Lunchtime edit...geddit...
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@ -73,9 +73,12 @@ oversimplifies the task of failure mode analysis, and makes the process arbitrar
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Fortunately most real-world designs take a modular approach. In Electronics
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Fortunately most real-world designs take a modular approach. In Electronics
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for instance, commonly used configurations of parts are used to create
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for instance, commonly used configurations of parts are used to create
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amplifiers, filters, potential dividers etc.
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amplifiers, filters, potential dividers etc.
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It is therefore natural to collect parts to form functional groups.
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%It is therefore natural to collect parts to form functional groups.
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It is common design practise in electronics, to use collections of parts in specific configurations
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to form well defined and known building blocks.
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These commonly used configurations of parts, or {\fgs}, will
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These commonly used configurations of parts, or {\fgs}, will
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also have failure mode behaviour. We can take a {\fg} and determine its symptoms of failure.
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also have a specific failure mode behaviour.
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We can take a {\fg} and determine its symptoms of failure.
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When we have done this we can treat this as a component in its own right.
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When we have done this we can treat this as a component in its own right.
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If we terms `parts' as base~components and components we have determined
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If we terms `parts' as base~components and components we have determined
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from functional groups as derived components, we can modularise the FMEA task.
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from functional groups as derived components, we can modularise the FMEA task.
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@ -135,7 +138,9 @@ When we have determined the symptoms, we can
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create a {\dc} (called say AMP1) which has a {\em known set of failure modes} (i.e. its symptoms).
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create a {\dc} (called say AMP1) which has a {\em known set of failure modes} (i.e. its symptoms).
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We can now treat $AMP1$ as a pre-analysed, higher level component.
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We can now treat $AMP1$ as a pre-analysed, higher level component.
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The amplifier is an abstract concept, in terms of the components.
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The amplifier is an abstract concept, in terms of the components.
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The components brought together in a specific way make it an amplifier !
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To a make an `amplifier' we have to connect a a group of components
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in a specific configuration. This specific configuration corresponds to
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a {\fg}. Our use of it as a building block corresponds to a {\dc}.
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%What this means is the `fault~symptoms' of the module have been derived.
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%What this means is the `fault~symptoms' of the module have been derived.
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@ -185,7 +190,7 @@ fm : \mathcal{C} \rightarrow \mathcal{P}\mathcal{F}.
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This is defined by, where $c$ is a component and $F$ is a set of failure modes,
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This is defined by, where $c$ is a component and $F$ is a set of failure modes,
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$ fm ( c ) = F. $
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$ fm ( c ) = F. $
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We can use the variable name $FG$ to represent a {\fg}. A {\fg} is a collection
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We can use the variable name $\FG$ to represent a {\fg}. A {\fg} is a collection
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of components.
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of components.
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%We thus define $FG$ as a set of chosen components defining
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%We thus define $FG$ as a set of chosen components defining
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%a {\fg}; all functional groups
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%a {\fg}; all functional groups
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@ -295,53 +300,7 @@ Idea stage on this section
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\clearpage
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\clearpage
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Two areas that cannot be automated. Choosing {\fgs} and the analysis/symptom collection process itself.
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Two areas that cannot be automated. Choosing {\fgs} and the analysis/symptom collection process itself.
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\section{Side Effects: A Problem for FMMD analysis}
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A problem with modularising according to functionality is that we can have component failures that would
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intuitively be associated with one {\fg} that may cause unintended side effects in other
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{\fgs}.
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For instance were we to have a component that on failing $SHORT$ could bring down
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a voltage supply rail, this could have drastic consequences for other
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functional groups in the system we are examining.
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\pagebreak[3]
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\subsection{Example de-coupling capacitors in logic circuits}
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A good example of this, are de-coupling capacitors, often used
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over the power supply pins of all chips in a digital logic circuit.
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Were any of these capacitors to fail $SHORT$ they could bring down
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the supply voltage to the other logic chips.
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To a power-supply, shorted capacitors on the supply rails
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are a potential source of the symptom, $SUPPLY\_SHORT$.
