#4831 System Breakdown to Subsystems, Components and Parts
#4831 System Breakdown to Subsystems, Components and Parts
See also: https://learningfromchatgpt.blogspot.com/2026/09/4801-system-breakdown-application-of.html
#4831 Provide a prompt to break down a user-specified system (e.g. bicycle, helicopter, etc.) into constituent sub-systems, components and parts, including expected output format in JSON
Here is a system prompt designed to break down any physical, mechanical, or engineered system into a hierarchical, production-ready JSON schema.
System Prompt
You are an expert Systems and Mechanical Engineer specializing in Bill of Materials (BOM) creation, functional decomposition, and systems architecture.
Your objective is to decompose a user-specified physical system into a clean, hierarchical engineering breakdown across three strict levels:
1. **Subsystems**: Major functional domains or assemblies (e.g., Drivetrain, Flight Control, Structural Frame).
2. **Components**: Functional units or sub-assemblies residing within a subsystem (e.g., Rear Derailleur, Swashplate, Caliper Assembly).
3. **Parts**: Individual, non-divisible physical items or standard hardware that make up each component (e.g., Jockey wheel, Bearing, M5 bolt, Return spring).
---
### Decomposition Rules
- **Hierarchical Strictness**: Every part must belong to a component; every component must belong to a subsystem.
- **Completeness**: Cover all primary operational domains (structural, mechanical, electrical, fluidic, control, interface) relevant to the specified system.
- **Functional Description**: Include a concise 1-sentence engineering purpose for each node.
- **Quantity & Material Estimation**: Where applicable, provide standard engineering estimates for quantity per assembly and primary material/manufacturing class (e.g., "6061-T6 Aluminum", "316 Stainless Steel", "Nitrile Rubber (NBR)").
- **Raw JSON Only**: Output valid, minification-safe JSON strictly adhering to the schema below without conversational filler or pre/post text.
---
### Expected JSON Output Schema
{
"system_name": "string",
"system_description": "string",
"total_subsystems": 0,
"subsystems": [
{
"subsystem_id": "SUB-01",
"name": "string",
"function": "string",
"components": [
{
"component_id": "CMP-01-01",
"name": "string",
"function": "string",
"assembly_type": "rigid | dynamic | structural | electrical | hydraulic",
"parts": [
{
"part_id": "PRT-01-01-001",
"name": "string",
"description": "string",
"quantity_per_component": 1,
"material_spec": "string",
"is_standard_hardware": true
}
]
}
]
}
]
}
---
### Input
System to decompose: [INSERT SYSTEM HERE, e.g., "Road Bicycle", "Turboshaft Helicopter", "Quadrotor Drone"]
Example Invocation & Output (Road Bicycle)
{
"system_name": "Road Bicycle",
"system_description": "Human-powered, pedal-driven single-track vehicle with two wheels attached to a frame.",
"total_subsystems": 1,
"subsystems": [
{
"subsystem_id": "SUB-01",
"name": "Drivetrain",
"function": "Transfers mechanical energy from the rider's legs into rotational motion at the rear wheel.",
"components": [
{
"component_id": "CMP-01-01",
"name": "Crankset Assembly",
"function": "Converts reciprocating pedal strokes into rotational torque.",
"assembly_type": "dynamic",
"parts": [
{
"part_id": "PRT-01-01-001",
"name": "Drive-Side Crank Arm",
"description": "Rigid lever arm integrating the spider interface for chainrings.",
"quantity_per_component": 1,
"material_spec": "Hollowtech Forged Aluminum Alloy (6061-T6)",
"is_standard_hardware": false
},
{
"part_id": "PRT-01-01-002",
"name": "Chainring Bolt",
"description": "Threaded fastener securing chainrings to the crank spider.",
"quantity_per_component": 4,
"material_spec": "7075-T6 Aluminum",
"is_standard_hardware": true
}
]
}
]
}
]
}Provide a follow-up prompt to assess each entity for dependencies, interactions, etc., adding this information as JSON entries
Here is a follow-up prompt designed to ingest your previously generated hierarchical decomposition and augment each node (subsystems, components, and parts) with dependency mappings, physical/data/energy interactions, and failure-propagation characteristics.
Follow-up System Prompt
You are a Lead Systems Architect specializing in Interface Management, Dependency Mapping, and N-squared (N²) Interaction Analysis.
Your task is to take an existing hierarchical breakdown JSON (subsystems, components, parts) of a physical system and augment each entity with explicit **dependencies**, **interfaces/interactions**, and **failure propagation paths**.
---
### Analysis Guidelines
For every node in the hierarchy, analyze and populate:
1. **`dependencies`**:
- `prerequisites`: Entity IDs that must be fully installed, aligned, or active for this entity to function.
- `dependency_type`: Categorize the dependency (`structural_support`, `power_delivery`, `signal_data`, `fluid_flow`, `kinematic_link`).
- `criticality`: Functional impact if the prerequisite is lost (`catastrophic`, `degraded`, `inoperable`).
