ITI-Symposium 2014 Model based Systems Engineering using SimulationX and ModelCenter Gerhard Pregitzer1, Alexander Blumör1, Dr. Sven Kleiner2, Dr. Marcus Krastel2, Michael Neubert2 1 KARL MAYER Textilmaschinenfabrik GmbH, Brühlstraße 2, 63179 Obertshausen www.karlmayer.com, [email protected] 2 :em engineering methods AG, Rheinstr. 97, 64295 Darmstadt, www.em.ag, [email protected] Summary: The introduction of Systems Engineering (SE) for the mechatronic product development is important even in classic engineering companies and shall be discussed. Therefore, companies are asking the question, what added value is offered by the integration of SE with respect to their conventional and established development process as well as what benefits will arise with respect to a shortening of the development time, cost savings such as an increase in productivity, quality and innovation. Rightly so, the question must also be asked, how high the investments in Systems Engineering processes, methods and IT- Tools are to be expected for a company. In the following contribution the challenges and benefits of SE will be presented. The deliberate introduction of “Model Based Systems Engineering” (MBSE) can aid in the conversion from a document-centered approach to a model-based development methodology in order to exploit the desired potential benefits. This paper presents the experience of the introduction and adaptation of MBSE based on the example of machine development. Zusammenfassung: Die Einführung von Systems Engineering (SE) für die mechatronische Produktentwicklung gewinnt auch in den klassischen Maschinen- bauunternehmen an Bedeutung und wird diskutiert. Unternehmen stellen sich dabei die Frage, was Ihnen der Einsatz von SE bezogen auf ihre konventionellen und etablierten Entwicklungsprozesse an Mehrwert bietet und welcher Nutzen hinsichtlich Verkürzung der Entwicklungszeit, Kosteneinsparung sowie Steigerung von Produktivität, Qualität und Innovation daraus entsteht. Zu Recht muss auch die Frage gestellt werden, wie sich die Investitionen in Systems Engineering Prozesse, Methoden und IT-Werkzeuge für ein Unternehmen rechnen. Im vorliegenden Beitrag werden dazu Herausforderungen und Nutzen von SE dargestellt. Die gezielte Einführung von „Model Based Systems Engineering“ (MBSE) kann dabei helfen von der dokumentenzentrierten Vorgehensweise zu einer modellbasierten Entwicklungsmethodik zu gelangen, um die gewünschten Nutzenpotentiale auszuschöpfen. Der vorliegende Beitrag zeigt die Erfahrung aus der Einführung und Erstanwendung von MBSE am Beispiel der Maschinenentwicklung auf. 1 TI-Symposium 2014 1 Quick introduction to Systems Engineering The Gesellschaft für Systems Engineering (GfSE e.V. which is the german chapter of INCOSE, International Council of Systems Engineering) describes Systems Engineering (SE) as a comprehensive engineering activity, which is necessary for the development of complex products [GfSE14]. The tasks associated with SE are varied and start with requirements engineering and system analysis and range to system development to safeguarding and testing. Due to the variety of disciplines involved in today’s innovative product development processes, such as mechanics, electronics, and software, the mastery of SE is increasingly becoming a real competitive advantage for companies. With the requirements for solutions in the context of Industrie 4.0 and the development of so-called cyber physical products presents new challenges. A competitive development of these products and systems without the introduction of a SE- Methodology is not feasible [MCP14]. A large number of companies currently fear a high methodological, organizational and financial expense in the introduction of SE: there is a lack in both the procedural and organizational basis as well as in experience and competencies for a successful introduction of SE in practice. The idea of an overall concept and presentation of the benefits of the introduction of SE in companies are critical in convincing the decision- makers to carry out such measures. 2 Benefits of Systems Engineering Companies face a legitimate question when considering and implementing SE, what SE offers with regard to value-added based on their conventional and established development processes. Therefore, the question must be asked whether and when the investment in SE methods and IT tools will pay off for a company. In the work „Systems Engineering Return on Investment“ by Eric C. Honour from the year 2013 a wide-ranging study of the return on investment (ROI) was calculated for Systems Engineering [HON13]. Thereby 51 development programs from 16 companies in the aerospace and the defense industry were analyzed. A key finding was that the optimal cost for SE lies at around 14.4% of the total development costs for an average development program (approximately 14 million EUR development budget). For smaller or larger programs and depending on other characteristics (depth of system integration, size of the system, Technological risk, etc.) the value may vary between 8% and 19%. For an average sized program the calculated SE-ROI was 3.5:1. 2 ITI-Symposium 2014 Figure 1: Benefits linked to the use of systems engineering components Figure 1 shows the points at which the benefit of SE can be generated. Through SE the transition from today’s numerous trial and prototype-driven functional verification to virtual system verification is made possible (1). Additionally both the development time (3) as well as the development costs (2) can be reduced. The benefits of SE are therefore combination of several effects [KK14]: SE helps to master the complexity of a system: The networking of the systems will grow massively through current and future innovations and the control of these cross-domain dependencies and relationships can only be mastered with SE methods. The transparency and traceability of dependencies are an integral part of increasing the efficiency of the development process. Through the use of SE methods interdisciplinary change processes can be introduced and implemented. SE enables interdisciplinary quality management and validation: The conformity of the system properties to the requirements (e.g. customer requirements, standards, certifications or country regulations) with respect to individual components and the overall system must be ensured during the development process. This is where the SE method comes into play, as it provides an assessment of the degree of fulfillment of requirements based on the total system throughout the development process. SE reduces Hardware and Prototypes: In particular, in the established experimental and calculation disciplines the number of real hardware tests has been significantly reduced by use of simulation, thus saving development time and cost. This development experiences your continuation in the increasing virtualization of validation - that is, in a 3 TI-Symposium 2014 transition from hardware- (HiL) via software- (SiL) to model-in-the-Loop (MiL) tests. To the same extent, through SE multidisciplinary system behavior can be integrated in early stages of development by networking behavior simulations from different disciplines. The presence of appropriate tool interface allows the re-use of behavior models for virtual testing in all Model granularities and thus in all phases of the development process. Thus, the number of hardware prototypes will be reduced by the early virtual validation. SE enables cooperative development processes: Cooperation with suppliers and development partners as well as OEM / OEM cooperation is in the design sector and in particular the exchange of CAD data has long been standard practice. With SE-methods the integration of suppliers for requirements definition, system design and optimization solution can also be made possible in the early stages of product development. This is supported by the increasing standardization of interfaces for tool coupling. An example of this is the Functional Mock-up Interface reference, a tool-independent standard for the exchange functional behavior models. [FMI14]. The overarching goal of SE is to increase the efficiency in the development of mechatronic systems by providing model-based methods and formulate the continuous networking of heterogeneous development tools. 3 Challenges in Systems Engineering The development process is characterized by constant decisions between different concepts and solution alternatives in order to achieve the best solution for the product. As a rule, there is a trade-off between the number of possible solutions and the amount of time available for the project development in order to evaluate all solution alternatives and make decisions early. An approach for the systematic development of solution concepts, system architectures and components based on the model-based systems engineering (MBSE), for example, provides the so-called FAS method [FAS14]. The method "Functional Architecture for Systems" (FAS) is understood as a communication tool and can be used to derive architecture decisions. The FAS method is independent of modeling languages and modeling tools. Modeling tools based on the SysML language support the model-based analysis and synthesis of systems from the perspective of the system engineer [Wei08]. At the same time, among other things requirement, functional and architectural models are developed, which are supplemented by the first parameter and behavior models in the design phase to the system level. Through which the so-called