The main focus of this paper is the integration of an integrated function modeling (IFM) framework in an engineering framework based on graph-based design languages (GBDLs). Over the last decade, GBDLs have received increasing attention as they offer a promising approach for addressing several important challenges in engineering, such as the frequent and time-consuming transfer of data between different computer aided engineering (CAE) tools. This absorbs significant amounts of manual labor in engineering design projects. GBDLs create digital system models at a meta level, encompassing all relevant information concerning a certain product design and feeding this into the relevant simulation tools needed for evaluating the impact of possible design variations on the performance of the resulting products/parts. It is possible to automate this process using digital compilers. Because of this, it is also possible to realize systematic design variations for a very large number of parameters and topological variants. Therefore, these kinds of graph-based languages are a powerful means for creating a large number of viable design alternatives and for permitting fast evaluation processes against the given specifications. While, thus far, such analyses tend to be based on a more or less fully defined system, this paper proposes an expansion of the applicability of GBDLs into the domain of product functions to cohesively link conceptual with embodiment design stages. This will also help with early systematic, automated generation and the validation of design alternatives through relevant simulation tools during embodiment design. Further, it will permit the automated exploration of function paths and enable extended analysis possibilities, such as the detection of functional bottlenecks, while enhancing the traceability of the design over the development process. For these extended analysis possibilities, a function analysis tool was developed that adopts core ideas of the failure mode and effects analysis (FMEA). In this, the functional distinction between function carriers and function-related processes allows the goal-directed assessment of component reliabilities and the detectability and importance of processes in a technical system. In the paper, the graph-based modeling of functions and the function analysis tools are demonstrated on the example of a multicopter.

The reliability of technical systems can be greatly reduced if possible faults cannot be accommodated but lead to system shut-down with sometimes catastrophic consequences. The algorithms and systems of fault-tolerant control were developed in the last years into a powerful tool to accommodate such faults. Additionally, it became obvious that the design of a technical system can ease or hinder the application of these tools and can also lead to the accommodation of faults be itself. This kind of design – fault-tolerant design – and its components are presented in this paper on the example of a shifting system for the gear box an autonomous driving race car. This race car competes in the well-known formula student driverless competition; in such competitions the reliability of the car and the capability to accommodate not avoidable faults is of paramount importance. The different elements of fault-tolerance incorporated in the design of the gear shifting system are explained on the basis of an established model of product concretization.

The current product and assembly processes of system development in the vehicle industry are characterised by a multitude of different model formats, a relatively low level of data integration, and an unsatisfactory management of information. This article presents an integrated design and assembly planning process which applies several model-to-model (M2M) transformations in order to ensure a seamless transition from product requirements to an assembly system layout and design. The digital process employs a framework based on graph-based design languages (GBDLs) and achieves an integration in a model-based systems engineering (MBSE) industrial context. The underlying hypothesis that this seamless transition is possible is tested on the basis of the product and assembly system development of a sports vehicle. In this article, a skateboard is used for detailing and explaining the different modelling perspectives throughout the engineering and assembly process of this product. Due to a conscious application of GBDLs in an MBSE framework, it is possible to achieve a continuous sequence of M2M transformations which guarantees a maximum level of information integrity. These two aspects are cornerstones for a future integrated design automation of a product and its assembly system. It is important to note that the presented approach is universal and can be used in the production of components for the automotive industry, entire vehicles, and their assembly.

Today, design engineers engaged in the development of a high-performance electrical drive-train are challenged by the multitude of possible topological choices and numerous mutually interconnected physical phenomena. Development teams around the globe struggle with this challenge; usually they employ several tools for simulation and topology optimization and transfer multiple versions of their product models in a mainly manual process. The research presented in this paper aims to explore a holistic possibility to realize a sensible analysis-synthesis cycle that takes into consideration current developments in design, simulation and optimization processes. This kind of process can enhance the transparency of design decisions, can reduce the risk of design and process flaws and can support the approach toward a holistic optimum. The investigation starts with the development of the topological concept of the drive-train and continues over the interconnected simulation of several decisive properties of the drive-train. Obviously, these properties concern several domains (mechanical, electrical, thermal and the control domain). The optimization of the drive-train takes into consideration the main requirement—in the investigated example, which is a formula student drive-train—the lap time. The result is a holistic concept for a design, simulation and optimization approach that considers topological variety, interconnected multi-domain simulation and a continuous connection to the decisive requirements.

Currently, a consensus in the scientific community can be observed that it is necessary to reduce the carbon footprint and the use of fossil resources in order to ensure the ongoing well-being of humanity and our planet. Battery electric vehicles (BEVs) can contribute to this reduction, as they can use energy from sustainable sources as well as store it in order to enable individual mobility. Still, as long as sustainable energy is not available in abundance and a share of our energy still is generated using fossil sources, it is important to consider the energy consumption of these BEVs in greater detail. BEVs may actually consume more energy than necessary due to an architecture borrowed from non-BEVs, due to their drive-train topology, due to many individual product development issues and last but not least because they are not operated at their highest efficiency. This paper addresses the evaluation of a specific sustainable product development process for BEVs. The study is based on detailed energy consumption simulations of smaller BEVs with different drive train technologies. A general consideration of sustainability and utility based on the design choices, as well as of societal consequences, leads to requirements and challenges for sustainable product development. A digital product development process is described, which addresses these challenges.

Graph-based design languages have received increasing attention in the research community, because they offer a promising approach to address several major issues in engineering, e.g., the frequent manual data transfer between computer-aided design (CAD) and computer-aided engineering (CAE) systems. Currently, these issues prevent the realization of machine executable digital design processes of complex systems such as vehicles. Promising scenarios for urban transportation include an interconnection of mass transportation systems such as buses and subways with individual vehicles for the so-called “last mile” transport. For several reasons, these vehicles should be as small and light as possible. A considerable reduction in weight and size can be achieved, if such vehicles are tailored to the individual size, weight and proportion of the individual user. However, tailoring vehicles for the individual characteristics of each user go beyond a simple building set and require a continuous digital design process. Consequently, the topic of this paper is a digital design process of a self-balanced scooter, which can be used as an individual last-mile means of transport. This process is based on graph-based design languages, because in these languages, a digital system model is generated, which contains all relevant information about a design and can be fed into any simulation tool which is needed to evaluate the impact of a possible design variation on the resulting product performance. As this process can be automated by digital compilers, it is possible to perform systematic design variations for an almost infinite amount of parameters and topological variants. Consequently, these kinds of graph-based languages are a powerful means to generate viable design alternatives and thus permit fast evaluations. The paper demonstrates the design process, focusing on the drive system of the respective balanced two-wheel scooter and highlights the advantages (data integration and possibility for machine execution).