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21. Whole-life engineering digital thread

The lifespan is not a feed of notes. It is a linked digital thread from design intent through manufacture, commissioning, operation, care, service, modification, transfer, restoration, repurpose and retirement. Every important change connects an exact…

Concept & directionLNK

The lifespan is not a feed of notes. It is a linked digital thread from design intent through manufacture, commissioning, operation, care, service, modification, transfer, restoration, repurpose and retirement. Every important change connects an exact baseline to an exact result while preserving the parts, people, tools, materials, software, evidence, rights and approvals involved.

Twelve-phase vehicle lifecycle from design and build through operation, care, maintenance, modification, verification, transfer, restoration, repurpose and retirement.
Picture 6

The asset remains durable while configuration, state, condition, custody and approvals change on separate planes.

#21.1 Five state planes

State planeChanged byExamples
Design baselineReleased design revision, approved deviation or waiverWing revision, gearbox definition, harness drawing, software requirement
Realized configurationInstallation, removal, connection, material load, deployment or software/calibration assignmentBattery swap, new propeller, temporary camera, firmware deployment
Operational stateNormal operation, motion, mode or resource changeJoint angle, landing gear position, tank level, road/water mode, controller engaged
Condition stateWear, inspection, damage, fault, contamination or repair assessmentCorrosion, tire wear, low battery health, crack, fouling, finish condition
Legal / approval stateAuthority, organizer, insurer or owner decisionAirworthiness, road authorization, race eligibility, deferred defect, restriction
Table
Avoid snapshot explosion
A robot moving a joint does not create a new engineering configuration every millisecond. The installed topology stays in ConfigurationSnapshot; pose and resource values belong in OperationalStateSnapshot. A discrete, safety-gated transformation can reference a MorphModeDefinition and a resulting configuration only when topology or controlled effectivity truly changes.

#21.2 Configuration-item kinds

Item kindIdentity behavior
Design definition / revisionIntended product, part, material, feature, software, task or test definition
Physical serialized instanceIndividually traceable frame, engine, battery, propeller, wheelset, controller or tool
Lot / batchShared manufacturing/material provenance without individual serialization
Integral featureHole, weld, adhesive bead, coating layer, repair patch, reinforcement or machining feature
Bulk material / substanceFluid, gas, coating, adhesive, propellant, lubricant, ballast, feedstock or mixture
Consumable / life itemFilter, tire, brake material, desiccant, chemical, sealant or component depleted by use
Software / firmwareExact signed executable, package, library, operating system, rules or map artifact
Calibration / parameter setVersioned values, maps, curves, limits, learned parameters and target compatibility
AI model / persona artifactWeights/service digest, runtime, inputs/outputs, evaluation, domain, limitations and authority class
Data / content artifactTechnical document, CAD/mesh, test data, manual, media, canon, prompt or evidence bundle
Tooling / support equipmentFixture, charger, diagnostic tool, launch/recovery gear, mold, stand or transport cradle
Temporary payload / attachmentMission kit, camera, cargo module, implement, carried vehicle or leased attachment

#21.3 Parallel BOM and structure views

ViewQuestion
Engineering BOMWhat does the released design define?
Manufacturing BOM / processWhat is built, in what sequence, with which materials and tooling?
Procurement / supplierWhat can be sourced, substituted, certified, costed and warranted?
Service / illustrated partsWhat is maintained, removed, replaced, inspected and provisioned?
Software / calibrationWhat artifacts, dependencies, targets, partitions and parameters are required?
Material / substanceWhat grades, lots, compositions, regulated substances and mixtures are present?
Mass / balanceWhich items and loads contribute to mass, CG/CB and inertia?
Cost / carbonWhich costs and environmental impacts are allocated under which method/boundary?
As-built / as-deliveredWhat physical configuration left production and entered custody?
As-maintained / as-repairedWhat does service evidence say is installed and repaired?
As-operated / as-testedWhat exact build, load, software, settings and connections produced the operation/result?
As-retiredWhat was removed, harvested, destroyed, recycled, retained or transferred?
  • BOM membership never proves installation; a realized placement and installation event are required.
  • One item can appear in product, function, location, power, fluid, data, control, safety, maintenance, ownership and certification structures simultaneously.
  • A configuration node can reference an item, material quantity, feature, software, calibration or data artifact; edges carry typed placement, connection and effectivity.
  • Exclusive slot occupancy cannot overlap. Shared cloud services, broadcast signals and non-exclusive functional providers use explicitly non-exclusive relations.

#21.4 Effectivity and applicability

Applicability must evaluate to TRUE, FALSE, UNKNOWN or ERROR. Missing serial, configuration, jurisdiction or software data cannot become FALSE and cannot authorize work. Expressions may combine time, identifier ranges, design revisions, installed items, quantities, versions, relationships, jurisdiction, operation mode and namespaced domain operators.