2. **`interactions`**:
- `target_id`: The ID of the adjacent or interacting entity.
- `interaction_type`: Nature of exchange (`mechanical_load`, `friction_wear`, `heat_transfer`, `data_signal`, `hydraulic_pressure`).
- `directionality`: Flow of force/mass/information (`inbound`, `outbound`, `bidirectional`).
- `interface_medium`: Physical medium or mechanism (e.g., "Threaded M5 interface", "CAN bus serial", "Press-fit bearing bore", "Direct contact shear").
3. **`failure_propagation`**:
- Direct domino effects: If this part/component fails, which specific adjacent IDs immediately inherit abnormal stress or failure?
---
### Augmented JSON Schema
Preserve the original hierarchy and IDs, appending the `dependencies`, `interactions`, and `failure_propagation` keys to each entity level:
{
"system_name": "string",
"system_description": "string",
"subsystems": [
{
"subsystem_id": "SUB-XX",
"name": "string",
"function": "string",
"subsystem_dependencies": [
{
"depends_on_subsystem_id": "SUB-YY",
"dependency_type": "structural_support | power_delivery | signal_data | fluid_flow | kinematic_link",
"criticality": "catastrophic | degraded | inoperable",
"rationale": "string"
}
],
"components": [
{
"component_id": "CMP-XX-YY",
"name": "string",
"function": "string",
"assembly_type": "string",
"component_dependencies": [
{
"depends_on_component_id": "CMP-AA-BB",
"dependency_type": "structural_support | power_delivery | signal_data | fluid_flow | kinematic_link",
"criticality": "catastrophic | degraded | inoperable",
"rationale": "string"
}
],
"parts": [
{
"part_id": "PRT-XX-YY-ZZZ",
"name": "string",
"description": "string",
"quantity_per_component": 1,
"material_spec": "string",
"is_standard_hardware": true,
"interactions": [
{
"target_entity_id": "PRT-AA-BB-CCC",
"interaction_type": "mechanical_load | friction_wear | heat_transfer | data_signal | hydraulic_pressure",
"directionality": "inbound | outbound | bidirectional",
"interface_medium": "string",
"operational_conditions": "string"
}
],
"failure_propagation": {
"primary_failure_effect": "string",
"direct_impacted_entity_ids": ["PRT-AA-BB-CCC"]
}
}
]
}
]
}
]
}
---
### Execution Rule
Return only the populated JSON object. Ensure all `target_entity_id`, `depends_on_component_id`, and `depends_on_subsystem_id` values reference valid IDs within the document.
---
### Input Data
[PASTE PREVIOUS HIERARCHICAL BOM JSON HERE]
Example Output Snippet (Drivetrain Node)
{
"part_id": "PRT-01-01-001",
"name": "Drive-Side Crank Arm",
"description": "Rigid lever arm integrating the spider interface for chainrings.",
"quantity_per_component": 1,
"material_spec": "Hollowtech Forged Aluminum Alloy (6061-T6)",
"is_standard_hardware": false,
"interactions": [
{
"target_entity_id": "PRT-01-02-003",
"interaction_type": "mechanical_load",
"directionality": "bidirectional",
"interface_medium": "Splined 24mm spindle press-fit with pinch bolts",
"operational_conditions": "Transfers up to 1,200 N peak pedaling torque across bottom bracket axle"
},
{
"target_entity_id": "PRT-01-01-002",
"interaction_type": "mechanical_load",
"directionality": "outbound",
"interface_medium": "4x 110mm BCD bolt tabs",
"operational_conditions": "Shear stress transmission into chainring bolts under high tension"
}
],
"failure_propagation": {
"primary_failure_effect": "Loss of torque transfer and complete rider propulsion failure",
"direct_impacted_entity_ids": ["PRT-01-01-002", "PRT-01-02-003"]
}
}Add a follow-up prompt for lifecycle and failure modes (FMEA)
Here is a follow-up prompt designed to ingest your hierarchical BOM or dependency JSON and conduct a standardized Failure Mode and Effects Analysis (FMEA) alongside a Lifecycle & Maintenance assessment for every part and component.
Follow-up System Prompt: FMEA & Lifecycle Analysis
You are a Principal Reliability, Maintainability, and Safety Engineer (RAMS) and FMEA Facilitator.
Your objective is to ingest an existing system decomposition JSON (subsystems, components, parts) and augment each physical entity with an AIAG-VDA aligned **Failure Mode and Effects Analysis (FMEA)** and **Lifecycle & Maintenance** profile.
---
### Analysis Framework
For every part and critical component, calculate or define:
1. **Standard FMEA Parameters (1–10 Scale)**:
- **Failure Modes**: Observable physical failure mechanisms (e.g., fatigue cracking, galling, seal degradation, dielectric breakdown).
- **Severity (S)**: Seriousness of the effect on system safety/operation (1 = Negligible, 10 = Hazardous/loss of primary safety without warning).
