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@ -625,16 +625,28 @@ approach in looking for system failures.
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In this section we examine some fundamental concepts and underlying philosophies of FMEA.
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\paragraph{Failure modes of a component and mutual exclusivity.}
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It is desirable that the failure modes for a component are mutually exclusive, were a component able
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to fail in several ways at the same time, this would complicate analysis.
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It would mean having to consider combinations of internal component failures
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as separate failure modes. This concept is discussed in sections ~\ref{ch4:mutex}
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and ~\ref{ch7:mutex}.
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%
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In general failure modes
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for simple components are mutually exclusive
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but large and complex components (such as integrated circuits), especially where they contain separate modules,
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could have non mutually exclusive failure modes and these need spacial handling, see section~\ref{ch3:mutex}.
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\paragraph{The signal path.}
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% C Garret does not like the terms afferent and efferent here, try to think of something else
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Most electronic systems are used to process a signal: with signal processing
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there is usually a clear afferent to transform to efferent path.
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there is usually a clear path from the signal coming into the system, it being processed in some way, and a resultant effect on
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an output or control signal. % afferent to transform to efferent path.
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%
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That is, there is an input, some processing and an output.
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%
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We define the signal path as the components used to process the signal.
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For the purpose of FMEA, we define the signal path as the components used to process the signal.
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%
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Some circuits have feedback loops or even circular signal paths, but it
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is normal for a signal path to exist.
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@ -2204,6 +2204,15 @@ in the model.
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With the above condition true, we term this a `complete' FMMD failure model.
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Ensuring this condition is described in section~\ref{sec:completetest}.
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\paragraph{Mutual exclusivity of {\dc} failure modes.}
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It is a desirable feature of a component that its failure modes
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are mutually exclusive.
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This also applies to {\dcs} produced in the FMMD process.
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In the FMMD process symptoms are are collected, i.e no component failure modes may be shared
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by a symptom within a {\fg}, and therefore the failure modes of a {\dc} are mutually exclusive.
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Thus FMMD naturally produces {\dc} failure modes that are mutually exclusive.
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This property is examined in more detail in section~\ref{ch7:mutex}.
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\paragraph{State explosion problem of FMEA solved by FMMD.}
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%
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Because FMMD considers failure modes within functional groups;
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@ -659,6 +659,7 @@ are level shifted, adding to the complication of analysing it for failures.
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%
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\section{Unitary State Component Failure Mode Sets}
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\label{sec:unitarystate}
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\label{ch7:mutex}
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\paragraph{Design Decision/Constraint}
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An important factor in defining a set of failure modes is that they
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should represent the failure modes as simply and minimally as possible.
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@ -679,29 +680,30 @@ This corresponds to the `mutually exclusive' definition in
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probability theory~\cite{probstat}.
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\begin{definition}
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A set of failure modes where only one failure mode
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can be active at one time is termed a {\textbf{unitary~state}} failure mode set.
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\end{definition}
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% \begin{definition}
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% A set of failure modes where only one failure mode
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% can be active at one time is termed a {\textbf{unitary~state}} failure mode set.
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% \end{definition}
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%
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% Let the set of all possible components be $ \mathcal{C}$
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% and let the set of all possible failure modes be $ \mathcal{F}$.
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% The set of failure modes of a particular component are of interest
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% here.
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Let the set of all possible components be $ \mathcal{C}$
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and let the set of all possible failure modes be $ \mathcal{F}$.
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The set of failure modes of a particular component are of interest
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here.
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What is required is to define a property for
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a set of failure modes where only one failure mode can be active at a time;
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or borrowing from the terms of statistics, the failure mode being an event that is mutually exclusive
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with a set $F$.
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We can define a set of failure mode sets called $\mathcal{U}$ to represent this
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property for a set of failure modes.
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%
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% \begin{definition}
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% We can define a set $\mathcal{U}$ which is a set of sets of failure modes, where
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% the component failure modes in each of its members are unitary~state.
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% Thus if the failure modes of a component $F$ are unitary~state, we can say $F \in \mathcal{U}$ is true.