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In a logic chip/digital circuit {\fg} open capacitors are a potential
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source of symptoms caused by the failure mode $INTERFERENCE$.
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So we have a `symptom' of the power-supply, and a `failure~mode' of
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the logic chip to consider.
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A possible solution to this is to include the de-coupling capacitors
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in the power-supply {\fg}.
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% decision, could they be included in both places ????
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% I think so
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Because the capacitor has two potential failure modes (EN298)
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this raises another issue for FMMD. A de-coupling capacitor going $OPEN$ might not be considered relevant to
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a power-supply module (but there might be additional noise on its output rails).
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But in {\fg} terms the power supply, now has a new symptom that of $INTERFERENCE$.
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Some logic chips are more susceptible to $INTERFERENCE$ than others.
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A logic chip with de-coupling capacitor failing, may operate correctly
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but interfere with other chips in the circuit.
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There is no reason why the de-coupling capacitors could not be included {\em in the {\fg} they would intuitively be associated with as well}.
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This allows for the general principle of a component failure affecting more than one {\fg} in a circuit.
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This allows functional groups to share components where necessary.
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This does not break the modularity of the FMMD technique, because, as {\irl}
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one component failure may affect more than one sub-system.
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It does uncover a weakness in the FMMD methodology though.
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It could be very easy to miss the side effect and include
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the component causing the side effect into the wrong {\fg}, or only one germane {\fg}.
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\pagebreak[3]
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\subsection{{\fgs} Sharing components and Hierarchy}
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\subsection{{\fgs} Sharing components and Hierarchy}
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With electronics we need to follow the signal path to make sense of failure modes
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With electronics we need to follow the signal path to make sense of failure modes
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@ -622,6 +581,56 @@ $$
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%
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%
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% can I say that ?
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% can I say that ?
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\section{Problems in choosing membership of functional groups}
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\subsection{Side Effects: A Problem for FMMD analysis}
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A problem with modularising according to functionality is that we can have component failures that would
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intuitively be associated with one {\fg} that may cause unintended side effects in other
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{\fgs}.
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For instance were we to have a component that on failing $SHORT$ could bring down
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a voltage supply rail, this could have drastic consequences for other
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functional groups in the system we are examining.
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\pagebreak[3]
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\subsubsection{Example de-coupling capacitors in logic circuits}
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A good example of this, are de-coupling capacitors, often used
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over the power supply pins of all chips in a digital logic circuit.
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Were any of these capacitors to fail $SHORT$ they could bring down
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the supply voltage to the other logic chips.
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To a power-supply, shorted capacitors on the supply rails
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are a potential source of the symptom, $SUPPLY\_SHORT$.
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In a logic chip/digital circuit {\fg} open capacitors are a potential
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source of symptoms caused by the failure mode $INTERFERENCE$.
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So we have a `symptom' of the power-supply, and a `failure~mode' of
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the logic chip to consider.
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A possible solution to this is to include the de-coupling capacitors
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in the power-supply {\fg}.
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% decision, could they be included in both places ????
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% I think so
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Because the capacitor has two potential failure modes (EN298)
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this raises another issue for FMMD. A de-coupling capacitor going $OPEN$ might not be considered relevant to
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a power-supply module (but there might be additional noise on its output rails).
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But in {\fg} terms the power supply, now has a new symptom that of $INTERFERENCE$.
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Some logic chips are more susceptible to $INTERFERENCE$ than others.
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A logic chip with de-coupling capacitor failing, may operate correctly
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but interfere with other chips in the circuit.
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There is no reason why the de-coupling capacitors could not be included {\em in the {\fg} they would intuitively be associated with as well}.
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This allows for the general principle of a component failure affecting more than one {\fg} in a circuit.
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This allows functional groups to share components where necessary.
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This does not break the modularity of the FMMD technique, because, as {\irl}
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one component failure may affect more than one sub-system.
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It does uncover a weakness in the FMMD methodology though.
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It could be very easy to miss the side effect and include
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the component causing the side effect into the wrong {\fg}, or only one germane {\fg}.