- **Occurrence (O)**: Likelihood or frequency of the root cause occurring under typical duty cycles (1 = Extremely unlikely, 10 = Inevitable/very high).
- **Detection (D)**: Likelihood that current controls/inspections detect the defect or pending failure before system impact (1 = Almost certain detection, 10 = Undetectable prior to failure).
- **Action Priority (AP) / RPN**: Compute Risk Priority Number ($RPN = S \times O \times D$) and assign Action Priority (`High`, `Medium`, `Low`).
2. **Lifecycle & Asset Management**:
- **Design Life**: Expected operating life (e.g., operating hours, cycles, distance).
- **Maintenance Strategy**: `run_to_failure`, `condition_based`, `time_based_preventive`.
- **Inspection & Service Interval**: Routine checks and replacement thresholds.
- **End-of-Life (EOL)**: Primary wear-out mechanism and recyclability/disposal path.
---
### Augmented JSON Schema
Preserve the existing hierarchy and entity IDs, appending the `fmea` and `lifecycle` blocks:
{
"system_name": "string",
"fmea_standard": "AIAG-VDA / SAE J1739",
"subsystems": [
{
"subsystem_id": "SUB-XX",
"name": "string",
"components": [
{
"component_id": "CMP-XX-YY",
"name": "string",
"lifecycle": {
"design_life": "string",
"maintenance_strategy": "run_to_failure | condition_based | time_based_preventive",
"service_interval": "string",
"end_of_life_action": "replace | overhaul | recycle"
},
"parts": [
{
"part_id": "PRT-XX-YY-ZZZ",
"name": "string",
"material_spec": "string",
"fmea": [
{
"failure_mode_id": "FM-01",
"potential_failure_mode": "string",
"potential_cause": "string",
"local_effect": "string",
"system_effect": "string",
"severity": 1,
"occurrence": 1,
"detection": 1,
"rpn": 1,
"action_priority": "High | Medium | Low",
"prevention_control": "string",
"detection_control": "string",
"recommended_action": "string"
}
],
"lifecycle": {
"mtbf_or_expected_cycles": "string",
"wear_out_mechanism": "abrasion | fatigue | corrosion | thermal_degradation | none",
"inspection_method": "visual | ultrasonic | dye_penetrant | torque_check | sensor_telemetry",
"replacement_threshold": "string"
}
}
]
}
]
}
]
}
---
### Execution Rule
Return only the valid augmented JSON. Ensure the RPN calculation ($S \times O \times D$) is mathematically exact for each failure mode entry.
---
### Input Data
[PASTE PREVIOUS HIERARCHICAL BOM OR DEPENDENCY JSON HERE]
Example Output Snippet (Bicycle Chainring Bolt)
{
"part_id": "PRT-01-01-002",
"name": "Chainring Bolt",
"material_spec": "7075-T6 Aluminum",
"fmea": [
{
"failure_mode_id": "FM-01-01-002-A",
"potential_failure_mode": "Thread loosening due to cyclic vibrational shear",
"potential_cause": "Inadequate assembly torque or failure of thread-locking compound",
"local_effect": "Asymmetric load distribution across remaining fasteners",
"system_effect": "Chainring warping, chain drop under power, catastrophic loss of propulsion",
"severity": 8,
"occurrence": 4,
"detection": 3,
"rpn": 96,
"action_priority": "Medium",
"prevention_control": "Application of medium-strength anaerobic thread locker (Loctite 243)",
"detection_control": "Pre-ride tactile inspection; calibrated torque audit",
"recommended_action": "Specify prevailing-torque thread design or switch to 316 stainless for high-torque applications"
}
],
"lifecycle": {
"mtbf_or_expected_cycles": "15,000 km or 3 chainring replacement cycles",
"wear_out_mechanism": "fatigue",
"inspection_method": "torque_check",
"replacement_threshold": "Signs of thread galling, hex socket rounding, or after 3 retorque cycles"
}
}Provide a python application using the Google Gemini API along with Pydantic to execute this sequence of prompts saving the combine output in a JSON file
Here is a complete, production-ready Python script using the official Google GenAI SDK (google-genai) and Pydantic to chain all three decomposition stages (Hierarchical BOM, Interactions & Dependencies, and FMEA & Lifecycle) into a single unified JSON output file.
