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Systems Approach To

Effective Diagnostics & Prognostics

07/23/2003

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Our CompanyOur Company

28 YEARS of TECHNICAL SERVICE28 YEARS of TECHNICAL SERVICE

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A Systems Engineering Approach to Integrated Diagnostics and Prognostics

•Requirements Derivation •Requirements Flow down •Design Development•Design Optimization•Embedded Systems•Life Cycle Support

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ILS INTEGRATED LOGISTICS SUPORT

RFP REQUEST FOR PROPOSAL

SDP SOFTWARE DEVELOPMENT PLAN

SEDS SYSTEMS ENGINEERING DETAILED SCHEDULE

SEMP SYSTEMS ENGINEERING MANAGEMENT PLAN

SEMS SYSTEMS ENGINEERING MASTER SCHEDULE

T&E TEST AND EVALUATION

URD USER REQUIERMENTS DOCUMENT

A SPEC SYSTEM FUNCTIONAL REQUIREMENTS

B SPEC ALLOCATED DEVELOPMENT REQUIREMENTS

C SPEC PRODUCT FUNCTION/FABRICATION REQUIREMENTS

D SPEC PROCESS REQUIREMENTS

E SPEC MATERIAL REQUIRMENTS

SSDD SYSTEM SEGMENT DESIGN DOCUMENT

ICD INTERFACE CONTROL DOCUMENT

TRS TEST REQUIREMENTS SPECIFICATION

MGMTDIRECTION

& REPORTING

T&EPLANS

SDP

A/B SPECSC/D/E SPECS

Product

SEMPSEMSSEDS

ExternalCustomer

ExternalCustomer

Project Mgr

Systems

Engineering

Management

Requirements

And

Architecture

Definition Design, ILS

Production

&

Test

System

Integration

&

Verification

Project Mgr

URD &Stakeholder

Requirements

RFPContract

Program PlanCost Objectives

Integrated andQualified System

SSDDICDTRS

Deployed System

System Design Package

Product Characteristics

SI&VPLAN

Staffing & Resource RequirementsTechnical Program Progress Reports

Conceptual Design, Support and IR&D Trade

Analyses

Technology Refresh / Operational Analysis / Historical Maintenance

Data & Analysis

Conceptual / IR&DConceptual / IR&DRequirements & Requirements &

Architectural Architectural DefinitionDefinition

SE ManagementSE ManagementSystem Integration System Integration

&& Verification (SI&V)Verification (SI&V)

Deployment Deployment & &

Fielded SystemFielded SystemDevelopmentDevelopment

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Performance Risk Defined

Performance Risk is• Uncertainty in the ability of a design to meet the specified

performance level and the consequences thereof• The gap between the validated and specified performance

levels and the consequences of that gap

“Performance” is defined broadly to include• Operability, Functionality, Safety, Testability, Affordability,

Reliability, Availability, Maintainability, etc.• Any dimension of value to the customer

ValidatedPerformance Level

SpecifiedPerformance LevelGap

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Today’s Technology Provides Process ImprovementTo

Fill the Gap

• Enhanced Diagnostics Modeling Provides:– Improved Fault Detection Confidence (FD%)– Improved Fault Isolation to Optimum Repair Level (FI

%)– Reduced False Alarms / False Removals (FA%)– Lower Mean Time to Isolate (MTTI)– Improved Operational Availability (Ao)– Improved Safety Through Critical Fault Analysis

(FMECA)– Reduced Life Cycle Cost

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Development Information Model• Topology (Visualization)

• Functions (Objects + Nets)

• Failure Modes (FMECA)

• Test Definitions (Testing)

• Diagnostic Strategy

• Failure Effects (FMECA)

• FMECA Report

• Working on DMECA

(Degraded Mode Effect and Criticality Analysis)

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Global Modeling• Electrical• Electronic• Mechanical• Hydraulic• Optical• Software• Process

• Fully Hierarchical

• Object-Oriented

• Networked

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Diagnostic Outputs

Light Green - partially proven good - not yet suspectedGreen- proven goodLight Blue Stimuli necessary for testYellow - suspected, in current suspect setTeal - secondary suspects, not in the current suspects set but could be responsible for a previously performed test that failed Dark Red - contains potentially failed components, in AGLight Red - higher level part for which a lower level part is color dark redDark Blue -I/O Test Point

Diagnostic Fault Tree

Provides an interactive interface to “exercise” the diagnostics.

