Complex technical systems such as autonomous driving, the electrification of car powertrains and the networking of machines and systems are increasing the complexity of product development processes to an unprecedented degree. At the same time, the legal framework is changing. Customers and authorities are increasingly demanding comprehensive verification requirements for the consistency of development processes and traceability of the entire product development process as part of product liability. Only a holistic approach to product development creates the necessary transparency for all groups involved. In terms of product lifecycle management (PLM), systems engineering spans the entire process from the determination of requirements through technical implementation and the finished product to recycling. The many disciplines such as mechanics, electrics/electronics and software in new products require companies to fully master systems engineering in order to gain a clear competitive advantage. Competitive development of mechatronic products cannot be realized without the introduction of a consistent systems engineering method.

When developing cars, different engineering disciplines have to work together in the engineering process.

© Dassault Systèmes

The use of systems engineering offers customers considerable advantages:

• Reduction of costs for real test vehicles through early model-based validation for hardware and software.
• Early, interdisciplinary quality management through the networking or integration of partial models from the various engineering disciplines into an overall system.
• Reduction or improved manageability of complexity during development through a systematic approach "from rough to detailed".
• Simplification of cooperation (customer-supplier, joint venture) and thus a significant improvement in efficiency through the exchange of executable models.
• Improved risk assessment and increased product quality with a simultaneous reduction in time-to-market.
• Greater product maturity right from the first generation; the end user receives a product that is less susceptible to faults much earlier.
• Fewer complaints or recalls and therefore an increase in brand reputation.

MBSE improves product development

One method of systems engineering is Model Based Systems Engineering (MBSE). System development, which today is still predominantly document-centered using specifications containing thousands of requirements, can be significantly improved using the model-based development methodology MBSE. It describes all requirements and specifications for the subsequent product and coordinates its entire life cycle, including quality tests and requirements for subsequent recycling.

Model-based also means that there is only one digital representation of the project on which all participants work in a globally distributed development process. This automatically creates the necessary collaboration and networking between the interdisciplinary teams within the digitalized product development process. Every single change is immediately visible to everyone on the work platform. Only one current version is ever available (single source of truth). This avoids errors and saves time and costs. MBSE completely maps the respective system including its sub-systems and also allows its evaluation. The developers derive the necessary processes and tools from the customer requirements and describe these in a comprehensible manner using various models. A critical success factor lies in the consistency of the data or the repeatability of the processes. MBSE integrates the existing models of the system via suitable interfaces. Different languages such as SysML, methods and IT tools are available to create the system model. They can also be combined with each other in different ways. However, there is still a lack of standardized methods and standard interfaces.

The big challenge for companies is therefore to link their PLM or MBSE concepts with each other in the future. The introduction of an integrated system such as the 3DExperience platform from Dassault Systèmes is a promising solution, as it links all authoring systems in a central database.

Holistic system support with MMS

In order to develop complex products in a multidisciplinary manner, it is important to describe the multitude of customer requirements, system functions and operating principles from different disciplines in a common product model and to handle them in an integrated manner. For a holistic view and consistent system support, federative or integrated development environments are required, which previous IT systems only fulfill to a limited extent. The right solution has now been found in the 'Modeling Methodology for Systems' (MMS). With the help of the MMS, the diverse system aspects of different model characteristics (static, dynamic, etc.) and model levels can be represented. They capture the analysis of the system from the outside (mission, service) as well as the detailed system design (functions, components). As the developers can simulate the behaviors, the selected models and their performance can be validated at an early stage.

The RFLP data structure is available to the MMS as a backbone. RFLP stands for

• Requirement - requirements model
• Functional - functional model
• Logical - Logical model or function carrier model
• Physical - Physical model corresponds to '3D model'

It was implemented for the first time in the conventionally available PLM environment CATIA V6 from Dassault Systèmes. This is a networked 3D solution for collaboration between designers and non-CAD specialists and is therefore ideal for systems engineering. The RFLP data structure is also integrated into the current 3DExperience platform and forms the central backbone within product development based on systems engineering. The data structure can be customized for specific companies and developments, allowing, for example, the integration of additional nodes into the data structure (such as Operational, System or Component).

Integrated solutions

Previous IT systems were unable to implement systems engineering methods because there was no integrated data model across the product development phases and disciplines. This has now been solved with the introduction of the 3DExperience platform.

It enables integrated solutions in the context of systems engineering as well as in the creation and handling of objects that arise during product development. All modeling results, product information and simulation data can be stored in the integrated central database in an object-oriented and structured manner. The database-based platform allows the desired consistent use for all disciplines and users without interface and media breaks.

Users are able to go through the individual phases of product development and gain important insights into the design process. They can see at a glance the relationships between the requirements and the resulting logical behavior of the system. They can also recognize the influences on the 3D geometry. The main advantage of model-based systems engineering in the 3DExperience platform is the integration of all relevant models into a higher-level system model, from which the required views of the system can be derived. Changes to a subsystem or component always have an effect on the surrounding areas and components, and these effects are immediately visible at all times thanks to the overall system model. System analyses and validations can now be carried out holistically and allow cross-domain simulations thanks to the complete integration of disciplines.

Author:
Klaus Löckel is Managing Director at Dassault Systèmes.

Digitally mapping the value chain

A prerequisite for successful systems engineering is that all data, standards and software tools in a company converge seamlessly in one platform. Ideally, suppliers and other parties involved in the product development process can also be integrated in order to avoid interface and media disruptions. The 3Dexperience platform from Dassault Systèmes is not limited to individual process steps, but digitally maps the entire value chain - from the initial idea through engineering and production to sales and service. Here, engineers from all sectors can develop their products and systems in real time in an environment that reflects reality and test various scenarios.

The platform uses a role-based system in which there is an associated role for each task type, which goes hand in hand with corresponding application solutions (apps) in the platform and thus digitally maps every step in the product development process. This enables efficient collaboration between all disciplines and, as a business platform, coordinates joint product development from the concept phase through to product launch via various apps.

Social and networked apps - such as Enovia or 3Dexcite - enable the creation of networked communities in which content on problems can be exchanged and discussed, and apps such as Exaled or Netvibes simplify visualizations and dashboarding. 3D modeling is integrated into the platform via the Catia, Solidworks, Geovia and Biovia applications, as are the apps for content and simulation (Simulia, Delmia, 3Dvia) at the interfaces between the virtual world and reality.

The web service infrastructure of the 3Dexperience platform is compatible with numerous interface standards. The customer-specific adaptation and integration of customer data in a single working environment creates a high level of transparency and accelerates the entire product development process.