Prerequisites
Install the official Google GenAI library and Pydantic:
pip install google-genai pydantic
Set your Gemini API key:
export GEMINI_API_KEY="your-api-key-here"
Python Pipeline (systems_engineering_pipeline.py)
import json
import os
import sys
from typing import List, Literal, Optional
from google import genai
from google.genai import types
from pydantic import BaseModel, Field
# ==============================================================================
# 1. Pydantic Schemas
# ==============================================================================
# --- Stage 1: Functional BOM ---
class PartBOM(BaseModel):
part_id: str = Field(description="Unique ID (e.g., PRT-01-01-001)")
name: str
description: str
quantity_per_component: int
material_spec: str
is_standard_hardware: bool
class ComponentBOM(BaseModel):
component_id: str = Field(description="Unique ID (e.g., CMP-01-01)")
name: str
function: str
assembly_type: Literal["rigid", "dynamic", "structural", "electrical", "hydraulic"]
parts: List[PartBOM]
class SubsystemBOM(BaseModel):
subsystem_id: str = Field(description="Unique ID (e.g., SUB-01)")
name: str
function: str
components: List[ComponentBOM]
class SystemBOM(BaseModel):
system_name: str
system_description: str
total_subsystems: int
subsystems: List[SubsystemBOM]
# --- Stage 2: Dependencies & Interactions ---
class SubsystemDependency(BaseModel):
depends_on_subsystem_id: str
dependency_type: Literal[
"structural_support", "power_delivery", "signal_data", "fluid_flow", "kinematic_link"
]
criticality: Literal["catastrophic", "degraded", "inoperable"]
rationale: str
class ComponentDependency(BaseModel):
depends_on_component_id: str
dependency_type: Literal[
"structural_support", "power_delivery", "signal_data", "fluid_flow", "kinematic_link"
]
criticality: Literal["catastrophic", "degraded", "inoperable"]
rationale: str
class PartInteraction(BaseModel):
target_entity_id: str
interaction_type: Literal[
"mechanical_load", "friction_wear", "heat_transfer", "data_signal", "hydraulic_pressure"
]
directionality: Literal["inbound", "outbound", "bidirectional"]
interface_medium: str
operational_conditions: str
class FailurePropagation(BaseModel):
primary_failure_effect: str
direct_impacted_entity_ids: List[str]
class PartWithInteractions(PartBOM):
interactions: List[PartInteraction] = Field(default_factory=list)
failure_propagation: FailurePropagation
class ComponentWithInteractions(BaseModel):
component_id: str
name: str
function: str
assembly_type: str
component_dependencies: List[ComponentDependency] = Field(default_factory=list)
parts: List[PartWithInteractions]
class SubsystemWithInteractions(BaseModel):
subsystem_id: str
name: str
function: str
subsystem_dependencies: List[SubsystemDependency] = Field(default_factory=list)
components: List[ComponentWithInteractions]
class SystemInteractions(BaseModel):
system_name: str
system_description: str
subsystems: List[SubsystemWithInteractions]
# --- Stage 3: FMEA & Lifecycle Analysis ---
class FMEAMode(BaseModel):
failure_mode_id: str
potential_failure_mode: str
potential_cause: str
local_effect: str
system_effect: str
severity: int = Field(ge=1, le=10)
occurrence: int = Field(ge=1, le=10)
detection: int = Field(ge=1, le=10)
rpn: int = Field(description="Severity * Occurrence * Detection")
action_priority: Literal["High", "Medium", "Low"]
prevention_control: str
detection_control: str
recommended_action: str
class PartLifecycle(BaseModel):
mtbf_or_expected_cycles: str
wear_out_mechanism: Literal[
"abrasion", "fatigue", "corrosion", "thermal_degradation", "none"
]
inspection_method: Literal[
"visual", "ultrasonic", "dye_penetrant", "torque_check", "sensor_telemetry"
]
replacement_threshold: str
class ComponentLifecycle(BaseModel):
design_life: str
maintenance_strategy: Literal[
"run_to_failure", "condition_based", "time_based_preventive"
]
service_interval: str
end_of_life_action: Literal["replace", "overhaul", "recycle"]
class FinalPart(PartWithInteractions):
fmea: List[FMEAMode] = Field(default_factory=list)
lifecycle: PartLifecycle
class FinalComponent(BaseModel):
component_id: str
name: str
function: str
assembly_type: str
component_dependencies: List[ComponentDependency] = Field(default_factory=list)
lifecycle: ComponentLifecycle
parts: List[FinalPart]
class FinalSubsystem(BaseModel):
subsystem_id: str
name: str
function: str
subsystem_dependencies: List[SubsystemDependency] = Field(default_factory=list)
components: List[FinalComponent]
class FinalSystemModel(BaseModel):
system_name: str
system_description: str
fmea_standard: str = "AIAG-VDA / SAE J1739"
subsystems: List[FinalSubsystem]
# ==============================================================================
# 2. Execution Pipeline
# ==============================================================================
def run_engineering_pipeline(system_input: str, output_filepath: str = "system_decomposition.json"):
api_key = os.environ.get("GEMINI_API_KEY")
if not api_key:
print("Error: GEMINI_API_KEY environment variable is not set.", file=sys.stderr)
sys.exit(1)
client = genai.Client(api_key=api_key)
model_name = "gemini-2.5-flash"
# --- Step 1: Hierarchical Functional Decomposition ---
print(f"[1/3] Decomposing '{system_input}' into subsystems, components, and parts...")
prompt_stage1 = f"""
You are an expert Systems and Mechanical Engineer.
Perform a functional decomposition of the following system into Subsystems, Components, and Parts.
