Analysis and synthesis of robust sensory functions—A digitally supported methodology for systematic identification and consideration of critical disturbance factors

Abstract Disturbance factors from the use context of sensory functions can have a significant impact on the reliability of the measurement data provided. To prevent costly and time-consuming iterations due to insufficient robustness in their development, a methodology for analysis and synthesis of robust sensory functions is presented. The methodology enables the systematic and comprehensive identification of critical disturbance factors and their subsequent consideration by means of suitable measures based on established approaches from Robust Design and Measurement Engineering. In the analysis part of the methodology, disturbance factors are first identified by systematically analyzing the use context of the sensory function with a disturbance factor matrix. The identified disturbance factors are then analyzed and selected in regard of their impact on the sensory function. Therefore, an abstraction on the level of physical effects is carried out. The identified disturbance factors are then evaluated in regard of their severity and significance in a modified FMEA. Based on the evaluation results, a reasoned and objective decision regarding the criticality of disturbance factors and their respective impacts on a sensory function is drawn. In the subsequent synthesis part of the methodology, measures for consideration of critical disturbance factors are first developed systematically and comprehensively. Therefore, a flow chart is used. The developed measures are then evaluated using a utility analysis and a standardized evaluation target system. Based on the evaluations results, a reasoned decision regarding the measures to be implemented is drawn. To facilitate the application of the methodology, an existing effect graph tool is taken up and functionally extended. Finally, the effectiveness of the methodology is experimentally verified using the example of an inventive sensory function for radial offset and rotational frequency measurement of a disk pack coupling. Furthermore, a user study is conducted to assess the methodology’s efficiency and usability.