Ambiguous Isolation(Multiple Items)

FM-1

FM-2

FM-1

FM-2

Item A Item B

Unambiguous Isolation(Single Item)

FM-1

FM-2

FM-1

FM-2

Item A Item B

Unique Isolation(Root Cause(s) of Single Failure)

FM-1

FM-2

FM-1

FM-2

Unambiguous vs. Unique Isolation


The “Uniquely Isolated” column indicates whether the fault group that is isolated for this failure contains

only root causes of the given failure. If the fault group contains any failure modes that are not a root

cause of that failure, then the failure has not been uniquely isolated by the diagnostics. The non-unique

isolation of critical failures is a primary driver of false alarms and unnecessary system or mission aborts.

FMECA Plus: Critical Failure Diagnosis Chart


eXpress FTA Module: Fault Tree with FD/FUI


Diagnostic

Engineering

Maintenance

Engineering

Reliability,

Risk & Safety

Engineering

Prognostics

CBMDiagnostics

CM

Scheduled

Maint.

RCM

eXpressFMECA+FTASTAGE


What is ISDD?


FMECA Plus

Commercial IETMs,

TRD & TPS Generation Tools,

Custom Diagnostic Solutions,

Written Documentation

STAGE

ISDD: The Big Picture

eXpress

History &

Feedback

Module

DSI

WorkbenchThird-party

Test Executive

Simulation-Based

Trade Studies,

Presentation-Ready

Graphics

Relational

Database

Maintenance

Module

FTA

Module


eXpress

Design Viewer

(freeware)

DSI Embedded

Reasoner

RTAT

TRD Module

DSI Dynamic

Reasoner

Dynamic

Diagnostics

Module

eXpressML

Module

Other Industry Formats

eXpressML

Proprietary DSI Formats

Tight Integration

Interoperability

DiagML

Diagnostic Analysis

& Reports

D-Matrix

Export

Module

Third-Party

Diagnostic Executive

Design

Import

Manager

MBSE data,

SYSML, etc.

Em

piric

al D

ata

Prognostics

Module

DFI

Design Viewer

Redline Module

with TestDRIVE

with TestDRIVE

Health Management

Platform, ATE. etc.

STAGE

ISDD: The Core Tools

eXpress

DSI

Workbench


RTAT


Interoperability

DiagML

FMECA Plus

Commercial IETMs,




STAGE

ISDD: The Big Picture

eXpress

History &

Feedback

Module

DSI


Test Executive

Simulation-Based

Trade Studies,

Presentation-Ready

Graphics

Relational

Database

Maintenance

Module

FTA

Module


eXpress

Design Viewer

(freeware)

DSI Embedded

Reasoner

RTAT

TRD Module

DSI Dynamic

Reasoner

Dynamic

Diagnostics

Module

eXpressML

Module


eXpressML


Tight Integration

Interoperability

DiagML

Diagnostic Analysis

& Reports

D-Matrix

Export

Module

Third-Party


Design

Import

Manager

MBSE data,

SYSML, etc.

Em

piric

al D

ata

Prognostics

Module

DFI

Design Viewer

Redline Module

with TestDRIVE

with TestDRIVE

Health Management

Platform, ATE. etc.

FMECA Plus

ISDD: Modeling and Analysis

eXpress

FTA

Module


eXpressML

Module


eXpressML


Tight Integration

Interoperability

DiagML

Design

Import

Manager

MBSE data,

SYSML, etc.

STAGESimulation-Based

Trade Studies,

Presentation-Ready

Graphics

Prognostics

Module

Diagnostic Analysis

& Reports

DFI

Maintenance

Module

Commercial IETMs,




ISDD: Diagnostic Development & Deployment

eXpress

History &

Feedback

Module

DSI


Test Executive

Relational

Database

Maintenance

Module


eXpress

Design Viewer

(freeware)

DSI Embedded

Reasoner

RTAT

Health Management

Platform, ATE. etc.