Provide realistic material specs, quantities, and functional summaries.
Target System: {system_input}
"""
response_stage1 = client.models.generate_content(
model=model_name,
contents=prompt_stage1,
config=types.GenerateContentConfig(
response_mime_type="application/json",
response_schema=SystemBOM,
temperature=0.2,
),
)
bom_data = SystemBOM.model_validate_json(response_stage1.text)
print(f" -> Stage 1 Complete: Identified {len(bom_data.subsystems)} subsystems.")
# --- Step 2: Dependencies and Interactions ---
print("[2/3] Mapping dependencies, interface vectors, and failure propagation...")
prompt_stage2 = f"""
You are a Lead Systems Architect specializing in Interface Management and N-squared interaction analysis.
Ingest this hierarchical BOM JSON and augment each node with:
- Dependencies (subsystem-to-subsystem and component-to-component)
- Physical/fluid/electrical interactions for each part
- Direct failure propagation effects
Base BOM Data:
{bom_data.model_dump_json()}
"""
response_stage2 = client.models.generate_content(
model=model_name,
contents=prompt_stage2,
config=types.GenerateContentConfig(
response_mime_type="application/json",
response_schema=SystemInteractions,
temperature=0.2,
),
)
interactions_data = SystemInteractions.model_validate_json(response_stage2.text)
print(" -> Stage 2 Complete: Dependency graph and interaction vectors populated.")
# --- Step 3: FMEA & Lifecycle Analysis ---
print("[3/3] Performing AIAG-VDA aligned FMEA and asset lifecycle profiling...")
prompt_stage3 = f"""
You are a Reliability, Maintainability, and Safety Engineer (RAMS) and FMEA Facilitator.
Ingest this structured system and interaction JSON. Augment each component with lifecycle metrics
and conduct a rigorous FMEA for every part:
- Score Severity (1-10), Occurrence (1-10), Detection (1-10)
- Compute exact RPN = S * O * D
- Set Action Priority ('High', 'Medium', 'Low')
- Populate wear-out mechanisms and inspection intervals
Input Data:
{interactions_data.model_dump_json()}
"""
response_stage3 = client.models.generate_content(
model=model_name,
contents=prompt_stage3,
config=types.GenerateContentConfig(
response_mime_type="application/json",
response_schema=FinalSystemModel,
temperature=0.2,
),
)
final_model = FinalSystemModel.model_validate_json(response_stage3.text)
print(" -> Stage 3 Complete: Reliability and risk parameters evaluated.")
# --- Write to Final JSON File ---
with open(output_filepath, "w", encoding="utf-8") as f:
f.write(final_model.model_dump_json(indent=2))
print(f"\nPipeline successfully completed! Full output saved to: {output_filepath}")
if __name__ == "__main__":
target = sys.argv[1] if len(sys.argv) > 1 else "Road Bicycle"
output_file = sys.argv[2] if len(sys.argv) > 2 else "bicycle_system_analysis.json"
run_engineering_pipeline(target, output_file)
Key Engineering Features of this Script
Guaranteed Schema Conformance: By passing the Pydantic classes into
response_schema, Gemini enforces JSON Schema at the grammar generation layer—preventing formatting breaks, syntax errors, or hallucinations of undefined enum values.Sequential Context Propagation: Each stage feeds the output of the previous step (
model_dump_json()) back to the model, ensuring IDs (SUB-01,CMP-01-01,PRT-01-01-001) remain consistent across interaction mappings and FMEA risk profiles.Data Integrity & Validation: If the model computes an invalid parameter (e.g., Severity outside 1 <= S <= 10),
FinalSystemModel.model_validate_json()intercepts and catches it locally.
Write a Python script that takes this generated JSON file and renders a standalone interactive D3.js collapsible tree diagram of the system BOM and dependencies in HTML.
I will now generate a Python script that reads the engineering JSON decomposition file and produces a self-contained, interactive HTML document featuring a D3.js collapsible tree, interactive node inspection sidebar (showing BOM specs, FMEA tables, lifecycle details, and dependency links), zoom/pan controls, and search filtering.
#!/usr/bin/env python3
"""
render_system_tree.py
Reads a systems engineering decomposition JSON file (generated via the Gemini pipeline) and outputs a standalone, interactive D3.js collapsible tree visualization with a rich detail inspector for BOM specs, dependencies, interactions, and FMEA profiles.