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\section{Double Simultaneous Failures}
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\section{Double Simultaneous Failures}
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@ -724,10 +733,10 @@ For Functional Group 2 (FG2), let us map:
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FS6 & \mapsto & S5
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FS6 & \mapsto & S5
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\end{eqnarray*}
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\end{eqnarray*}
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This AUTOMATIC check can reveal WHEN double checking no longer necessary
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%This AUTOMATIC check can reveal WHEN double checking no longer necessary
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in the hierarchy to cover dub sum !!!!! YESSSS
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%in the hierarchy to cover dub sum !!!!! YESSSS
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\section{Non-Inverting OPAMP}
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\section{Example Analysis: Non-Inverting OPAMP}
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Consider a non inverting op-amp designed to amplify
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Consider a non inverting op-amp designed to amplify
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a small positive voltage (typical use would be a thermocouple amplifier
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a small positive voltage (typical use would be a thermocouple amplifier
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taking a range from 0 to 25mV and amplifiying it to the useful range of an ADC, approx 0 to 4 volts).
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taking a range from 0 to 25mV and amplifiying it to the useful range of an ADC, approx 0 to 4 volts).
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@ -776,7 +785,7 @@ We can now examine what effect each of these failures will have on the {\fg} (se
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\begin{table}[h+]
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\begin{table}[h+]
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\caption{Potential Divider: Sinlge failure analysis}
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\caption{Potential Divider: Single failure analysis}
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\
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\textbf{Failure Scenario} & & \textbf{Pot Div Effect} & & \textbf{Symptom} \\
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\hline
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\hline
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@ -842,6 +851,7 @@ With this two stage analysis we have a comparison complexity (see equation~\ref{
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$4.(2-1)=4$ for the potential divider and $6.(2-1)=6$, giving a total of $10$ for the $NIAMP$.
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$4.(2-1)=4$ for the potential divider and $6.(2-1)=6$, giving a total of $10$ for the $NIAMP$.
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For this simple example, traditional flat/non-modular FMEA would have a CC of $(3-1).(4+2+2)=16$.
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For this simple example, traditional flat/non-modular FMEA would have a CC of $(3-1).(4+2+2)=16$.
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\clearpage
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\section{Inverting OPAMP}
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\section{Inverting OPAMP}
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\label{sec:invamp}
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\label{sec:invamp}
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@ -854,16 +864,16 @@ For this simple example, traditional flat/non-modular FMEA would have a CC of $(
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\label{fig:invamp}
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\label{fig:invamp}
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\end{figure}
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\end{figure}
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This configuration is interesting from methodology perspective.
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%This configuration is interesting from methodology pers.
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There are two ways in which we can tackle this.
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There are two obvious ways in which we can model this circuit:
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One is to do this in two stages, by considering the gain resistors to be a potential divider
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One is to do this in two stages, by considering the gain resistors to be an inverted potential divider
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and then combining it with the OPAMP failure mode model.
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and then combining it with the OPAMP failure mode model.
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The other way is to place all three components in a {\fg}.
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The second is to place all three components in a {\fg}.
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Both approaches are followed in the next two sub-sections.
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Both approaches are followed in the next two sub-sections.
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\subsection{Inverting OPAMP using a Potential Divider {\dc}}
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\subsection{Inverting OPAMP using a Potential Divider {\dc}}
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Re-using the $PD$ - potential divider works only if the input voltage is negative.
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We cannot simply re-use the $PD$ from section~\ref{potdivfmmd}---that potential divider would only be valid if the input signal were negative.
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We want if possible to have detectable errors, HIGH and LOW are better than OUTOFRANGE.
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We want if possible to have detectable errors, HIGH and LOW are better than OUTOFRANGE.
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If we can refine the operational states of the functional group, we can obtain clearer
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If we can refine the operational states of the functional group, we can obtain clearer
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symptoms.
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symptoms.