TRD Module

DSI Dynamic

Reasoner

Dynamic

Diagnostics

Module


eXpressML


Tight Integration

Interoperability

DiagML

D-Matrix

Export

Module

Third-Party


Em

piric

al D

ata

DFI

Design Viewer

Redline Module

with TestDRIVE

with TestDRIVE

eXpressDiagnostic Modeling and Analysis

eXpress creates the models used by all tools in the ISDD tool suite. It also performs standardized

analyses to help engineers optimize and assess system diagnostics/prognostics, as well as the

design’s ability to support effective HM.

DSI

Workbench

Run-Time Diagnostic Executive

DSI Workbench allows diagnostics developed in eXpress to be fielded in a maintenance or

production environment. DSI Workbench supports integration with a test executive, as well as

guided troubleshooting and free-form test entry.

RTATEnhancing Exported Diagnostics

The eXpress Run-Time Authoring Tool (RTAT) allows diagnostic procedures exported from

eXpress to be enhanced with graphic overlays and links to external documents. Diagnostics can

also be reformatted for use in a variety of tools. This tool includes the eXpress Design Viewer.

STAGESimulation-based Analysis

Using data from eXpress, STAGE simulates failures, diagnoses and repairs that would occur in a

fielded system. Calculations (represented as graphs) show changes over time, as well as the

impact of maintenance upon failure.


The ISDD Tool Suite

eXpress Modules

Diagnostic Modeling and Analysis

eXpress creates the models used by all tools in the ISDD tool suite. It also performs standardized

analyses to help engineers optimize and assess system diagnostics/prognostics, as well as the

design’s ability to support effective HM.

FMECA Plus (eXpress Reliability Module)

Module that allows FMECA data (either imported or developed in

eXpress) to be enhanced with metrics derived from eXpress

diagnostics. Automatically included with all eXpress licenses.


FMECA Plus

eXpress

eXpress FTA Module

Fully integrated with FMECA Plus and the eXpress diagnostics, this

module allows eXpress to produce diagnostic/prognostic-informed

fault trees for Reliability and Safety analysis.

FTA

Module

eXpress Maintenance Module

Module that allows eXpress to support multiple levels of diagnosis.

It has been designed to facilitate the concurrent development of

embedded diagnostics and troubleshooting procedures (IETMs).

Maintenance

Module

eXpress Dynamic Diagnostics Module

Module that allows eXpress to export resource files to be used by

the eXpress Dynamic Reasoner. It also allows Dynamic Diagnostics

to be validated using the eXpress Desktop Fault Insertion capability.

Dynamic

Diagnostics

Module

eXpress Prognostics Module

Module that allows eXpress to analyze the impact of prognostics

upon diagnostic performance. Prognostic definitions can also be

exported to be used in trade studies within STAGE.

Prognostics

Module

RTAT and Design Viewer Modules

D-Matrix Export Module

Plug-in module that allows RTAT to export test dependency data

from eXpress in a Dependency Matrix format


D-Matrix

Export

Module

RTATEnhancing Exported Diagnostics

The eXpress Run-Time Authoring Tool (RTAT) allows diagnostic procedures exported from

eXpress to be enhanced with graphic overlays and links to external documents. Diagnostics can

also be reformatted for use in a variety of tools.

eXpress Design Viewer Redline Module

Plug-in module that allows users to add comments and feedback

within the eXpress Design Viewer.

Design Viewer

Redline Module

eXpress

Design Viewer

eXpress Design Viewer

The eXpress Design Viewer allows design and diagnostic data to be shared and/or reviewed on

systems where eXpress has not been installed. This not only facilitates team collaboration and in-

house reviews, but also provides a deliverable for customer evaluation.

Diagnostic Engineering Applications


Design Assessment &

Influence

Diagnostic Development &

Deployment

New Systems New Systems

Legacy Systems Legacy Systems

• Assess ability to meet contracted

requirements

• Optimize design for effective

supportability

• Support interoperability with other

model-based design activities

• Generate optimized diagnostics

based on eXpress analysis

• Link HM to troubleshooting and/or

maintenance procedures

• Determine successful mixes of

corrective, predictive and periodic

maintenance.