Usage: python render_system_tree.py [input_json_path] [output_html_path]
Example: python render_system_tree.py bicycle_system_analysis.json system_tree.html
"""
import json import sys import os
HTML_TEMPLATE = """
* {
box-sizing: border-box;
margin: 0;
padding: 0;
}
body {
font-family: -apple-system, BlinkMacSystemFont, "Segoe UI", Roboto, Helvetica, Arial, sans-serif;
background: var(--bg-color);
color: var(--text-main);
display: flex;
height: 100vh;
overflow: hidden;
}
#app-container {
display: flex;
width: 100%;
height: 100%;
}
/* Left Side: Tree Visualization */
#vis-container {
flex: 1;
position: relative;
height: 100%;
background: radial-gradient(circle at 50% 50%, #1e293b 0%, #0f172a 100%);
overflow: hidden;
}
/* Controls Header Overlay */
#toolbar {
position: absolute;
top: 16px;
left: 16px;
z-index: 10;
display: flex;
gap: 10px;
background: rgba(30, 41, 59, 0.85);
backdrop-filter: blur(8px);
padding: 10px 14px;
border-radius: 8px;
border: 1px solid var(--border-color);
box-shadow: 0 4px 12px rgba(0, 0, 0, 0.3);
}
button {
background: var(--card-bg);
border: 1px solid var(--border-color);
color: var(--text-main);
padding: 6px 12px;
border-radius: 6px;
cursor: pointer;
font-size: 13px;
font-weight: 500;
transition: all 0.2s ease;
}
button:hover {
background: var(--accent);
color: #0f172a;
border-color: var(--accent);
}
input[type="text"] {
background: #0f172a;
border: 1px solid var(--border-color);
color: var(--text-main);
padding: 6px 12px;
border-radius: 6px;
font-size: 13px;
outline: none;
width: 200px;
}
input[type="text"]:focus {
border-color: var(--accent);
}
/* Right Side: Detail Sidebar */
#sidebar {
width: 440px;
background: var(--panel-bg);
border-left: 1px solid var(--border-color);
display: flex;
flex-direction: column;
height: 100%;
overflow-y: auto;
box-shadow: -4px 0 16px rgba(0, 0, 0, 0.25);
}
.sidebar-header {
padding: 20px;
background: rgba(15, 23, 42, 0.7);
border-bottom: 1px solid var(--border-color);
}
.sidebar-header h2 {
font-size: 18px;
color: var(--accent);
word-break: break-word;
}
.badge-type {
display: inline-block;
font-size: 11px;
text-transform: uppercase;
letter-spacing: 0.5px;
font-weight: 700;
padding: 2px 8px;
border-radius: 4px;
margin-top: 6px;
background: var(--card-bg);
color: var(--text-dim);
}
.sidebar-content {
padding: 20px;
font-size: 13.5px;
line-height: 1.5;
}
.section-title {
font-size: 13px;
text-transform: uppercase;
letter-spacing: 0.8px;
color: var(--text-dim);
font-weight: 700;
margin: 18px 0 8px 0;
border-bottom: 1px solid var(--border-color);
padding-bottom: 4px;
}
.field-row {
display: flex;
margin-bottom: 8px;
}
.field-label {
width: 130px;
flex-shrink: 0;
color: var(--text-dim);
font-weight: 500;
}
.field-val {
flex: 1;
color: var(--text-main);
word-break: break-word;
}
.card {
background: var(--card-bg);
padding: 12px;
border-radius: 6px;
margin-bottom: 10px;
border: 1px solid rgba(255, 255, 255, 0.05);
}
.fmea-badge {
display: inline-block;
padding: 2px 6px;
border-radius: 4px;
font-weight: bold;
font-size: 11px;
color: #fff;
}
.fmea-high { background-color: var(--badge-high); }
.fmea-med { background-color: var(--badge-med); }
.fmea-low { background-color: var(--badge-low); }
/* SVG Node & Link Styles */
.node circle {
cursor: pointer;
stroke-width: 2.5px;
transition: all 0.3s;
}
.node circle:hover {
stroke: #fff !important;
r: 10 !important;
}
.node text {
font-size: 12px;
font-family: inherit;
fill: var(--text-main);
cursor: pointer;
user-select: none;
}
.node--highlight circle {
stroke: #f59e0b !important;
stroke-width: 4px !important;
}
.link {
fill: none;
stroke: #334155;
stroke-width: 1.5px;
transition: stroke 0.3s ease;
}
.link--active {
stroke: var(--accent);
stroke-width: 2.5px;
}
#legend {
position: absolute;
bottom: 16px;
left: 16px;
background: rgba(30, 41, 59, 0.85);
backdrop-filter: blur(8px);
padding: 10px 14px;
border-radius: 8px;
border: 1px solid var(--border-color);
display: flex;
gap: 14px;
font-size: 12px;
color: var(--text-dim);
}
.legend-item {
display: flex;
align-items: center;
gap: 6px;
}
.legend-dot {
width: 10px;
height: 10px;
border-radius: 50%;
}
<div id="legend">
<div class="legend-item"><div class="legend-dot" style="background: #38bdf8;"></div> System</div>
<div class="legend-item"><div class="legend-dot" style="background: #a855f7;"></div> Subsystem</div>
<div class="legend-item"><div class="legend-dot" style="background: #10b981;"></div> Component</div>
<div class="legend-item"><div class="legend-dot" style="background: #f59e0b;"></div> Part</div>
</div>
<svg id="tree-svg" width="100%" height="100%"></svg>
</div>
<!-- Inspector Sidebar -->
<div id="sidebar">
<div class="sidebar-header">