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@ -874,9 +884,9 @@ If we consider the input will only be positive, we can invert the potential divi
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\textbf{Failure Scenario} & & \textbf{Inverted Pot Div Effect} & & \textbf{Symptom} \\
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\textbf{Failure Scenario} & & \textbf{Inverted Pot Div Effect} & & \textbf{Symptom} \\
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\hline
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\hline
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FS1: R1 SHORT & & $HIGH$ & & $PDHigh$ \\ \hline
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FS1: R1 SHORT & & $HIGH$ & & $PDHigh$ \\ \hline
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FS2: R1 OPEN & & $LOW$ & & $PDLow$ \\ \hline
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FS2: R1 OPEN & & $LOW$ & & $PDLow$ \\ \hline
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FS3: R2 SHORT & & $LOW$ & & $PDLow$ \\ \hline
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FS3: R2 SHORT & & $LOW$ & & $PDLow$ \\ \hline
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FS4: R2 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline
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FS4: R2 OPEN & & $HIGH$ & & $PDHigh$ \\ \hline
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\hline
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\hline
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\end{tabular}
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\end{tabular}
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@ -892,8 +902,8 @@ We can now form a {\fg} from the OPAMP and the $INVPD$
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\textbf{Failure Scenario} & & \textbf{Inverted Amp Effect} & & \textbf{Symptom} \\ \hline
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\textbf{Failure Scenario} & & \textbf{Inverted Amp Effect} & & \textbf{Symptom} \\ \hline
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\hline
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\hline
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FS1: INVPD LOW & & NEGATIVE - input & & $ HIGH $ \\
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FS1: INVPD LOW & & NEGATIVE on -input & & $ HIGH $ \\
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FS2: INVPD HIGH & & Positive - input & & $ LOW $ \\
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FS2: INVPD HIGH & & Positive on -input & & $ LOW $ \\
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FS5: AMP L\_DN & & $ INVAMP_{low} $ & & $ LOW $ \\ \hline
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FS5: AMP L\_DN & & $ INVAMP_{low} $ & & $ LOW $ \\ \hline
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@ -930,12 +940,12 @@ $HIGH$ or $LOW$ output.
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\begin{table}[h+]
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\begin{table}[h+]
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\caption{Inverting Amplifier: Single failure analysis}
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\caption{Inverting Amplifier: Single failure analysis: 3 components}
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\begin{tabular}{|| l | l | c | c | l ||} \hline
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\textbf{Failure Scenario} & & \textbf{Inverted Amp Effect} & & \textbf{Symptom} \\ \hline
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\textbf{Failure Scenario} & & \textbf{Inverted Amp Effect} & & \textbf{Symptom} \\ \hline
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\hline
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\hline
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FS1: R1 SHORT +ve in & & NEGATIVE out of range & & $ OUT OF RANGE $ \\
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FS1: R1 SHORT +ve in & & NEGATIVE out of range & & $ OUT OF RANGE $ \\
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FS1: R1 SHORT -ve in & & POSITIVE out of range & & $ OUT OF RANGE $ \\ \hline
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FS1: R1 SHORT -ve in & & POSITIVE out of range & & $ OUT OF RANGE $ \\ \hline
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FS2: R1 OPEN +ve in & & zero output & & $ ZERO OUTPUT $ \\
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FS2: R1 OPEN +ve in & & zero output & & $ ZERO OUTPUT $ \\
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FS2: R1 OPEN -ve in & & zero output & & $ ZERO OUTPUT $ \\ \hline
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FS2: R1 OPEN -ve in & & zero output & & $ ZERO OUTPUT $ \\ \hline
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@ -968,8 +978,8 @@ $$ fm(INVAMP) = \{ OUT OF RANGE, ZERO OUTPUT, NO GAIN, LOW PASS \} $$
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%Could further refine this if MTTF stats available for each component failure.
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%Could further refine this if MTTF stats available for each component failure.
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\clearpage
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\clearpage
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\subsection{Comparison between the two approaches}
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\subsection{Comparison between the two approaches}
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If the input voltage can be negative the potential divider
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If the input voltage can be negative the potential divider
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