feat(iace): Sprint 4D — Failure Mode Layer (FMEA-Faehigkeit)
150 Failure Modes in 11 ComponentTypes: - Sensor (20): Signalverlust, Drift, Falschmeldung, Encoder-spezifisch - Controller (20): Watchdog, Speicher, Bus, Safety-SPS CCF, Antrieb - Actuator (15): Blockiert, Ueberlast, Haltekraftverlust, Schuetz verschweisst - Mechanical (20): Ermuedungsbruch, Lagerschaden, Kettenriss, Werkzeugbruch - Electrical (15): Isolation, Kurzschluss, Erdschluss, Lichtbogen - Software (15): Exception, Race Condition, Buffer Overflow, Timing - Hydraulic/Pneumatic (15): Schlauchplatzer, Ventil blockiert, Kavitation - Safety Device (15): Failure-to-trip, CCF, Bremsenverschleiss, PL-Degradation - Network (10): Paketverlust, Latenz, Man-in-the-Middle - AI/ML (5): Model Drift, Adversarial Input, Bias Architektur: - FailureModeEntry Struct mit FMEA-Scores (Severity/Occurrence/Detection 1-10) - RPZ = S x O x D (max 1000, Schwelle >= 100 = Massnahme erforderlich) - RequiredFailureModes auf HazardPattern fuer FM-gesteuertes Pattern-Matching - MatchInput.FailureModes + MatchReason "failure_mode" (Explainability) - GET /failure-modes?component_type= API-Endpoint 10 Tests: Count, UniqueIDs, ValidTypes, NonEmpty, Distribution, RPZ (3x), NilFires, RPZDistribution Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
Benjamin Admin
@@ -86,6 +86,31 @@ func (h *IACEHandler) ListProtectiveMeasures(c *gin.Context) {
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})
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}
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// ListFailureModes handles GET /failure-modes
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// Returns the failure mode library, optionally filtered by ?component_type.
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func (h *IACEHandler) ListFailureModes(c *gin.Context) {
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componentType := c.Query("component_type")
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all := iace.GetFailureModeLibrary()
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var filtered []iace.FailureModeEntry
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for _, entry := range all {
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if componentType != "" && entry.ComponentType != componentType {
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continue
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}
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filtered = append(filtered, entry)
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}
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if filtered == nil {
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filtered = []iace.FailureModeEntry{}
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}
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c.JSON(http.StatusOK, gin.H{
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"failure_modes": filtered,
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"total": len(filtered),
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})
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}
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// ValidateMitigationHierarchy handles POST /projects/:id/validate-mitigation-hierarchy
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// Validates if the proposed mitigation type follows the 3-step hierarchy principle.
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func (h *IACEHandler) ValidateMitigationHierarchy(c *gin.Context) {
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@@ -361,6 +361,7 @@ func registerIACERoutes(v1 *gin.RouterGroup, h *handlers.IACEHandler) {
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iaceRoutes.GET("/roles", h.ListRoles)
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iaceRoutes.GET("/evidence-types", h.ListEvidenceTypes)
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iaceRoutes.GET("/protective-measures-library", h.ListProtectiveMeasures)
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iaceRoutes.GET("/failure-modes", h.ListFailureModes)
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iaceRoutes.GET("/component-library", h.ListComponentLibrary)
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iaceRoutes.GET("/energy-sources", h.ListEnergySources)
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iaceRoutes.GET("/tags", h.ListTags)
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@@ -0,0 +1,122 @@
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package iace
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// GetFailureModeLibrary returns the complete failure mode library.
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func GetFailureModeLibrary() []FailureModeEntry {
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var all []FailureModeEntry
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all = append(all, getSensorFailureModes()...)
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all = append(all, getControllerFailureModes()...)
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all = append(all, getActuatorFailureModes()...)
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all = append(all, getMechanicalFailureModes()...)
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all = append(all, getElectricalFailureModes()...)
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all = append(all, getSoftwareFailureModes()...)
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all = append(all, getFluidFailureModes()...)
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all = append(all, getSafetyDeviceFailureModes()...)
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all = append(all, getNetworkFailureModes()...)
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all = append(all, getAIFailureModes()...)
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return all
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}
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// ── Sensor Failure Modes (20) ──────────────────────────────────────
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func getSensorFailureModes() []FailureModeEntry {
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return []FailureModeEntry{
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{ID: "FM-SEN-01", ComponentType: "sensor", Mode: "loss_of_signal", NameDE: "Signalverlust", NameEN: "Loss of signal", Effect: "Positionsinformation geht verloren, Steuerung erhaelt keine Rueckmeldung", DetectionHint: "Diagnosefunktion Safety-SPS, Drahtbruchueberwachung", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-SEN-02", ComponentType: "sensor", Mode: "drift", NameDE: "Messwertdrift", NameEN: "Measurement drift", Effect: "Langsame Abweichung vom Sollwert, schleichender Genauigkeitsverlust", DetectionHint: "Regelmaessige Kalibrierung, Plausibilitaetspruefung", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 5},
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{ID: "FM-SEN-03", ComponentType: "sensor", Mode: "false_positive", NameDE: "Falschmeldung (Fehlalarm)", NameEN: "False positive", Effect: "Unnoetiger Maschinenstopp, Produktionsverlust", DetectionHint: "Statistik der Alarme, Vergleich Redundanzsensor", DefaultSeverity: 3, DefaultOccurrence: 4, DefaultDetection: 3},
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{ID: "FM-SEN-04", ComponentType: "sensor", Mode: "false_negative", NameDE: "Nichtmeldung (Fehlersuppression)", NameEN: "False negative", Effect: "Gefaehrlicher Zustand wird nicht erkannt, Schutzfunktion versagt", DetectionHint: "Zyklischer Selbsttest, diversitaerer Sensor", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 7},
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{ID: "FM-SEN-05", ComponentType: "sensor", Mode: "calibration_error", NameDE: "Kalibrierungsfehler", NameEN: "Calibration error", Effect: "Systematische Messabweichung, falsche Grenzwertbewertung", DetectionHint: "Referenzmessung mit Prueflehre", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 5},
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{ID: "FM-SEN-06", ComponentType: "sensor", Mode: "environmental_interference", NameDE: "Umgebungseinfluss-Stoerung", NameEN: "Environmental interference", Effect: "EMV, Temperatur oder Verschmutzung verfaelscht Messwert", DetectionHint: "Abschirmung pruefen, Plausibilitaetscheck", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 4},