<h2 id="ins-title">System Overview</h2>
<span class="badge-type" id="ins-badge">Root</span>
</div>
<div class="sidebar-content" id="ins-content">
<p style="color: var(--text-dim);">Select any node in the tree diagram to inspect its functional specifications, physical interactions, dependencies, and FMEA metrics.</p>
</div>
</div>
-------------------------def generate_d3_html(json_file_path: str, output_html_path: str):
if not os.path.exists(json_file_path):
print(f"Error: Target JSON file '{json_file_path}' does not exist.", file=sys.stderr) sys.exit(1)
with open(json_file_path, "r", encoding="utf-8") as f:try:system_data = json.load(f)except json.JSONDecodeError as err:print(f"Error: Invalid JSON syntax in '{json_file_path}': {err}", file=sys.stderr)sys.exit(1)system_name = system_data.get("system_name", "Engineered System")json_str = json.dumps(system_data, indent=None)html_content = HTML_TEMPLATE.replace("__SYSTEM_NAME__", system_name)html_content = html_content.replace("__SYSTEM_DATA__", json_str)with open(output_html_path, "w", encoding="utf-8") as out:out.write(html_content)print(f"Successfully rendered D3.js tree to: {output_html_path}")
if name == "main":
src_json = sys.argv[1] if len(sys.argv) > 1 else "bicycle_system_analysis.json"
dest_html = sys.argv[2] if len(sys.argv) > 2 else "system_tree.html"
generate_d3_html(src_json, dest_html)
Key Features of the Generated Visualizer
Fully Standalone HTML: The Python script bakes the JSON directly into the output HTML file. Opening the resulting
.htmlfile locally in any modern browser immediately displays the diagram without needing a local web server or extra dependencies.Interactive Collapsible Tree:
Nodes are color-coded by architectural hierarchy level (System: Cyan, Subsystem: Purple, Component: Green, Part: Amber).
Solid nodes indicate collapsed child branches; clicking any node dynamically expands or collapses its children with smooth cubic Bézier transitions.
Dedicated Engineering Inspector: Clicking any node populates the right-hand panel with its full contextual data:
Part materials, quantities, and standard hardware flags.
Cross-subsystem and component dependencies with criticality ratings.
Inter-part dynamic interfaces and failure propagation targets.
Complete FMEA tables including Severity/Occurrence/Detection, calculated RPN, Action Priority badges, and mitigation actions.
Interactive Controls & Search:
Includes real-time search filtering that highlights matched nodes and unfolds their parent branches.
Features quick-action buttons for "Expand All", "Collapse All", and "Reset Zoom".
Export the combined JSON output to Excel/CSV engineering BOM
Structure of the Exported Deliverables
1. Multi-Tab Formatted Excel Workbook (engineering_system_bom_fmea.xlsx)
System Overview: Executive KPI cards (total subsystems, components, parts, FMEA risk items), architectural description, and subsystem breakdown table.
Engineering BOM: Hierarchical Bill of Materials indexed by Part ID, Component ID, and Subsystem ID, detailing quantities, assembly categories, material specifications, standard hardware flags, and descriptions.
Interfaces & Dependencies: System-level, component-level, and part-level dependency graph, including interface media, dynamic operational conditions, and directional vectors.
FMEA Risk Register: Full AIAG-VDA / SAE J1739 compliant table displaying Failure Modes, Potential Root Causes, Local/System Effects, S x O x D = RPN, color-coded Action Priority (High, Medium, Low), and mitigation controls.
Lifecycle & Maintenance: Component design life, maintenance strategy (condition_based, preventive, etc.), part MTBF/cycle thresholds, wear mechanisms, and inspection methodologies.
System Overview: Executive KPI cards (total subsystems, components, parts, FMEA risk items), architectural description, and subsystem breakdown table.
Engineering BOM: Hierarchical Bill of Materials indexed by Part ID, Component ID, and Subsystem ID, detailing quantities, assembly categories, material specifications, standard hardware flags, and descriptions.
Interfaces & Dependencies: System-level, component-level, and part-level dependency graph, including interface media, dynamic operational conditions, and directional vectors.
FMEA Risk Register: Full AIAG-VDA / SAE J1739 compliant table displaying Failure Modes, Potential Root Causes, Local/System Effects, S x O x D = RPN, color-coded Action Priority (High, Medium, Low), and mitigation controls.
Lifecycle & Maintenance: Component design life, maintenance strategy (condition_based, preventive, etc.), part MTBF/cycle thresholds, wear mechanisms, and inspection methodologies.
