Design Failure Modes Effects Analysis (DFMEA)

When a system is designed, risk must be calculated and accounted for. As Table 1 illustrates, the closed
loop motor control project also includes risk to be managed. As the system was developed, design choices
were made to ensure that a more secure product was built. Our team began a simple design for our system
and moved forward to implementation. To carry signals from the Tohoku DC Motor to the Quansar Q4
Encoder Port 0, the initial design called for a standard telephone cable with 4 wires encapsulated in one
insulator and terminated at each end with an RJ12 connection. The RJ12 terminators were stripped,
leaving 4 22 AWG stranded wires. It was assumed that these wires were of a sufficient gauge to carry the
signal and to handle the fatigue induced at the terminals. However, testing soon showed that the cable did
not offer adequate resistance to fatigue and upon failure, the motor spun at a very high speed without user
interaction since the control system had lost its feedback mechanism. As the block diagram in Figure 1
shows, the system was redesigned to account for this failure mode and a thicker cable was used to reduce
the probability of this failure mode in the future. As additional safety issues were discovered, their risk
quantified, and if necessary, steps were taken to reduce the probability of the event. In this fashion, risks
were quantified in the DFMEA matrix in Table 1 and addressed as needed. After the discussed safety
analysis, the team concluded that the solution for project managed risk to an acceptable level for the
project.
Figure 1: DFMEA Block Diagram and Actions Taken

System designed to meet specifications

Enumerate risk using DFMEA table

i.e. Discover encoder risk of
encoder cable failure

Discuss accident scenarios

i.e. motor spinning uncontrollably

Determine probability of failure event

i.e. initial cabling give high probability
of failure due to fatigue

Determine consequences of accident

i.e. Operator could injure hand or clock
hand could be damaged

Quantify risk with DFMEA Table

Implement design
modified for safety
(Done)

No

Yes
Is the risk for all hazards acceptable?

Modify design
i.e. use lower
gauge wire

Table 1: DFMEA Table for Project 5: Closed Loop Motor Control

Description
of
Component
or Subsystem
Encoder
connection

Failure Mode
(Hazard)

Symptom

Effect

Probability
of Failure

Severity
of Effect

Risk
Index

Cable Broken

Feedback does
not work

II

II-C

Cable Frayed

Feedback
works
intermittently

II

II-D

Board
Connection
Broken

Feedback
works
intermittently
or not at all

III

III-D

Connection to
motor
fatigued/broken

Motor power
fluctuates
randomly

IV

IV-C

Disconnected
Cable

No power to
motor

IV

IV-C

Clock Hand
Connection

Clock hand
loosely connected
or joint fatigued

Clock hand
wobbles or is
loose

IV

IV-D

Motor to
Board
Connection

Motor loosely
connected or joint
fatigued

Motor wobbles
or oscillates
during
operation

Without
feedback, motor
could spin at
high speed
Motor could
spin at high
speed without
any user input
Motor could
spin at high
speed and fail to
respond to user
commands
Possible
exposed
energized cable,
damage to user
if proper safety
protocols not
followed
Possible
exposed live
wire
Hand could fly
off and damage
operator or
system
Motor could
disengage from
table and
damage
operator or
system

II

II-D

Amplifier
Connection