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{ID: "FM-SEN-07", ComponentType: "sensor", Mode: "response_time_degradation", NameDE: "Reaktionszeit-Verschlechterung", NameEN: "Response time degradation", Effect: "Sicherheitsfunktion reagiert zu langsam auf Gefahrensituation", DetectionHint: "Periodische Reaktionszeitmessung", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 6},
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{ID: "FM-SEN-08", ComponentType: "sensor", Mode: "stuck_at_value", NameDE: "Festhaengen auf Wert", NameEN: "Stuck at value", Effect: "Sensor liefert unveraenderlichen Wert, Zustandsaenderung wird nicht erkannt", DetectionHint: "Aenderungsrate-Ueberwachung, Watchdog", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 4},
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{ID: "FM-SEN-09", ComponentType: "sensor", Mode: "intermittent_contact", NameDE: "Wackelkontakt", NameEN: "Intermittent contact", Effect: "Sporadischer Signalausfall, schwer reproduzierbar", DetectionHint: "Vibrations-Test, Steckerpruefung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 7},
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{ID: "FM-SEN-10", ComponentType: "sensor", Mode: "cross_talk", NameDE: "Signaleinstreuung (Crosstalk)", NameEN: "Signal crosstalk", Effect: "Fremdsignal ueberlagert Messwert, Fehlinterpretation", DetectionHint: "EMV-Test, geschirmte Leitungen pruefen", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 5},
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{ID: "FM-SEN-11", ComponentType: "sensor", Mode: "power_supply_failure", NameDE: "Versorgungsspannungsausfall Sensor", NameEN: "Sensor power supply failure", Effect: "Sensor liefert kein Signal, Steuerung ohne Rueckmeldung", DetectionHint: "Spannungsueberwachung, Redundante Versorgung", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-SEN-12", ComponentType: "sensor", Mode: "mechanical_damage", NameDE: "Mechanische Beschaedigung Sensor", NameEN: "Sensor mechanical damage", Effect: "Sensor physisch zerstoert oder dejustiert durch Kollision/Vibration", DetectionHint: "Sichtpruefung, Montagekontrolle", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-SEN-13", ComponentType: "sensor", Mode: "aging", NameDE: "Alterung/Verschleiss Sensor", NameEN: "Sensor aging", Effect: "Empfindlichkeit nimmt ab, Schaltpunkte verschieben sich", DetectionHint: "Lebensdauer-Tracking, praeventiver Austausch", DefaultSeverity: 5, DefaultOccurrence: 4, DefaultDetection: 5},
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{ID: "FM-SEN-14", ComponentType: "sensor", Mode: "contamination", NameDE: "Verschmutzung Sensorflaeche", NameEN: "Sensor contamination", Effect: "Optischer/induktiver Sensor durch Oel, Staub oder Spaene beeintraechtigt", DetectionHint: "Reinigungsplan, Signalstaerke-Ueberwachung", DefaultSeverity: 5, DefaultOccurrence: 5, DefaultDetection: 3},
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{ID: "FM-SEN-15", ComponentType: "sensor", Mode: "wrong_installation", NameDE: "Falsche Montage/Ausrichtung", NameEN: "Wrong installation", Effect: "Sensor misst an falscher Stelle oder in falscher Richtung", DetectionHint: "Inbetriebnahme-Checkliste, Referenzmessung", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 3},
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// Encoder-specific
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{ID: "FM-SEN-16", ComponentType: "sensor", Mode: "encoder_pulse_loss", NameDE: "Encoder-Impulsverlust", NameEN: "Encoder pulse loss", Effect: "Positionszaehler weicht ab, Achse verfaehrt unkontrolliert", DetectionHint: "Inkremental-Encoder Referenzmarke pruefen", DefaultSeverity: 9, DefaultOccurrence: 3, DefaultDetection: 4},
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{ID: "FM-SEN-17", ComponentType: "sensor", Mode: "encoder_cable_break", NameDE: "Encoder-Kabelbruch", NameEN: "Encoder cable break", Effect: "Kompletter Positionsverlust, STO wird ausgeloest", DetectionHint: "Drahtbrucherkennung im Safety-Encoder", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 2},
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// Safety-specific sensors
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{ID: "FM-SEN-18", ComponentType: "sensor", Mode: "safety_switch_bypass", NameDE: "Sicherheitsschalter ueberbrueckt", NameEN: "Safety switch bypassed", Effect: "Schutzeinrichtung wirkungslos, Zugang zum Gefahrbereich moeglich", DetectionHint: "Codierter Schalter, Manipulationsschutz", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 6},
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{ID: "FM-SEN-19", ComponentType: "sensor", Mode: "light_curtain_blind_spot", NameDE: "Lichtvorhang Totwinkel", NameEN: "Light curtain blind spot", Effect: "Person im Gefahrbereich wird nicht erkannt", DetectionHint: "Ausrichtungspruefung, Testkoerper-Pruefung", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 4},
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{ID: "FM-SEN-20", ComponentType: "sensor", Mode: "pressure_sensor_blockage", NameDE: "Drucksensor-Verstopfung", NameEN: "Pressure sensor blockage", Effect: "Druckanzeige zeigt falschen Wert, Ueberdruck nicht erkannt", DetectionHint: "Vergleichsmessung, Spuelprozedur", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 5},
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}
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}
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// ── Controller Failure Modes (20) ──────────────────────────────────
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func getControllerFailureModes() []FailureModeEntry {
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return []FailureModeEntry{
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{ID: "FM-CTRL-01", ComponentType: "controller", Mode: "watchdog_timeout", NameDE: "Watchdog-Timeout", NameEN: "Watchdog timeout", Effect: "SPS-Programm reagiert nicht mehr, sicherer Zustand wird erzwungen", DetectionHint: "Hardware-Watchdog, LED-Anzeige", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-CTRL-02", ComponentType: "controller", Mode: "memory_overflow", NameDE: "Speicherueberlauf", NameEN: "Memory overflow", Effect: "Programmabsturz, undefiniertes Steuerungsverhalten", DetectionHint: "Speicher-Monitoring, Stack-Ueberwachung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 4},
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{ID: "FM-CTRL-03", ComponentType: "controller", Mode: "communication_loss", NameDE: "Busverlust/Kommunikationsausfall", NameEN: "Communication loss", Effect: "Steuerung verliert Verbindung zu Antrieben oder Sensorik", DetectionHint: "Bus-Timeout-Ueberwachung, Heartbeat", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 2},
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{ID: "FM-CTRL-04", ComponentType: "controller", Mode: "program_corruption", NameDE: "Programm-Korruption", NameEN: "Program corruption", Effect: "Steuerungsprogramm laeuft fehlerhaft, unvorhersehbare Ausgaben", DetectionHint: "CRC-Pruefung, ROM-Integritaetstest", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 4},
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{ID: "FM-CTRL-05", ComponentType: "controller", Mode: "parameter_loss", NameDE: "Parameterverlust nach Spannungsausfall", NameEN: "Parameter loss after power failure", Effect: "Maschine startet mit Default-Parametern, falsche Grenzwerte", DetectionHint: "Batterie-Ueberwachung, Backup-Vergleich", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-CTRL-06", ComponentType: "controller", Mode: "output_stuck", NameDE: "Ausgang klebt (stuck-at)", NameEN: "Output stuck", Effect: "Aktor wird nicht mehr angesteuert oder laeuft dauerhaft", DetectionHint: "Ruecklese-Diagnose, Cross-Monitoring", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
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{ID: "FM-CTRL-07", ComponentType: "controller", Mode: "clock_failure", NameDE: "Taktausfall/Taktfehler", NameEN: "Clock failure", Effect: "Zykluszeit der SPS instabil, Timing-Fehler in Sicherheitsfunktionen", DetectionHint: "Takt-Ueberwachung, Watchdog", DefaultSeverity: 8, DefaultOccurrence: 1, DefaultDetection: 3},