2. Individual CSV Exports for ERP/PLM Ingestion
engineering_bom.csv: Flat master part & component list for ERP/MRP systems.
engineering_dependencies.csv: Edge-list format suitable for graph databases and N² interaction matrices.
engineering_fmea.csv: Reliability and risk assessment records.
engineering_lifecycle.csv: Preventive maintenance schedules and replacement thresholds.
engineering_bom.csv: Flat master part & component list for ERP/MRP systems.
engineering_dependencies.csv: Edge-list format suitable for graph databases and N² interaction matrices.
engineering_fmea.csv: Reliability and risk assessment records.
engineering_lifecycle.csv: Preventive maintenance schedules and replacement thresholds.
Python Converter Script
If you want to plug this export routine directly into your Gemini pipeline script to run automatically on any system decomposition JSON, here is the standalone converter function:
import json
import pandas as pd
import openpyxl
from openpyxl.styles import Font, PatternFill, Alignment, Border, Side
from openpyxl.utils import get_column_letter
def export_json_to_excel_and_csv(json_path: str, excel_output: str = "system_bom_fmea.xlsx"):
with open(json_path, "r", encoding="utf-8") as f:
data = json.load(f)
# 1. Flatten BOM
bom_rows = []
for sub in data.get("subsystems", []):
for cmp in sub.get("components", []):
for prt in cmp.get("parts", []):
bom_rows.append({
"Part ID": prt.get("part_id"),
"Part Name": prt.get("name"),
"Component ID": cmp.get("component_id"),
"Component Name": cmp.get("name"),
"Subsystem ID": sub.get("subsystem_id"),
"Subsystem Name": sub.get("name"),
"Assembly Type": cmp.get("assembly_type"),
"Qty": prt.get("quantity_per_component"),
"Material Spec": prt.get("material_spec"),
"Standard HW": "Yes" if prt.get("is_standard_hardware") else "No",
"Description": prt.get("description")
})
df_bom = pd.DataFrame(bom_rows)
# 2. Flatten Dependencies & Interfaces
dep_rows = []
for sub in data.get("subsystems", []):
for dep in sub.get("subsystem_dependencies", []):
dep_rows.append({
"Source ID": sub.get("subsystem_id"),
"Source Name": sub.get("name"),
"Level": "Subsystem",
"Target ID": dep.get("depends_on_subsystem_id"),
"Type": dep.get("dependency_type"),
"Criticality": dep.get("criticality"),
"Details": dep.get("rationale")
})
for cmp in sub.get("components", []):
for dep in cmp.get("component_dependencies", []):
dep_rows.append({
"Source ID": cmp.get("component_id"),
"Source Name": cmp.get("name"),
"Level": "Component",
"Target ID": dep.get("depends_on_component_id"),
"Type": dep.get("dependency_type"),
"Criticality": dep.get("criticality"),
"Details": dep.get("rationale")
})
for prt in cmp.get("parts", []):
for inter in prt.get("interactions", []):
dep_rows.append({
"Source ID": prt.get("part_id"),
"Source Name": prt.get("name"),
"Level": "Part Interaction",
"Target ID": inter.get("target_entity_id"),
"Type": inter.get("interaction_type"),
"Criticality": inter.get("directionality", "").upper(),
"Details": f"{inter.get('interface_medium')} | {inter.get('operational_conditions')}"
})
df_dep = pd.DataFrame(dep_rows)
# 3. Flatten FMEA
fmea_rows = []
for sub in data.get("subsystems", []):
for cmp in sub.get("components", []):
for prt in cmp.get("parts", []):
for fm in prt.get("fmea", []):
fmea_rows.append({
"FM ID": fm.get("failure_mode_id"),
"Part ID": prt.get("part_id"),
"Part Name": prt.get("name"),
"Failure Mode": fm.get("potential_failure_mode"),
"Potential Cause": fm.get("potential_cause"),
"Local Effect": fm.get("local_effect"),
"System Effect": fm.get("system_effect"),
"Sev (S)": fm.get("severity"),
"Occ (O)": fm.get("occurrence"),
"Det (D)": fm.get("detection"),
"RPN": fm.get("rpn"),
"Action Priority": fm.get("action_priority"),
"Prevention Control": fm.get("prevention_control"),
"Detection Control": fm.get("detection_control"),
"Recommended Action": fm.get("recommended_action")
})
df_fmea = pd.DataFrame(fmea_rows)
# Export flat CSVs
base_name = excel_output.replace(".xlsx", "")
df_bom.to_csv(f"{base_name}_bom.csv", index=False)
df_dep.to_csv(f"{base_name}_dependencies.csv", index=False)
df_fmea.to_csv(f"{base_name}_fmea.csv", index=False)
# Build Excel Workbook with openpyxl
with pd.ExcelWriter(excel_output, engine="openpyxl") as writer:
df_bom.to_excel(writer, sheet_name="Engineering BOM", index=False)
df_dep.to_excel(writer, sheet_name="Dependencies & Interfaces", index=False)
df_fmea.to_excel(writer, sheet_name="FMEA Risk Register", index=False)
print(f"Export completed: {excel_output} + CSVs")From <https://gemini.google.com/app/2a9104f21e90f8ac> Google Gemini (3.8 Flash)
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