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% \end{definition}
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\begin{definition}
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We can define a set $\mathcal{U}$ which is a set of sets of failure modes, where
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the component failure modes in each of its members are unitary~state.
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Thus if the failure modes of a component $F$ are unitary~state, we can say $F \in \mathcal{U}$ is true.
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\end{definition}
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\section{Component failure modes: Unitary State example}
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\subsection{Example of unitary state component failure modes}
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An example of a component with an obvious set of ``unitary~state'' failure modes is the electrical resistor.
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%
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@ -750,10 +752,10 @@ Note where there are more than two failure~modes,
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by banning any pairs from being active at the same time,
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we have banned larger combinations as well.
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\subsection{Design Rule: Unitary State}
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%\subsection{Design Rule: Unitary State}
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\paragraph{Design Rule: Unitary State}
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All components must have unitary state failure modes to be used with the FMMD methodology and
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for base~components this is usually the case. Most simple components fail in one
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@ -761,15 +763,15 @@ clearly defined way and generally stay in that state.
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Traditional FMEA has problems dealing with non unitary state failure modes.
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This is mainly because combinations of failure modes could cause
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effects very difficult to predict (as they are in effect new failure modes of the component).
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However, where a complex component is used, for instance a microcontroller
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%
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However, where a complex component is used, for instance a micro-controller
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with several modules that could all fail simultaneously, a process
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of reduction into smaller theoretical components will have to be made.
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We can term this `heuristic~de-composition'.
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%
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A modern micro-controller will typically have several modules which are configured to operate on
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pre-assigned pins on the device. Typically voltage inputs (\adcten / \adctw), digital input and outputs,
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PWM (pulse width modulation), UARTs and other modules will be found on simple cheap microcontrollers~\cite{pic18f2523}.
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PWM (pulse width modulation), UARTs and other modules will be found on simple cheap micro-controllers~\cite{pic18f2523}.
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%
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For instance, the voltage reading functions which consist
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of a multiplexer and ADC---which must work together to channel readings--- could be considered to be components
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@ -780,10 +782,9 @@ that can be analysed separately~\footnote{It is common for the signal paths
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in a safety critical product to be traced, and when entering a complex
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component like a micro-controller, the process of heuristic de-compostion
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is then applied to it.}.
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\paragraph{Reason for FMMD unitary failure mode constraint.} Were this constraint not to be applied,
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%
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%\paragraph{Reason for FMMD unitary failure mode constraint.}
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Were this constraint not to be applied,
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each component would not contribute $N$ failure modes, % to consider
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but potentially
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$2^N$.
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@ -892,20 +893,27 @@ be less than this.
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This is because certain combinations of faults within a components failure mode set
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are impossible under the conditions of unitary state failure mode.
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To modify equation \ref{eqn:ccps} for unitary state conditions, we must subtract the number of component `internal combinations'
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for each component in the functional group under analysis.
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for each component in the {\fg} under analysis.
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Note we must sequentially subtract using combinations above 1 up to the cardinality constraint.
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For example, say
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the cardinality constraint was 3, we would need to subtract both
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$|{n \choose 2}|$ and $|{n \choose 3}|$ for each component in the functional~group.
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$|{n \choose 2}|$ and $|{n \choose 3}|$ for each component in the {\fg}.
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\subsubsection{Example: Two Component functional group Cardinality Constraint of 2}
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\subsubsection{Example: Two Component {\fg} Cardinality Constraint of 2}
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For example: suppose we have a simple functional group with two components R and T, of which
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For example: suppose we have a simple {\fg} with two components R and T, of which
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$$fm(R) = \{R_o, R_s\}$$ and $$fm(T) = \{T_o, T_s, T_h\}.$$
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This means that the functional~group $FG=\{R,T\}$ will have a component failure mode set
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of $fm(FG) = \{R_o, R_s, T_o, T_s, T_h\}$
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This means that the {\fg} $FG=\{R,T\}$ will have a component failure mode set
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of $fm(FG) = \{R_o, R_s, T_o, T_s, T_h\}$. Note this set of failure modes
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is as we would use them for single failure analysis.