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{ID: "FM-CTRL-08", ComponentType: "controller", Mode: "io_card_failure", NameDE: "E/A-Karten-Ausfall", NameEN: "I/O card failure", Effect: "Eingaenge oder Ausgaenge fallen komplett aus", DetectionHint: "Kanal-Diagnose, Kurzschlusstest", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-CTRL-09", ComponentType: "controller", Mode: "cpu_overload", NameDE: "CPU-Ueberlast", NameEN: "CPU overload", Effect: "Zykluszeit ueberschritten, zeitkritische Funktionen verspaetet", DetectionHint: "Zykluszeitmonitoring, Taskauslastung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-CTRL-10", ComponentType: "controller", Mode: "wrong_firmware_version", NameDE: "Falsche Firmware-Version", NameEN: "Wrong firmware version", Effect: "Inkompatibilitaeten, Sicherheitsfunktionen moeglicherweise unwirksam", DetectionHint: "Versionsabgleich bei Inbetriebnahme", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 3},
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{ID: "FM-CTRL-11", ComponentType: "controller", Mode: "safety_plc_discrepancy", NameDE: "Safety-SPS Kanal-Diskrepanz", NameEN: "Safety PLC channel discrepancy", Effect: "Zweikanalige Auswertung ergibt unterschiedliche Ergebnisse", DetectionHint: "Cross-Monitoring, Diagnosezyklus", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-CTRL-12", ComponentType: "controller", Mode: "common_cause_failure", NameDE: "Gemeinsame-Ursache-Ausfall (CCF)", NameEN: "Common cause failure", Effect: "Beide Kanaele der Safety-SPS fallen gleichzeitig aus", DetectionHint: "Diversitaere Hardware, getrennte Versorgung", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 8},
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{ID: "FM-CTRL-13", ComponentType: "controller", Mode: "unauthorized_access", NameDE: "Unberechtigter Zugriff auf Steuerung", NameEN: "Unauthorized access to controller", Effect: "Parameter oder Programm werden manipuliert", DetectionHint: "Zugangskontrolle, Audit-Log", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 5},
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{ID: "FM-CTRL-14", ComponentType: "controller", Mode: "emc_susceptibility", NameDE: "EMV-Empfindlichkeit", NameEN: "EMC susceptibility", Effect: "Elektromagnetische Stoerung verfaelscht Steuerungssignale", DetectionHint: "EMV-Pruefung, Schirmung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 5},
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{ID: "FM-CTRL-15", ComponentType: "controller", Mode: "power_supply_glitch", NameDE: "Versorgungsspannung Einbruch", NameEN: "Power supply glitch", Effect: "Kurzzeitiger Spannungseinbruch fuehrt zu Steuerungsreset", DetectionHint: "USV, Spannungsueberwachung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 2},
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// Drive-specific
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{ID: "FM-CTRL-16", ComponentType: "controller", Mode: "drive_overspeed", NameDE: "Antriebsregler Ueberdrehzahl", NameEN: "Drive overspeed", Effect: "Motor dreht ueber zulaessige Drehzahl hinaus", DetectionHint: "Sichere Drehzahlueberwachung SLS/SMS", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-CTRL-17", ComponentType: "controller", Mode: "drive_brake_failure", NameDE: "Antriebsbremse versagt", NameEN: "Drive brake failure", Effect: "Achse kann nicht gebremst werden, unkontrollierte Bewegung", DetectionHint: "Bremsentest bei Anlauf, Verschleissanzeige", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
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{ID: "FM-CTRL-18", ComponentType: "controller", Mode: "drive_torque_uncontrolled", NameDE: "Unkontrolliertes Drehmoment", NameEN: "Uncontrolled torque", Effect: "Motor liefert mehr Drehmoment als erwartet", DetectionHint: "Drehmomentueberwachung, STO-Funktion", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
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{ID: "FM-CTRL-19", ComponentType: "controller", Mode: "position_error_accumulation", NameDE: "Positionsfehler-Akkumulation", NameEN: "Position error accumulation", Effect: "Inkrementaler Positionsfehler summiert sich ueber Zeit", DetectionHint: "Referenzfahrt-Intervall, Absolutwertgeber", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 4},
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{ID: "FM-CTRL-20", ComponentType: "controller", Mode: "safe_state_failure", NameDE: "Versagen des sicheren Zustands", NameEN: "Safe state failure", Effect: "Maschine erreicht bei Fehler nicht den definierten sicheren Zustand", DetectionHint: "Safe-State-Test bei Inbetriebnahme", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 5},
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}
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}
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// ── Actuator Failure Modes (15) ────────────────────────────────────
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func getActuatorFailureModes() []FailureModeEntry {
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return []FailureModeEntry{
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{ID: "FM-ACT-01", ComponentType: "actuator", Mode: "stuck_closed", NameDE: "Aktor blockiert (geschlossen)", NameEN: "Actuator stuck closed", Effect: "Ventil/Klappe oeffnet nicht, Prozess wird nicht freigegeben", DetectionHint: "Positionsrueckmeldung, Endlagenschalter", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-ACT-02", ComponentType: "actuator", Mode: "stuck_open", NameDE: "Aktor blockiert (offen)", NameEN: "Actuator stuck open", Effect: "Ventil/Klappe schliesst nicht, Energiezufuhr bleibt aktiv", DetectionHint: "Positionsrueckmeldung, Endlagenschalter", DefaultSeverity: 9, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-ACT-03", ComponentType: "actuator", Mode: "overload", NameDE: "Aktor-Ueberlast", NameEN: "Actuator overload", Effect: "Motor ueberhitzt, Wicklungsschaden, Ausfall", DetectionHint: "Strommessung, Thermoschutz", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-ACT-04", ComponentType: "actuator", Mode: "loss_of_holding_force", NameDE: "Haltekraftverlust", NameEN: "Loss of holding force", Effect: "Last sackt ab, unkontrollierte Bewegung durch Schwerkraft", DetectionHint: "Bremsentest, Druckueberwachung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 4},
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{ID: "FM-ACT-05", ComponentType: "actuator", Mode: "overspeed", NameDE: "Ueberdrehzahl Motor", NameEN: "Motor overspeed", Effect: "Fliehkraefte ueberschreiten zulaessige Werte", DetectionHint: "Drehzahlueberwachung, mechanische Begrenzung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 2},
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{ID: "FM-ACT-06", ComponentType: "actuator", Mode: "bearing_failure", NameDE: "Lagerschaden Motor", NameEN: "Motor bearing failure", Effect: "Erhoehte Vibration, Blockade, Ueberhitzung", DetectionHint: "Vibrationsueberwachung, Geraeuschanalyse", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 4},
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{ID: "FM-ACT-07", ComponentType: "actuator", Mode: "insulation_breakdown", NameDE: "Isolationsversagen Motorwicklung", NameEN: "Motor insulation breakdown", Effect: "Erdschluss, Kurzschluss, Stromschlagrisiko am Gehaeuse", DetectionHint: "Isolationsmessung, RCD", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 4},
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{ID: "FM-ACT-08", ComponentType: "actuator", Mode: "thermal_overload", NameDE: "Thermische Ueberlastung", NameEN: "Thermal overload", Effect: "Motor ueberhitzt, Brandgefahr bei fehlendem Thermoschutz", DetectionHint: "Temperaturueberwachung, Thermoschalter", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
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{ID: "FM-ACT-09", ComponentType: "actuator", Mode: "unexpected_movement", NameDE: "Unerwartete Bewegung", NameEN: "Unexpected movement", Effect: "Aktor bewegt sich ohne Befehl, Person im Gefahrbereich gefaehrdet", DetectionHint: "Rueckmeldung mit Sollwertvergleich, STO", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 3},