Provides means to “check” models for validity. Quickly Identifies problem areas (i.e.. Large fault / ambiguity groups)

Can be used for Intelligent troubleshooting

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FMECA Output

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Process Interoperability

Testability / Diagnosability

Reliability / Safety

MaintainabilityMaintainability

Testability Updates

Reliability Updates

Maintainability UpdatesMaintainability Updates

TopologicalModel

TopologicalModel

ReliabilityPredictionsReliabilityPredictions

FunctionalAllocationFunctionalAllocation

SystemPartitioning

SystemPartitioning

Part SelectionPart Selection

FunctionalModeling

FunctionalModeling Test DefinitionTest Definition Diagnostic

DevelopmentDiagnostic

Development

MaintenancePlanning

MaintenancePlanning

DiagnosticReports

DiagnosticReports

FMECA/SafetyAnalysis

FMECA/SafetyAnalysis

FMECA ReportsFMECA Reports

FMECA ValidationFMECA Validation

MaintenanceProcedures

MaintenanceProcedures

Em

bedded D

iagnost

ics

& P

rognost

ics

Opera

tion a

nd S

upport

Envir

onm

ent Prognostics &

Failure Trendanalysis

Prognostics &Failure Trend

analysis

Prognostics modeling

Prognostics modeling

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•Reliability•Provides Data to Diagnostics Models

•Functional•Dependency•Failure Mode

•Rule Base•Case Base•Model Based Reasoner (MBR)•AI•Prognostic

Typical Model Types Developed or Supported

Design DirectionDesign AssessmentDesign OptimizationSupport to Ground Operations

Higher Order Run Time

Require Developed System

Derive Information fromFunctional, Dependencyand Failure Information

Support to OptimizationStudies

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Systems Process at Work

• RAH-66 Comanche Program• Boeing-Sikorsky-US Army

Diagnostic Design Requirements Analysis Guide (DDRAG)

Note: Document contents are export restricted with distribution limited to US Government agencies

For Distribution and questions, please contact:

Steve DesantisBoeing

610-591-6558stephen.f.desantis@boeing.com

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Systems Process at Work

DDRAG Purpose• Comanche Team Desktop Reference

– Ensures Standard Processes and Procedures for All Levels of Diagnostics Design Development

• Identifies Processes Needed to Define Diagnostics Design Requirements– Equipment– Subsystems– System / Segment– Air Vehicle– External Diagnostics

• Defines Operational Flight Program and Off-Board Diagnostics Requirements

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Design Process management• All Levels of Design Data and Tools Need to be Interoperable• Tools Need to Support Open Information Architecture• Process Needs to be Managed Through an Integrated Product

Development Environment (IPDE)– A Concept Development System was Developed for NASA on the

2nd Gen RLV / SLI Project to Meet the Interoperability Needs• IVHM Systems Management Environment (ISME)

– Data Management– Translation between Tools, Data and ISME– Version / Configuration Control– Audit Trail Management– User Control– Security

KEEP EVERYONE ON SAME PAGEKEEP EVERYONE ON SAME PAGE

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Important Enterprise Features

TYXTestBase ®

DSIeXpress™

TYX TestRequirements

Document

EmbeddedDiagnosis &

Health Mgmt.

FactoryTest

FieldTest

Interactive ElectronicTechnical Manual

(IETM)

MaintenanceData Collection

Gateway

VehicleGround OpsDepot/Vendor