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% Did J Howse actually read this? 06APR2013
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% This set does not contain
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% mutually exclusive failure modes, because both $R$ and $T$ could fail.
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% The failure modes of $R$ and $T$ are mutually exclusive though, and so some
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% combinations of the failure mode set $\{R_o, R_s, T_o, T_s, T_h\}$ cannot occur.
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% We use equation~\ref{eqn:ccps} to determine the number of valid combinations.
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%
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For a cardinality constrained powerset of 2, because there are 5 error modes ( $|fm(FG)|=5$),
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applying equation \ref{eqn:ccps} gives :-
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@ -913,17 +921,22 @@ $$ | P_2 (fm(FG)) | = \frac{5!}{1!(5-1)!} + \frac{5!}{2!(5-2)!} = 15.$$
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This is composed of ${5 \choose 1}$
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five single fault modes, and ${5 \choose 2}$ ten double fault modes.
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However we know that the faults are mutually exclusive within a component.
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%
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However we know that the {\fms} are mutually exclusive within a component.
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%
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We must then subtract the number of `internal' component fault combinations
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for each component in the functional~group.
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for each component in the {\fg}.
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%
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For component R there is only one internal component fault that cannot exist
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$R_o \wedge R_s$. As a combination ${2 \choose 2} = 1$. For the component $T$ which has
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three fault modes ${3 \choose 2} = 3$.
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%
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Thus for $cc = 2$, under the conditions of unitary state failure modes in the components $R$ and $T$, we must subtract $(3+1)$.
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The number of combinations to check is thus 11, $|\mathcal{P}_{2}(fm(FG))| = 11$, for this example and this can be verified
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by listing all the required combinations:
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% Because there are only two components, this is simply the cross product
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% of fm(R) and fm(T) but this does not hold for larger {\fgs}...
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$$ \mathcal{P}_{2}(fm(FG)) = \{
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\{R_o T_o\}, \{R_o T_s\}, \{R_o T_h\}, \{R_s T_o\}, \{R_s T_s\}, \{R_s T_h\}, \{R_o \}, \{R_s \}, \{T_o \}, \{T_s \}, \{T_h \}
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@ -986,7 +999,7 @@ Expanding the combination in equation \ref{eqn:correctedccps}
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\label{eqn:correctedccps2}
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\end{equation}
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\paragraph{Use of Equation \ref{eqn:correctedccps2} }
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%\paragraph{Use of Equation \ref{eqn:correctedccps2} }
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Equation \ref{eqn:correctedccps2} is useful for an automated tool that
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would verify that a single or double simultaneous failures model has complete failure mode coverage.
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By knowing how many test cases should be covered, and checking the cardinality
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@ -37,6 +37,7 @@ we are able to collect common symptoms of failure for the {\fg}.
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With the collected common symptoms, we can treat the {\fg}
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as a component in its own right.
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This new component being derived from the {\fg}.
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%
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In the field of safety engineering this derived component corresponds to a low~level sub-system.
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%The technique uses a graphical notation, based on Euler\cite{eulerviz} and Constraint diagrams\cite{constraint} to model failure modes and failure mode common symptom collection. The technique is designed for making building blocks for a hierarchical fault model.
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%
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@ -66,8 +67,13 @@ The symptom extraction or abstraction process, is the key process in creating an
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}
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\vspace{40pt}
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%\today
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\paragraph{Mutual exclusive property of the failure modes of a {\dc}}
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Because the symptoms have been collected from
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identical failure effects of the {\fg} they are mutually exclusive.
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That is to say no failure mode effects of a component of a {\fg}
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can be shared by a {\dc} failure mode.
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This ensures the mutually exclusive, or unitary state failure mode property, meaning
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the failure modes of a {\dc} are suitable for use in higher level {\fgs}.
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\subsection{Diagnostic analysis and Failure Mode Analysis}
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Fault finding is a closely related discipline to failure mode analysis.
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