• Improve existing diagnostics

based on eXpress analysis

• Repurpose existing diagnostics for

new run-time platforms

• Develop empirical diagnostics

from field analytics

• Identify weaknesses in current

diagnostic capability

• Generate case studies evaluating

the impact of proposed upgrades

• Create models to incorporate into

MBSE databases


Systems Engineering Vision

Diagnostics Requirements

Test

Definition

Functional

System

Design

Equipment

Specifications

Equipment

Development

Sub System

Integration

Functional

Validation

System

Integration

Equipment

Functional

Validation

Equipment

Validation

System

Specification

Diagnostic

Development

Safety Analysis

Safety

Analysis

Diagnostic Environment

Analysis Phases

Implementation Phases

Testability Requirement

Validation

FMECA

Validation

Diagnostic

Validation

Diagnostic

Report

FMECA

Validation

Diagnostic

Validation

Diagnostic

Report

Hierarchical Tests

Definition In Service

Requirements to Test / Diagnostics


Model-based Sustainment

How We Do It


eXpress

eXpressML

Design Topology

Model Appearance

Test Definitions

FMECA Data

Attribute Values

COM

Design Topology

Model Appearance

FMECA Data

Attribute Values

RTF

Test Definitions

FMECA Data

Attribute Values

Analysis Results

DiagML

Static Diagnostics

Model Appearance

Test Definitions

Attribute Values

Symbol Graphics

Model Graphics

Diagnostic Graphics

XML Reports

MS-Excel Reports

MS-Word Reports

Adobe PDF Reports

eXpress Interoperability

Design Topology

Model Appearance

Attribute Values

FMECA Data

Test Definitions

Static Diagnostics

Inserted Faults

MS-Excel


Hierarchical System Model

• Linked models representing different levels of indenture in the system hierarchy

• Diagnostic & FMECA/FTA analyses can be performed for (and to) any level of the hierarchy


Dependency-Based Test Definitions

• Test coverage defines what diagnostics “learns” when a test passes or fails

• Initially, coverage can be based upon the modeled dependencies

• Test definitions can be reviewed both graphically and in the Explorer tree


Hierarchical Diagnostics

• Diagnostic Sequences can developed for different levels of the system hierarchy

• You can descend within the hierarchy to view suspected elements or isolated fault groups

at different levels of indenture


Diagnostic / Design Assessment

• eXpress reports provide a variety of analysis results, designed to help you meet diagnostic

requirements for testability, reliability, system availability, maintainability and safety.


Integration of Functional & Failure Propagation

• Functional Propagation (horizontal) model

Functional dependencies show how functions are impacted by other functions.

Relationship settings show how functions are impacted by specific failures modes.

• Failure Propagation (vertical) model

Failure effects show how failure modes manifest themselves at different design levels


Diagnostics-Informed Reliability Analysis

• FMEA/FMECA charts can be developed within eXpress or imported from external tools.

• eXpress FMECA charts can contain a variety of columns detailing how and when failures

are detected and isolated by the actual diagnostics.


Diagnostics-Informed Fault Tree Analysis

• Fault Trees include diagnostic metrics that indicate how well diagnostics can detect and

isolate individual failures that lead up to a critical event.

• Allows you to assess the overall Risk of having less-than-perfect diagnostics


Desktop Fault Insertion

• Consists of an interactive dialog and corresponding report

• Allows analysts to validate diagnostics developed in eXpress by examining how inserted

faults are detected and isolated

• Provides a variety of features to support both in-house and customer reviews

• Supports the troubleshooting of issues identified during maintenance demos or for fielded

systems


eXpress

Design Viewer

(freeware)

Third-Party

Industry Formats

Diagnostic Interoperability via RTAT

eXpress

Relational

Database

History &

Feedback

Module

DSI

Workbench

RTAT

Test & Repair

Procedures,

Graphics, Videos

& Documentation

Additional Views,

Hot Spots and

Rules for Display

Settings &

Constraints


DiagML


Tight Integration

Interoperability

DSI Embedded

Reasoner

TRD

Module



Diagnostic Deployment using DSI Workbench

RTAT eXpress

DSI

Workbench

Run-Time Diagnostics in DSI Workbench

• DSI Workbench is a full-featured diagnostic executive for maintenance and production environments

• With minimal effort, you can field the same diagnostics you used to evaluate your system Testability


eXpressFly-Over


Introduction to Diagnostic Engineering

Documents

Transcript of Introduction to Diagnostic Engineering