Operator familyExamples
BooleanALL, ANY, NOT, XOR with explanation tree
ComparisonEQ, NEQ, GT/GTE, LT/LTE, BETWEEN, IN
PresenceEXISTS, IS_UNKNOWN, HAS_COMPONENT, HAS_MODIFICATION, HAS_PORT
VersionVERSION_EQ, VERSION_RANGE, REVISION_AT_LEAST, DIGEST_EQ
TemporalBEFORE, AFTER, DURING, OVERLAPS, METER_SINCE, EVENT_SINCE
QuantityDimension-aware unit conversion, range, tolerance and uncertainty
GraphCONNECTED_TO, INSTALLED_IN, POWERED_BY, COUNT, ALL_MEMBERS, ANY_MEMBER
ContextJURISDICTION_IN, DOMAIN_MATCHES, OPERATION_MODE_IN, CONTROL_MODE_IN

#21.5 Maintenance program and task anatomy

LayerRequired content
Strategycalendar/usage/cycle preventive; event-triggered; condition-based; predictive; opportunity; corrective; emergency; inspection; calibration; care; preservation; overhaul; directive/recall
Trigger / intervalcalendar, distance, hours, starts, landings, laps, missions, pressure/thermal cycles, charge-equivalent cycles, throughput, exposure, condition threshold or named event
Applicabilitytarget selector, configuration, design revision, installed options, software, jurisdiction, duty and environmental state
Prerequisitesisolation, safe state, access, cleanliness, environment, tools, support equipment, skills and permits
Procedureordered steps, warnings, parameters, target, hold points, witnesses, conditional branches and evidence
As foundcondition, measurements, findings, contamination, faults, photos/scans and uncertainty
Work executionactual workers, times, steps, parts, lots, materials, tools, deviations, interruptions and signoffs
Close / releaseas-left condition, measurements, tests, unresolved findings, limitations, release authority and next due
Table
Meter rules
Distance, time, cycles, starts, launches, landings, pressure events, energy throughput and component-specific meters are independent. Resetting, replacing or overhauling never erases the prior reading. A component carries its meters when removed and reused; zero-time or life-reset status requires an explicit policy and authority.

#21.6 Care, wash, detailing, and preservation execution

AreaRecord fields
Target + conditionsurface/zone/component, configuration, contamination before, finish/coating and protected ports
Activityrinse, hand/touchless/pressure/steam wash, degrease, decontaminate, polish, correct paint, coat, disinfect, defoul, preserve or depreserve
Materialsproduct/lot, pH, dilution, water source/hardness, pad/brush/media and compatibility
Processtemperature, pressure, nozzle, stand-off, dwell, agitation, abrasive grade, drying and masking
Environment + wastelocation/privacy, weather, energization, runoff capture, waste, biosecurity and jurisdiction
Evidence + findingsbefore/during/after media, gloss/thickness/roughness, newly exposed damage and public derivative
Outcomecondition after, protection applied, cure/expiry, cost, provider, next care and story rights

The same contract supports a car-wash photo, salt removal from a truck, aircraft wash, underwater hull biofouling removal, blimp-envelope cleaning, RC-car bearing protection and museum conservation. A care task can finish successfully while independently creating a defect record when cleaning reveals damage.

#21.7 Modification, fabrication, and tuning

LayerRequired content
Definitionpurpose, baseline/effectivity, planned change operations, target outcome, interface/material/software deltas and rollback
Impact assessmentmass/CG/inertia, structure/fatigue, energy/range, thermal, handling, braking, safety, reliability, emissions/noise, cyber, privacy, approvals, value
Embodimentactual removal/installation/fabrication, material lots, tools/machines, process parameters, workers, deviations and as-built evidence
Tuning/calibrationparameter schema, baseline, changed values/maps, protected limits, target compatibility, dyno/simulation/field evidence and rollback artifact
Verificationinspection, NDT, dimensional checks, functional test, dyno, software diagnostics, acceptance criteria and anomalies
Releaseapproval basis, limitations, maintenance instructions, competition/warranty/insurance impact, new configuration and public disclosure
Reversalnew work and configuration that reverses effects; original history remains and full reversibility is never assumed

#21.8 Software, calibration, and AI deployment

AreaRequired record
Artifact identitykind, supplier/author, version claim, exact digest, signature, package IDs, license and release notes
Build provenancesource revisions, builder/toolchain, dependencies/lockfiles, feature flags, environment, tests and attestation
Compatibilitytarget controller/item, partition, hardware/design revision, operating system, interfaces and effectivity
Deploymentinstaller, method, previous artifact, active/standby state, secure boot, anti-rollback, activation and post-install test
Calibrationparameter schema/values, units, target, author/tool, as-found/as-left, protected limits, evidence and approval
AI modelpurpose, authority class, runtime, input/output schemas, training provenance claims, evaluation, ODD, limitations and monitoring
Rollbackknown-good artifact, compatibility, trigger, state migration, evidence and incident linkage
Table
Authority class is structural
A vehicle persona, diagnostic assistant and steering controller may all use AI models, but their allowed output ports, grants, evidence and safety partitions differ. Sharing a model/runtime concept never grants the social plane access to a physical-control interface.

#21.9 Restoration, repurpose, salvage, and retirement

DispositionRequired distinction
Preservation / conservationArrest deterioration and stabilize historic material without inventing original state
Repair / restorationRestore function or a documented earlier state; mark and document replacement/reproduction parts
Reconstruction / replica / recreationCreate missing or representative material under a new or explicit continuity relationship
Restomod / rebuildCombine historic continuity with deliberate modern change; disclose removed/retained substance and identity policy
Repurpose / second lifeSame component/asset can gain a new duty, configuration, approvals and responsible operator
Part harvestDonor, removal, as-removed condition, traceability, inspection, reuse eligibility and new custody
Unsalvageable dispositionQuarantine, permanent service ineligibility, mutilation or controlled research/display use
Recycle / destroy / consume / loseMaterial outputs, hazardous inventory, facility, certificates, retained evidence and identity disposition