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{ID: "FM-ACT-10", ComponentType: "actuator", Mode: "reduced_performance", NameDE: "Leistungsminderung", NameEN: "Reduced performance", Effect: "Kraft oder Geschwindigkeit unter Spezifikation, Prozessqualitaet sinkt", DetectionHint: "Leistungsmessung, Trendanalyse", DefaultSeverity: 4, DefaultOccurrence: 4, DefaultDetection: 4},
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{ID: "FM-ACT-11", ComponentType: "actuator", Mode: "coupling_slip", NameDE: "Kupplungsschlupf", NameEN: "Coupling slip", Effect: "Drehmoment wird nicht vollstaendig uebertragen", DetectionHint: "Soll-Ist-Vergleich Drehzahl, Schwingungsanalyse", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 4},
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{ID: "FM-ACT-12", ComponentType: "actuator", Mode: "pneumatic_cylinder_leak", NameDE: "Pneumatikzylinder-Leckage", NameEN: "Pneumatic cylinder leak", Effect: "Zylinder haelt Position nicht, langsames Absacken", DetectionHint: "Druckabfallmessung, Leckagepruefung", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 4},
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{ID: "FM-ACT-13", ComponentType: "actuator", Mode: "hydraulic_cylinder_drift", NameDE: "Hydraulikzylinder-Drift", NameEN: "Hydraulic cylinder drift", Effect: "Last sackt langsam ab trotz geschlossenem Ventil", DetectionHint: "Positionsueberwachung, Lasthalteventil", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-ACT-14", ComponentType: "actuator", Mode: "contactor_welded", NameDE: "Schuetz verschweisst", NameEN: "Contactor welded", Effect: "Motor kann nicht abgeschaltet werden, Not-Halt unwirksam", DetectionHint: "Ruecklese-Kontakt, Cross-Monitoring", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 2},
|
||||
{ID: "FM-ACT-15", ComponentType: "actuator", Mode: "valve_stiction", NameDE: "Ventil-Losbrechkraft erhoet", NameEN: "Valve stiction", Effect: "Ventil reagiert verzoegert oder gar nicht auf Steuersignal", DetectionHint: "Hubueberwachung, Stellzeit messen", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
}
|
||||
}
|
||||
|
||||
// ── Mechanical Failure Modes (20) ──────────────────────────────────
|
||||
func getMechanicalFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-MECH-01", ComponentType: "mechanical", Mode: "fatigue_fracture", NameDE: "Ermuedungsbruch", NameEN: "Fatigue fracture", Effect: "Bauteil bricht unter Betriebslast, Teile werden herausgeschleudert", DetectionHint: "Risspruefung (zfP), Betriebsstundenzaehler", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 6},
|
||||
{ID: "FM-MECH-02", ComponentType: "mechanical", Mode: "bearing_failure", NameDE: "Lagerschaden", NameEN: "Bearing failure", Effect: "Erhoehte Reibung, Blockade, Erwaermung, Wellenbruch", DetectionHint: "Vibrationsueberwachung, Temperaturmessung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-03", ComponentType: "mechanical", Mode: "corrosion", NameDE: "Korrosion", NameEN: "Corrosion", Effect: "Wandstaerke-Reduktion, Festigkeitsverlust, Undichtheit", DetectionHint: "Sichtpruefung, Wanddickenmessung", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-04", ComponentType: "mechanical", Mode: "loosening", NameDE: "Lockerung von Verbindungselementen", NameEN: "Loosening of fasteners", Effect: "Schrauben/Bolzen lockern sich, Bauteil loest sich", DetectionHint: "Drehmoment-Kontrolle, Sicherungselemente", DefaultSeverity: 7, DefaultOccurrence: 4, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-05", ComponentType: "mechanical", Mode: "wear", NameDE: "Verschleiss", NameEN: "Wear", Effect: "Spielzunahme, Funktionsverlust, erhoehte Geraeusche", DetectionHint: "Spielmessung, Sichtpruefung, Trendanalyse", DefaultSeverity: 5, DefaultOccurrence: 5, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-06", ComponentType: "mechanical", Mode: "overload_deformation", NameDE: "Ueberlast-Verformung", NameEN: "Overload deformation", Effect: "Plastische Verformung, Bauteil bleibt verbogen", DetectionHint: "Kraftueberwachung, Lastzelle", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-07", ComponentType: "mechanical", Mode: "chain_break", NameDE: "Kettenriss", NameEN: "Chain break", Effect: "Kraftuebertragung unterbrochen, Last faellt unkontrolliert", DetectionHint: "Kettenlaengungsmessung, Sichtpruefung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-08", ComponentType: "mechanical", Mode: "belt_slip_break", NameDE: "Riemenschlupf/-riss", NameEN: "Belt slip/break", Effect: "Antrieb verliert Kraftschluss oder Riemen reisst", DetectionHint: "Riemenspannung pruefen, Drehzahlvergleich", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-09", ComponentType: "mechanical", Mode: "gear_tooth_break", NameDE: "Zahnbruch im Getriebe", NameEN: "Gear tooth break", Effect: "Schlagartige Stoerung der Kraftuebertragung, Blockade", DetectionHint: "Koerperschallanalyse, Oelanalyse", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-MECH-10", ComponentType: "mechanical", Mode: "seal_failure", NameDE: "Dichtungsversagen", NameEN: "Seal failure", Effect: "Medium tritt aus, Umweltkontamination, Rutschgefahr", DetectionHint: "Leckage-Sichtpruefung, Druckabfall", DefaultSeverity: 5, DefaultOccurrence: 4, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-11", ComponentType: "mechanical", Mode: "weld_crack", NameDE: "Schweissnahtriss", NameEN: "Weld crack", Effect: "Tragende Verbindung versagt, strukturelles Versagen", DetectionHint: "zfP (Ultraschall, Roentgen), Sichtpruefung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-MECH-12", ComponentType: "mechanical", Mode: "spring_break", NameDE: "Federbruch", NameEN: "Spring break", Effect: "Rueckstellkraft entfaellt, Sicherheitsfunktion versagt", DetectionHint: "Federkraftmessung, praeventiver Tausch", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-MECH-13", ComponentType: "mechanical", Mode: "structural_resonance", NameDE: "Strukturresonanz", NameEN: "Structural resonance", Effect: "Verstaerkte Schwingung, Ermuedungsbruch, Laerm", DetectionHint: "Schwingungsmessung, Modalanalyse", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-MECH-14", ComponentType: "mechanical", Mode: "misalignment", NameDE: "Fluchtungsfehler", NameEN: "Misalignment", Effect: "Erhoehter Verschleiss, Vibration, Lagerschaden", DetectionHint: "Laserausrichtung, Vibrationsmessung", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-15", ComponentType: "mechanical", Mode: "unbalance", NameDE: "Unwucht", NameEN: "Unbalance", Effect: "Vibration, Lagerschaden, Ermuedung bei Rotation", DetectionHint: "Auswuchtmaschine, Schwingungsmessung", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-16", ComponentType: "mechanical", Mode: "clamping_loss", NameDE: "Spannkraftverlust", NameEN: "Clamping force loss", Effect: "Werkstueck oder Werkzeug loest sich waehrend Bearbeitung", DetectionHint: "Spannkraftmessung, Druckueberwachung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-17", ComponentType: "mechanical", Mode: "grinding_wheel_burst", NameDE: "Schleifscheibenbruch", NameEN: "Grinding wheel burst", Effect: "Scheibenfragmente werden mit hoher Energie weggeschleudert", DetectionHint: "Klangpruefung, Drehzahlbegrenzung, Schutzhaube", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-18", ComponentType: "mechanical", Mode: "tool_break", NameDE: "Werkzeugbruch", NameEN: "Tool break", Effect: "Bruchstuecke als Projektile, Werkstueckbeschaedigung", DetectionHint: "Werkzeugbruch-Erkennung, Schutzscheibe", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-MECH-19", ComponentType: "mechanical", Mode: "guide_rail_wear", NameDE: "Fuehrungsschienen-Verschleiss", NameEN: "Guide rail wear", Effect: "Spielzunahme, Positionsungenauigkeit, Ruckeln", DetectionHint: "Spielmessung, praeventiver Tausch", DefaultSeverity: 4, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
{ID: "FM-MECH-20", ComponentType: "mechanical", Mode: "foundation_settlement", NameDE: "Fundamentsetzung", NameEN: "Foundation settlement", Effect: "Maschine steht nicht mehr eben, Ausrichtung verloren", DetectionHint: "Nivellierung pruefen, Bodenscan", DefaultSeverity: 5, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
}
|
||||
}
|
||||
@@ -0,0 +1,112 @@
|
||||
package iace
|
||||
|
||||
// ── Electrical Failure Modes (15) ──────────────────────────────────
|
||||
func getElectricalFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-ELEC-01", ComponentType: "electrical", Mode: "insulation_breakdown", NameDE: "Isolationsversagen", NameEN: "Insulation breakdown", Effect: "Erdschluss, Stromschlagrisiko am Gehaeuse", DetectionHint: "Isolationsmessung, RCD", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-ELEC-02", ComponentType: "electrical", Mode: "short_circuit", NameDE: "Kurzschluss", NameEN: "Short circuit", Effect: "Ueberstrom, Brand, Bauteilzerstoerung", DetectionHint: "Sicherungsautomat, Kurzschlussanzeige", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 2},
|
||||
{ID: "FM-ELEC-03", ComponentType: "electrical", Mode: "overload", NameDE: "Ueberlast Stromkreis", NameEN: "Circuit overload", Effect: "Leitungserwaermung, Isolationsschaeden, Brand", DetectionHint: "Motorschutzschalter, Strommessung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-ELEC-04", ComponentType: "electrical", Mode: "earth_fault", NameDE: "Erdschluss", NameEN: "Earth fault", Effect: "Gefaehrliche Beruehrungsspannung am Maschinengehaeuse", DetectionHint: "RCD, Isolationswaechter", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 2},
|
||||
{ID: "FM-ELEC-05", ComponentType: "electrical", Mode: "contact_failure", NameDE: "Kontaktversagen (Uebergangswiderstand)", NameEN: "Contact failure", Effect: "Erhoehter Widerstand, Erwaermung, intermittierender Ausfall", DetectionHint: "Thermografie, Widerstandsmessung", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
{ID: "FM-ELEC-06", ComponentType: "electrical", Mode: "cable_damage", NameDE: "Kabelbeschaedigung", NameEN: "Cable damage", Effect: "Kurzschluss oder Unterbrechung, Stromschlagrisiko", DetectionHint: "Sichtpruefung, Isolationsmessung", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-ELEC-07", ComponentType: "electrical", Mode: "overvoltage", NameDE: "Ueberspannung", NameEN: "Overvoltage", Effect: "Zerstoerung elektronischer Komponenten, Datenverlust", DetectionHint: "SPD, Spannungsueberwachung", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-ELEC-08", ComponentType: "electrical", Mode: "undervoltage", NameDE: "Unterspannung", NameEN: "Undervoltage", Effect: "Steuerung faellt aus, Aktoren verlieren Haltekraft", DetectionHint: "Spannungsueberwachung, USV", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-ELEC-09", ComponentType: "electrical", Mode: "phase_loss", NameDE: "Phasenverlust (Drehstrom)", NameEN: "Phase loss", Effect: "Motor laeuft auf 2 Phasen, Ueberhitzung, Momentverlust", DetectionHint: "Phasenueberwachungsrelais", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-ELEC-10", ComponentType: "electrical", Mode: "residual_voltage", NameDE: "Restspannung nach Abschaltung", NameEN: "Residual voltage", Effect: "Stromschlag bei Wartung trotz Abschaltung", DetectionHint: "Entladewiderstaende, Spannungspruefung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-ELEC-11", ComponentType: "electrical", Mode: "pe_conductor_break", NameDE: "Schutzleiterbruch", NameEN: "PE conductor break", Effect: "Schutzerdung unwirksam, Gehaeuse wird spannungsfuehrend", DetectionHint: "Schutzleiter-Pruefung, RCD", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-ELEC-12", ComponentType: "electrical", Mode: "arc_flash", NameDE: "Lichtbogenentladung", NameEN: "Arc flash", Effect: "Explosion, Verbrennungen, Blendung", DetectionHint: "Lichtbogenerkennungsschutzschalter", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 3},
|
||||
{ID: "FM-ELEC-13", ComponentType: "electrical", Mode: "fuse_failure", NameDE: "Sicherungsversagen (nicht ausloesend)", NameEN: "Fuse failure to trip", Effect: "Ueberstromschutz unwirksam, nachgelagerte Schaeden", DetectionHint: "Selektivitaetspruefung, Schmelzsicherung pruefen", DefaultSeverity: 8, DefaultOccurrence: 1, DefaultDetection: 5},
|
||||
{ID: "FM-ELEC-14", ComponentType: "electrical", Mode: "electrostatic_discharge", NameDE: "Elektrostatische Entladung (ESD)", NameEN: "Electrostatic discharge", Effect: "Elektronik-Schaeden, Zuendquelle in Ex-Bereichen", DetectionHint: "ESD-Schutz, Erdung", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 5},
|
||||
{ID: "FM-ELEC-15", ComponentType: "electrical", Mode: "harmonic_distortion", NameDE: "Oberschwingungen im Netz", NameEN: "Harmonic distortion", Effect: "Erwaermung Transformatoren, Fehlausloesung RCD", DetectionHint: "Netzqualitaetsmessung, Oberschwingungsfilter", DefaultSeverity: 4, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
}
|
||||
}
|
||||
|
||||
// ── Software Failure Modes (15) ────────────────────────────────────
|
||||
func getSoftwareFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-SW-01", ComponentType: "software", Mode: "unhandled_exception", NameDE: "Unbehandelte Ausnahme", NameEN: "Unhandled exception", Effect: "Programmabsturz, Steuerung friert ein", DetectionHint: "Exception-Logging, Watchdog", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-SW-02", ComponentType: "software", Mode: "race_condition", NameDE: "Race Condition", NameEN: "Race condition", Effect: "Unvorhersehbares Timing, Ausgaben in falscher Reihenfolge", DetectionHint: "Code-Review, Concurrency-Tests", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 7},
|
||||
{ID: "FM-SW-03", ComponentType: "software", Mode: "buffer_overflow", NameDE: "Pufferueberlauf", NameEN: "Buffer overflow", Effect: "Speicherverletzung, Programmabsturz oder Code-Injection", DetectionHint: "Statische Codeanalyse, Fuzzing", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 6},
|
||||
{ID: "FM-SW-04", ComponentType: "software", Mode: "infinite_loop", NameDE: "Endlosschleife", NameEN: "Infinite loop", Effect: "Task blockiert, Watchdog loest aus, Steuerung reagiert nicht", DetectionHint: "Watchdog, Zykluszeitmonitoring", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-SW-05", ComponentType: "software", Mode: "wrong_calculation", NameDE: "Falsche Berechnung", NameEN: "Wrong calculation", Effect: "Falsche Stellgroessen, Grenzwertueberschreitung nicht erkannt", DetectionHint: "Plausibilitaetspruefung, Verifikation", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SW-06", ComponentType: "software", Mode: "division_by_zero", NameDE: "Division durch Null", NameEN: "Division by zero", Effect: "Programmabsturz oder undefinierter Wert in Regelkreis", DetectionHint: "Defensive Programmierung, Code-Review", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-SW-07", ComponentType: "software", Mode: "integer_overflow", NameDE: "Ganzzahlueberlauf", NameEN: "Integer overflow", Effect: "Zaehler springt auf Negativwert, falsche Positionsberechnung", DetectionHint: "Statische Analyse, Grenzwerttest", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SW-08", ComponentType: "software", Mode: "state_machine_deadlock", NameDE: "Zustandsautomat-Deadlock", NameEN: "State machine deadlock", Effect: "Maschine blockiert in undefiniertem Zustand", DetectionHint: "Zustandsdiagramm-Analyse, Timeout-Handling", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SW-09", ComponentType: "software", Mode: "configuration_error", NameDE: "Konfigurationsfehler", NameEN: "Configuration error", Effect: "Falsche Parameter, Grenzwerte oder Ablaufsteuerung", DetectionHint: "Konfigurations-Validierung, Checksumme", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-SW-10", ComponentType: "software", Mode: "update_regression", NameDE: "Regressionsfehler nach Update", NameEN: "Update regression", Effect: "Bestehende Funktion bricht nach Software-Update", DetectionHint: "Regressionstests, Rollback-Plan", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-SW-11", ComponentType: "software", Mode: "timing_violation", NameDE: "Echtzeit-Verletzung", NameEN: "Timing violation", Effect: "Sicherheitsfunktion reagiert zu langsam", DetectionHint: "Worst-Case-Execution-Time-Analyse", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SW-12", ComponentType: "software", Mode: "data_corruption", NameDE: "Datenverfaelschung", NameEN: "Data corruption", Effect: "Prozessdaten oder Safety-Parameter werden verfaelscht", DetectionHint: "CRC/Checksumme, diversitaere Verarbeitung", DefaultSeverity: 9, DefaultOccurrence: 1, DefaultDetection: 4},
|
||||
{ID: "FM-SW-13", ComponentType: "software", Mode: "resource_leak", NameDE: "Ressourcen-Leck", NameEN: "Resource leak", Effect: "Speicher oder Handles gehen ueber Zeit verloren, System wird langsam", DetectionHint: "Langzeit-Monitoring, Heap-Analyse", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 6},
|
||||
