One approach to tackle the complexity in the development of cyber-physical systems is system decomposition and modelling in a central system model with model-based system engineering (MBSE). However, MBSE also requires increased development effort due to the high degree of formalisation of the development results using the Systems Modelling Language (SysML). One solution is reusing system elements from model libraries, which requires formalization that allows them to be networked into consistent models. Due to the abstract nature of SysML, the options for formalizing system elements are extremely diverse, meaning that even identical technical system elements are modelled with a different structure by engineers. As a consequence, no standardized structure is maintained and the reuse of system elements from model libraries is very unlikely. This leads to high, redundant modelling efforts as well as a considerable error potential and significantly hinders the economic application of MBSE in mechanical engineering. A standardized structure of the system elements can be ensured through MBSE methodology specific modelling guidelines. Current modelling guidelines for MBSE are based on the SysMLv1 language standard and cannot be used unchanged in SysML v2. Nevertheless, SysML v2 offers great potential for modelling reusable system elements, especially with its synonymous textual and graphical modelling capabilities, enabling the easy linkage of knowledge from various domain-specific tools. Consequently, modelling guidelines based on SysML v2, which guarantee a standardized structure, are required to fully exploit the potential of model libraries in MBSE. To solve this deficit, this paper presents modelling guidelines based on SysML v2 and their application for building reusable system elements.

As product development cycles become increasingly short while products grow more complex, new approaches in product development are needed to accommodate these developments. One of these approaches is Model-based Systems Engineering (MBSE). MBSE enables the representation of products, which are seen as systems, in one seamless system model. To do so the product and its different aspects, such as physical behavior, are described by different models, that are then interconnected with each other. One advantage of applying MBSE is, that the usage of physical behavior models allows efficient virtual validation of many different product features and evaluation of implication due to design changes. However, performing sufficiently accurate virtual tests, especially for mechanical properties, requires detailed behavior models, which leads to a high modeling effort. For this reason, in the past efforts were made to standardize model components, referred to as system elements, that could be reused and thus reducing the modeling effort. The aim is to enable the modeling of any technical product from the composition of these base components. However, these system elements have not yet been modeled and organized in a library, which could then be distributed across modelers. For this reason, the aim of this paper is to firstly create a model library based on previously defined system elements that satisfies the required physical model properties. Furthermore, the applicability of this library in modeling is investigated and improvement potentials are derived. To do so a simplified gearbox model is created from multiple elements contained in a predefined library. The model created is then used to specifically investigate the ability to verify static safety using the physical behavior models contained in the library. The result of this work is an expandable model library of reusable system elements, that allows the aggregation of system models, representing products and the virtual verification of these products. Thus, enabling for a faster product development process as the modeling effort for the application of MBSE is reduced.

New emission regulations and the associated mobility transition has led to an increased demand for new drivetrain concepts. These new cross-domain concepts, such as electromechanical drivetrains, are characterized by a high number of interactions between components which must be tested to ensure the functionality of the developed system. To achieve a short time-to-market, it is necessary to test subsystems and components early in the development process. Although virtual testing through simulation offers cost-effective solutions, physical testing remains essential for validating real physical behavior. Nevertheless, due to high costs and disparate delivery times of components, physical testing alone is insufficient. To counteract, Hardware-in-the-Loop (HiL) testing can be performed to combine the benefits of physical and virtual testing in the early stages of development, particularly when not all components are yet physically available. However, the problem arises, that for HiL testing a virtual HiL model must be available which suits the individual test case consisting of the Device Under Test (DUT) and the associated purpose of the test including the test bench on which the test will be performed. These models must be created with high manual effort. To counteract reusability can be achieved by using predefined model elements. Therefore, we present an approach for creating configurable HiL models. For this approach, a vehicle model consisting of standardized, modular model element for each subsystem is set up to be used for HiL testing. Modularization of models ensures quick and easy adjustment and efficient product development which is also beneficial for the creation of HiL models. The created vehicle model serves as a basis for all required HiL models which can then configured. For the configuration a workflow is developed which allows an automatic derivation of the required HiL model by considering the defined test case.

Today, the development of electrified commercial vehicles requires efficient validation methods that enable early system testing while maintaining consistency between development and testing models. Hardware-in-the-Loop (HiL) testing provides a suitable approach by combining real hardware with executable real-time simulation models. However, HiL models are typically created manually for specific test cases, resulting in high modeling effort and limited reuse of development knowledge. This paper presents a methodology for the automated synthesis of executable, test-specific system-level HiL simulation models from predefined and reusable simulation components based on function-oriented SysML system architecture models. The approach combines filtering of architectural data, automated analysis of model availability and parameter completeness and configurable selection of the desired model fidelity. Reusable simulation components aligned with the system architecture are automatically selected, parametrized, connected, and aggregated into executable Simulink HiL models including test-bench interfaces. The methodology was validated for three electrified vehicle architectures and deployed on a dSPACE-based HiL test bench for drivetrain functionality and range analyses. The generated system-level HiL models were created in a few seconds while maintaining consistency with the central MBSE system architecture.