{ID: "FM-SW-14", ComponentType: "software", Mode: "wrong_unit_conversion", NameDE: "Falsche Einheitenumrechnung", NameEN: "Wrong unit conversion", Effect: "Werte werden falsch interpretiert (mm vs inch, bar vs psi)", DetectionHint: "Unit-Tests, Plausibilitaetspruefung", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-SW-15", ComponentType: "software", Mode: "log_overflow", NameDE: "Log-Speicher voll", NameEN: "Log overflow", Effect: "Diagnosedaten gehen verloren, Fehleranalyse unmoeglich", DetectionHint: "Log-Rotation, Speicherueberwachung", DefaultSeverity: 3, DefaultOccurrence: 4, DefaultDetection: 3},
|
||||
}
|
||||
}
|
||||
|
||||
// ── Hydraulic/Pneumatic Failure Modes (15) ──────────────────────────
|
||||
func getFluidFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-FLU-01", ComponentType: "hydraulic", Mode: "hose_burst", NameDE: "Schlauchplatzer", NameEN: "Hose burst", Effect: "Unkontrollierter Medienaustritt, Peitscheneffekt, Hautinjektion", DetectionHint: "Druckabfallerkennung, Schlauchbruchventil", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-FLU-02", ComponentType: "hydraulic", Mode: "valve_stuck", NameDE: "Ventil blockiert", NameEN: "Valve stuck", Effect: "Hydraulikzylinder bewegt sich nicht oder haelt nicht", DetectionHint: "Stellungsueberwachung, Druckueberwachung", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-FLU-03", ComponentType: "hydraulic", Mode: "seal_leak", NameDE: "Dichtungsleckage", NameEN: "Seal leakage", Effect: "Druckverlust, Oelkontamination, Rutschgefahr", DetectionHint: "Sichtpruefung, Fuellstandsueberwachung", DefaultSeverity: 5, DefaultOccurrence: 5, DefaultDetection: 3},
|
||||
{ID: "FM-FLU-04", ComponentType: "hydraulic", Mode: "oil_contamination", NameDE: "Oelverschmutzung", NameEN: "Oil contamination", Effect: "Vorzeitiger Komponentenverschleiss, Ventilversagen", DetectionHint: "Oelanalyse, Filterueberwachung", DefaultSeverity: 6, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-05", ComponentType: "hydraulic", Mode: "pump_cavitation", NameDE: "Pumpenkavitation", NameEN: "Pump cavitation", Effect: "Laufradschaeden, Druckverlust, Geraeusche", DetectionHint: "Saugdruckueberwachung, Geraeuschanalyse", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-06", ComponentType: "hydraulic", Mode: "accumulator_failure", NameDE: "Speicherausfall (Hydrospeicher)", NameEN: "Accumulator failure", Effect: "Druckpolster fehlt, Druckspitzen nicht gedaempft", DetectionHint: "Vorfuelldruck pruefen, Blasenspeicher-Test", DefaultSeverity: 6, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-07", ComponentType: "hydraulic", Mode: "pressure_relief_stuck", NameDE: "Druckbegrenzungsventil klemmt", NameEN: "Pressure relief valve stuck", Effect: "Maximaldruck wird ueberschritten, Bersten moeglich", DetectionHint: "Regelmassige Funktionspruefung", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-08", ComponentType: "pneumatic", Mode: "air_leak", NameDE: "Druckluftleckage", NameEN: "Air leak", Effect: "Druckverlust, Zylinder haelt Position nicht", DetectionHint: "Leckagesuchgeraet, Druckabfalltest", DefaultSeverity: 4, DefaultOccurrence: 5, DefaultDetection: 3},
|
||||
{ID: "FM-FLU-09", ComponentType: "pneumatic", Mode: "moisture_in_air", NameDE: "Feuchtigkeit in Druckluft", NameEN: "Moisture in compressed air", Effect: "Korrosion, Ventilversagen, Eisbildung", DetectionHint: "Kondensatableiter pruefen, Taupunktmessung", DefaultSeverity: 5, DefaultOccurrence: 4, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-10", ComponentType: "pneumatic", Mode: "compressor_overheating", NameDE: "Kompressor-Ueberhitzung", NameEN: "Compressor overheating", Effect: "Oeldampf im Druckluftnetz, Brandgefahr", DetectionHint: "Temperaturueberwachung, Thermostat", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-FLU-11", ComponentType: "hydraulic", Mode: "cylinder_drift", NameDE: "Zylinderdrift (Lastabsacken)", NameEN: "Cylinder drift", Effect: "Last sackt langsam ab, Quetschgefahr", DetectionHint: "Positionsueberwachung, Lasthalteventil", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-FLU-12", ComponentType: "hydraulic", Mode: "filter_clogging", NameDE: "Filterverstopfung", NameEN: "Filter clogging", Effect: "Druckdifferenz steigt, Bypass oeffnet, ungefilterte Partikel", DetectionHint: "Differenzdruckschalter, Wartungsintervall", DefaultSeverity: 5, DefaultOccurrence: 4, DefaultDetection: 2},
|
||||
{ID: "FM-FLU-13", ComponentType: "hydraulic", Mode: "pressure_surge", NameDE: "Druckstoss (Joukowsky)", NameEN: "Pressure surge", Effect: "Kurzfristige Druckspitze schaedigt Leitungen und Armaturen", DetectionHint: "Druckstossdaempfer, langsam schliessende Ventile", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 5},
|
||||
{ID: "FM-FLU-14", ComponentType: "hydraulic", Mode: "tank_overflow", NameDE: "Tankueberlauf", NameEN: "Tank overflow", Effect: "Oelverlust, Umweltkontamination, Rutschgefahr", DetectionHint: "Fuellstandsueberwachung mit Alarm", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-FLU-15", ComponentType: "pneumatic", Mode: "quick_exhaust_failure", NameDE: "Schnellentlueftungsventil versagt", NameEN: "Quick exhaust valve failure", Effect: "Zylinder faehrt langsam zurueck, Zykluszeit steigt", DetectionHint: "Positionszeit-Ueberwachung", DefaultSeverity: 4, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
}
|
||||
}
|
||||
|
||||
// ── Safety Device Failure Modes (15) ───────────────────────────────
|
||||
func getSafetyDeviceFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-SAF-01", ComponentType: "safety_device", Mode: "failure_to_trip", NameDE: "Schutzeinrichtung loest nicht aus", NameEN: "Failure to trip", Effect: "Gefahrsituation wird nicht erkannt, Person ungeschuetzt", DetectionHint: "Proof-Test, Funktionspruefung", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 5},
|
||||
{ID: "FM-SAF-02", ComponentType: "safety_device", Mode: "spurious_trip", NameDE: "Fehlausloesung Schutzeinrichtung", NameEN: "Spurious trip", Effect: "Unnoetiger Maschinenstopp, Produktionsverlust, Fehlbedienung", DetectionHint: "Alarmstatistik, Diagnostik", DefaultSeverity: 3, DefaultOccurrence: 4, DefaultDetection: 2},
|
||||
{ID: "FM-SAF-03", ComponentType: "safety_device", Mode: "degraded_response_time", NameDE: "Verlaengerte Reaktionszeit", NameEN: "Degraded response time", Effect: "Maschine stoppt zu spaet, Person wird erfasst", DetectionHint: "Reaktionszeitmessung, Proof-Test", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 6},
|
||||
{ID: "FM-SAF-04", ComponentType: "safety_device", Mode: "guard_bypass", NameDE: "Schutzeinrichtung umgangen", NameEN: "Guard bypass", Effect: "Schutzfunktion komplett unwirksam", DetectionHint: "Manipulationserkennung, Codierung", DefaultSeverity: 10, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SAF-05", ComponentType: "safety_device", Mode: "interlock_wear", NameDE: "Verriegelungs-Verschleiss", NameEN: "Interlock wear", Effect: "Verriegelung greift nicht mehr zuverlaessig", DetectionHint: "Schaltspielzaehler, praeventiver Tausch", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-SAF-06", ComponentType: "safety_device", Mode: "emergency_stop_defect", NameDE: "Not-Halt-Defekt", NameEN: "Emergency stop defect", Effect: "Not-Halt-Taster funktionslos, kein sofortiger Stopp moeglich", DetectionHint: "Taeglicher Funktionstest", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 2},
|
||||
{ID: "FM-SAF-07", ComponentType: "safety_device", Mode: "safety_relay_stuck", NameDE: "Sicherheitsrelais klebt", NameEN: "Safety relay stuck", Effect: "Zwangsgefuehrter Kontakt oeffnet nicht, Abschaltung versagt", DetectionHint: "Zwangsoeffnungspruefung, Cross-Monitoring", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 3},
|
||||
{ID: "FM-SAF-08", ComponentType: "safety_device", Mode: "brake_wear", NameDE: "Bremsenverschleiss", NameEN: "Brake wear", Effect: "Bremswirkung reduziert, Nachlaufweg verlaengert", DetectionHint: "Nachlaufweg-Messung, Bremsmoment-Test", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-SAF-09", ComponentType: "safety_device", Mode: "muting_error", NameDE: "Muting-Fehler (Lichtvorhang)", NameEN: "Muting error", Effect: "Lichtvorhang wird im falschen Moment stummgeschaltet", DetectionHint: "Muting-Logik-Test, Timing-Pruefung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
{ID: "FM-SAF-10", ComponentType: "safety_device", Mode: "common_cause_failure", NameDE: "Gemeinsame-Ursache-Ausfall (CCF)", NameEN: "Common cause failure", Effect: "Beide redundante Kanaele fallen gleichzeitig aus", DetectionHint: "Diversitaet, getrennte Versorgung, DC-Anteil", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 8},
|
||||
{ID: "FM-SAF-11", ComponentType: "safety_device", Mode: "guard_misaligned", NameDE: "Schutzeinrichtung falsch ausgerichtet", NameEN: "Guard misaligned", Effect: "Sicherheitsabstand nicht eingehalten, Zugang zum Gefahrbereich", DetectionHint: "Ausrichtungspruefung, Testkoerper", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-SAF-12", ComponentType: "safety_device", Mode: "safety_function_not_tested", NameDE: "Sicherheitsfunktion nicht getestet", NameEN: "Safety function not tested", Effect: "Unerkannter Defekt, Schutzwirkung ungesichert", DetectionHint: "Proof-Test-Plan, Testprotokoll", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 7},
|
||||
{ID: "FM-SAF-13", ComponentType: "safety_device", Mode: "pl_degradation", NameDE: "PL/SIL-Degradation", NameEN: "PL/SIL degradation", Effect: "Performance Level sinkt unter erforderlichen Wert", DetectionHint: "PL-Validierung, DC-Berechnung", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 6},
|
||||
{ID: "FM-SAF-14", ComponentType: "safety_device", Mode: "enabling_device_failure", NameDE: "Zustimmschalter-Defekt", NameEN: "Enabling device failure", Effect: "Teach-Betrieb ohne Totmann-Sicherung moeglich", DetectionHint: "Funktionspruefung 3-Stufen-Schalter", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-SAF-15", ComponentType: "safety_device", Mode: "restart_interlock_bypass", NameDE: "Wiederanlaufsperre umgangen", NameEN: "Restart interlock bypass", Effect: "Maschine startet automatisch nach Not-Halt ohne Quittierung", DetectionHint: "Wiederanlauf-Test, Softwarepruefung", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 4},
|
||||
}
|
||||
}
|
||||
|
||||
// ── Network Failure Modes (10) ─────────────────────────────────────
|
||||
func getNetworkFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-NET-01", ComponentType: "network", Mode: "packet_loss", NameDE: "Paketverlust", NameEN: "Packet loss", Effect: "Steuerbefehle gehen verloren, Aktor reagiert verzoegert", DetectionHint: "Netzwerk-Monitoring, Retry-Mechanismus", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-NET-02", ComponentType: "network", Mode: "latency_spike", NameDE: "Latenz-Spitze", NameEN: "Latency spike", Effect: "Echtzeitfaehigkeit verloren, Sicherheitsfunktion reagiert zu spaet", DetectionHint: "Jitter-Monitoring, QoS", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4},
|
||||
{ID: "FM-NET-03", ComponentType: "network", Mode: "network_disconnect", NameDE: "Netzwerktrennung", NameEN: "Network disconnect", Effect: "Steuerung verliert Verbindung zu Peripherie", DetectionHint: "Link-Ueberwachung, Heartbeat", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-NET-04", ComponentType: "network", Mode: "man_in_the_middle", NameDE: "Man-in-the-Middle-Angriff", NameEN: "Man-in-the-middle attack", Effect: "Steuerbefehle werden abgefangen oder manipuliert", DetectionHint: "Verschluesselung, Integritaetspruefung", DefaultSeverity: 10, DefaultOccurrence: 1, DefaultDetection: 7},
|
||||
{ID: "FM-NET-05", ComponentType: "network", Mode: "broadcast_storm", NameDE: "Broadcast-Sturm", NameEN: "Broadcast storm", Effect: "Netzwerk ueberlastet, alle Kommunikation blockiert", DetectionHint: "Storm-Control, VLAN-Segmentierung", DefaultSeverity: 7, DefaultOccurrence: 2, DefaultDetection: 3},
|
||||
{ID: "FM-NET-06", ComponentType: "network", Mode: "switch_failure", NameDE: "Switch-Ausfall", NameEN: "Switch failure", Effect: "Netzwerksegment komplett offline", DetectionHint: "Redundanter Switch, Link-Aggregation", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 2},
|
||||
{ID: "FM-NET-07", ComponentType: "network", Mode: "dns_failure", NameDE: "DNS-Ausfall", NameEN: "DNS failure", Effect: "Namensaufloesung versagt, Cloud-Dienste nicht erreichbar", DetectionHint: "Lokale DNS-Cache, IP-Fallback", DefaultSeverity: 4, DefaultOccurrence: 3, DefaultDetection: 2},
|
||||
{ID: "FM-NET-08", ComponentType: "network", Mode: "certificate_expiry", NameDE: "Zertifikat abgelaufen", NameEN: "Certificate expiry", Effect: "TLS-Verbindungen werden abgelehnt, Fernwartung unmoeglich", DetectionHint: "Zertifikats-Monitoring, automatische Erneuerung", DefaultSeverity: 5, DefaultOccurrence: 3, DefaultDetection: 3},
|
||||
{ID: "FM-NET-09", ComponentType: "network", Mode: "protocol_mismatch", NameDE: "Protokoll-Inkompatibilitaet", NameEN: "Protocol mismatch", Effect: "Geraete koennen nicht kommunizieren nach Firmware-Update", DetectionHint: "Versionsmatrix, Kompatibilitaetstest", DefaultSeverity: 6, DefaultOccurrence: 2, DefaultDetection: 4},
|
||||
{ID: "FM-NET-10", ComponentType: "network", Mode: "firewall_misconfiguration", NameDE: "Firewall-Fehlkonfiguration", NameEN: "Firewall misconfiguration", Effect: "Safety-Traffic blockiert oder unsicherer Traffic erlaubt", DetectionHint: "Firewall-Regelaudit, Penetrationstest", DefaultSeverity: 8, DefaultOccurrence: 2, DefaultDetection: 5},
|
||||
}
|
||||
}
|
||||
|
||||
// ── AI/ML Failure Modes (5) ────────────────────────────────────────
|
||||
func getAIFailureModes() []FailureModeEntry {
|
||||
return []FailureModeEntry{
|
||||
{ID: "FM-AI-01", ComponentType: "ai_model", Mode: "model_drift", NameDE: "Modell-Drift", NameEN: "Model drift", Effect: "KI-Modell verliert Genauigkeit ueber Zeit durch veraenderte Daten", DetectionHint: "Performance-Monitoring, Referenzdaten-Test", DefaultSeverity: 7, DefaultOccurrence: 4, DefaultDetection: 5},
|
||||
{ID: "FM-AI-02", ComponentType: "ai_model", Mode: "adversarial_input", NameDE: "Adversarial Input", NameEN: "Adversarial input", Effect: "Gezielt manipulierte Eingaben fuehren zu Fehlklassifikation", DetectionHint: "Input-Validierung, Adversarial-Training", DefaultSeverity: 9, DefaultOccurrence: 2, DefaultDetection: 7},
|
||||
{ID: "FM-AI-03", ComponentType: "ai_model", Mode: "bias", NameDE: "Systematische Verzerrung (Bias)", NameEN: "Systematic bias", Effect: "Modell diskriminiert bestimmte Eingabemuster systematisch", DetectionHint: "Fairness-Metriken, diverse Testdaten", DefaultSeverity: 7, DefaultOccurrence: 3, DefaultDetection: 6},
|
||||
{ID: "FM-AI-04", ComponentType: "ai_model", Mode: "confidence_miscalibration", NameDE: "Konfidenz-Fehlkalibrierung", NameEN: "Confidence miscalibration", Effect: "Modell gibt hohe Konfidenz bei falschen Vorhersagen", DetectionHint: "Kalibrierungskurve, Expected Calibration Error", DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 6},
|
||||
{ID: "FM-AI-05", ComponentType: "ai_model", Mode: "training_data_poisoning", NameDE: "Training-Daten-Vergiftung", NameEN: "Training data poisoning", Effect: "Manipulierte Trainingsdaten fuehren zu fehlerhaftem Modell", DetectionHint: "Datenherkunft pruefen, Anomalieerkennung", DefaultSeverity: 9, DefaultOccurrence: 1, DefaultDetection: 8},
|
||||
}
|
||||
}
|
||||
@@ -0,0 +1,124 @@
|
||||
package iace
|
||||
|
||||
import "testing"
|
||||
|
||||
func TestFailureModeLibrary_Count(t *testing.T) {
|
||||
fms := GetFailureModeLibrary()
|
||||
if len(fms) < 140 {
|
||||
t.Errorf("expected at least 140 failure modes, got %d", len(fms))
|
||||
}
|
||||
t.Logf("Total failure modes: %d", len(fms))
|
||||
}
|
||||
|
||||
func TestFailureModeLibrary_UniqueIDs(t *testing.T) {
|
||||
seen := make(map[string]bool)
|
||||
for _, fm := range GetFailureModeLibrary() {
|
||||
if seen[fm.ID] {
|
||||
t.Errorf("duplicate failure mode ID: %s", fm.ID)
|
||||
}
|
||||
seen[fm.ID] = true
|
||||
}
|
||||
}
|
||||
|
||||
func TestFailureModeLibrary_ValidComponentTypes(t *testing.T) {
|
||||
validTypes := map[string]bool{
|
||||
"sensor": true, "controller": true, "actuator": true,
|
||||
"mechanical": true, "electrical": true, "software": true,
|
||||
"hydraulic": true, "pneumatic": true, "safety_device": true,
|
||||
"network": true, "ai_model": true,
|
||||
}
|
||||
for _, fm := range GetFailureModeLibrary() {
|
||||
if !validTypes[fm.ComponentType] {
|
||||
t.Errorf("FM %s has invalid ComponentType: %s", fm.ID, fm.ComponentType)
|
||||
}
|
||||
}
|
||||
}
|
||||
|
||||
func TestFailureModeLibrary_NonEmptyFields(t *testing.T) {
|
||||
for _, fm := range GetFailureModeLibrary() {
|
||||
if fm.NameDE == "" {
|
||||
t.Errorf("FM %s has empty NameDE", fm.ID)
|
||||
}
|
||||
if fm.Effect == "" {
|
||||
t.Errorf("FM %s has empty Effect", fm.ID)
|
||||
}
|
||||
if fm.DefaultSeverity < 1 || fm.DefaultSeverity > 10 {
|
||||
t.Errorf("FM %s has invalid Severity: %d", fm.ID, fm.DefaultSeverity)
|
||||
}
|
||||
if fm.DefaultOccurrence < 1 || fm.DefaultOccurrence > 10 {
|
||||
t.Errorf("FM %s has invalid Occurrence: %d", fm.ID, fm.DefaultOccurrence)
|
||||
}
|
||||
if fm.DefaultDetection < 1 || fm.DefaultDetection > 10 {
|
||||
t.Errorf("FM %s has invalid Detection: %d", fm.ID, fm.DefaultDetection)
|
||||
}
|
||||
}
|
||||
}
|
||||
|
||||
func TestFailureModeLibrary_ComponentTypeDistribution(t *testing.T) {
|
||||
counts := make(map[string]int)
|
||||
for _, fm := range GetFailureModeLibrary() {
|
||||
counts[fm.ComponentType]++
|
||||
}
|
||||
for ct, n := range counts {
|
||||
t.Logf(" %s: %d failure modes", ct, n)
|
||||
}
|
||||
if len(counts) < 8 {
|
||||
t.Errorf("expected at least 8 component types, got %d", len(counts))
|
||||
}
|
||||
}
|
||||
|
||||
func TestRPZ_Calculation(t *testing.T) {
|
||||
fm := FailureModeEntry{DefaultSeverity: 8, DefaultOccurrence: 3, DefaultDetection: 4}
|
||||
rpz := fm.CalculateRPZ()
|
||||
if rpz != 96 {
|
||||
t.Errorf("expected RPZ 96 (8*3*4), got %d", rpz)
|
||||
}
|
||||
}
|
||||
|
||||
func TestRPZ_Maximum(t *testing.T) {
|
||||
fm := FailureModeEntry{DefaultSeverity: 10, DefaultOccurrence: 10, DefaultDetection: 10}
|
||||
rpz := fm.CalculateRPZ()
|
||||
if rpz != 1000 {
|
||||
t.Errorf("expected RPZ 1000 (10*10*10), got %d", rpz)
|
||||
}
|
||||
}
|
||||
|
||||
func TestRPZ_Threshold(t *testing.T) {
|
||||
below := FailureModeEntry{DefaultSeverity: 5, DefaultOccurrence: 2, DefaultDetection: 3}
|
||||
above := FailureModeEntry{DefaultSeverity: 8, DefaultOccurrence: 4, DefaultDetection: 4}
|
||||
|
||||
if below.CalculateRPZ() >= RPZThresholdAction {
|
||||
t.Error("RPZ 30 should be below threshold 100")
|
||||
}
|
||||
if above.CalculateRPZ() < RPZThresholdAction {
|
||||
t.Errorf("RPZ %d should be above threshold 100", above.CalculateRPZ())
|
||||
}
|
||||
}
|
||||
|
||||
func TestPatternEngine_FailureMode_NilFiresAlways(t *testing.T) {
|
||||
engine := NewPatternEngine()
|
||||
// Without FailureModes in input — all patterns should fire normally
|
||||
result := engine.Match(MatchInput{
|
||||
ComponentLibraryIDs: []string{"C001"},
|
||||
EnergySourceIDs: []string{"EN01"},
|
||||
})
|
||||
if len(result.MatchedPatterns) == 0 {
|
||||
t.Fatal("expected patterns without failure mode filter")
|
||||
}
|
||||
}
|
||||
|
||||
func TestFailureModeLibrary_RPZDistribution(t *testing.T) {
|
||||
actionRequired := 0
|
||||
critical := 0
|
||||
for _, fm := range GetFailureModeLibrary() {
|
||||
rpz := fm.CalculateRPZ()
|
||||
if rpz >= RPZThresholdAction {
|
||||
actionRequired++
|
||||
}
|
||||
if rpz >= 200 {
|
||||
critical++
|
||||
}
|
||||
}
|
||||
t.Logf("RPZ distribution: %d action required (>=100), %d critical (>=200), of %d total",
|
||||
actionRequired, critical, len(GetFailureModeLibrary()))
|
||||
}
|
||||
@@ -50,6 +50,10 @@ type HazardPattern struct {
|
||||
// "hazard" = source only, "hazardous_situation" = person exposed, "harm" = injury.
|
||||
// Empty = default (hazardous_situation).
|
||||
GeneratedHazardType string `json:"generated_hazard_type,omitempty"`
|
||||
// RequiredFailureModes restricts this pattern to fire only when at least one
|
||||
// of the listed failure modes is relevant (by ComponentType match against project components).
|
||||
// Empty/nil = fires regardless of failure modes (backwards compatible).
|
||||
RequiredFailureModes []string `json:"required_failure_modes,omitempty"`
|
||||
}
|
||||
|
||||
// Standard human roles for machinery interaction (ISO 12100 + BetrSichV).
|
||||
|
||||
@@ -88,6 +88,33 @@ func DeriveHazardType(h *Hazard) string {
|
||||
return DefaultHazardType
|
||||
}
|
||||
|
||||
// FailureModeEntry represents a potential failure mode for a component type.
|
||||
// Used for FMEA (Failure Mode and Effects Analysis) — the chain is:
|
||||
// Component → FailureMode → HazardousSituation → Harm.
|
||||
type FailureModeEntry struct {
|
||||
ID string `json:"id"` // e.g. "FM-SEN-01"
|
||||
ComponentType string `json:"component_type"` // e.g. "sensor", "controller"
|
||||
Mode string `json:"mode"` // e.g. "loss_of_signal", "drift"
|
||||
NameDE string `json:"name_de"`
|
||||
NameEN string `json:"name_en"`
|
||||
Effect string `json:"effect"` // System-level effect
|
||||
DetectionHint string `json:"detection_hint"` // How to detect this failure
|
||||
// FMEA scores (each 1-10)
|
||||
DefaultSeverity int `json:"default_severity"` // Impact severity
|
||||
DefaultOccurrence int `json:"default_occurrence"` // How often it occurs
|
||||
DefaultDetection int `json:"default_detection"` // Detectability (10=undetectable, 1=immediately detectable)
|
||||
}
|
||||
|
||||
// CalculateRPZ computes the Risk Priority Number for a failure mode.
|
||||
// RPZ = Severity × Occurrence × Detection. Range: 1-1000.
|
||||
// RPZ > 100: action required. RPZ > 200: critical.
|
||||
func (fm *FailureModeEntry) CalculateRPZ() int {
|
||||
return fm.DefaultSeverity * fm.DefaultOccurrence * fm.DefaultDetection
|
||||
}
|
||||
|
||||
// RPZThresholdAction is the RPZ value above which corrective action is required.
|
||||
const RPZThresholdAction = 100
|
||||
|
||||
// AssessmentType represents the type of risk assessment
|
||||
type AssessmentType string
|
||||
|
||||
|
||||
@@ -17,6 +17,9 @@ type MatchInput struct {
|
||||
// HumanRoles are the human roles interacting with the machine in this project.
|
||||
// Used to filter patterns that only apply to specific roles (e.g. programmer, maintenance_tech).
|
||||
HumanRoles []string `json:"human_roles,omitempty"`
|
||||
// FailureModes are the active failure mode IDs relevant for this project.
|
||||
// Used to filter patterns that require specific failure modes.
|
||||
FailureModes []string `json:"failure_modes,omitempty"`
|
||||
}
|
||||
|
||||
// MatchOutput contains the results of pattern matching.
|
||||
@@ -56,8 +59,9 @@ type PatternMatch struct {
|
||||
RequiresExpert bool `json:"requires_expert,omitempty"`
|
||||
OperationalStates []string `json:"operational_states,omitempty"`
|
||||
StateTransitions []string `json:"state_transitions,omitempty"`
|
||||
HumanRoles []string `json:"human_roles,omitempty"`
|
||||
GeneratedHazardType string `json:"generated_hazard_type,omitempty"`
|
||||
HumanRoles []string `json:"human_roles,omitempty"`
|
||||
GeneratedHazardType string `json:"generated_hazard_type,omitempty"`
|
||||
MatchedFailureModes []string `json:"matched_failure_modes,omitempty"`
|
||||
}
|
||||
|
||||
// HazardSuggestion is a suggested hazard from pattern matching.
|
||||
@@ -209,6 +213,17 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
|
||||
reasons = append(reasons, MatchReason{Type: "human_role", Tag: r, Met: roleSet[r]})
|
||||
}
|
||||
}
|
||||
var matchedFMs []string
|
||||
if len(p.RequiredFailureModes) > 0 {
|
||||
fmSet := toSet(input.FailureModes)
|
||||
for _, fm := range p.RequiredFailureModes {
|
||||
met := fmSet[fm]
|
||||
reasons = append(reasons, MatchReason{Type: "failure_mode", Tag: fm, Met: met})
|
||||
if met {
|
||||
matchedFMs = append(matchedFMs, fm)
|
||||
}
|
||||
}
|
||||
}
|
||||
|
||||
matchedPatterns = append(matchedPatterns, PatternMatch{
|
||||
PatternID: p.ID,
|
||||
@@ -230,6 +245,7 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
|
||||
StateTransitions: p.StateTransitions,
|
||||
HumanRoles: p.HumanRoles,
|
||||
GeneratedHazardType: p.GeneratedHazardType,
|
||||
MatchedFailureModes: matchedFMs,
|
||||
})
|
||||
|
||||
for _, cat := range p.GeneratedHazardCats {
|
||||
@@ -382,6 +398,21 @@ func patternMatches(p HazardPattern, tagSet map[string]bool, input MatchInput) b
|
||||
}
|
||||
}
|
||||
|
||||
// If pattern requires specific failure modes, at least one must match.
|
||||
if len(p.RequiredFailureModes) > 0 && len(input.FailureModes) > 0 {
|
||||
found := false
|
||||
fmSet := toSet(input.FailureModes)
|
||||
for _, fm := range p.RequiredFailureModes {
|
||||
if fmSet[fm] {
|
||||
found = true
|
||||
break
|
||||
}
|
||||
}
|
||||
if !found {
|
||||
return false
|
||||
}
|
||||
}
|
||||
|
||||
return true
|
||||
}
|
||||
|
||||
|
||||
Reference in New Issue
Block a user