Systems Engineering Status of Industrial Use, Opportunities and Needs Clas A. Jacobson Chief Scientist Systems & Controls Engineering LCCC Lund September 19, 2012
TEAM Alberto Sangiovanni Vincentelli, Alberto Ferrari, Mark Myers, John Cassidy, Richard Murray, Andrzej Banaszuk, Sean Meyn, Johan Akesson, Hubertus Tummescheit, Karl Astrom, Manfred Morari, Eelco Scholte, Rich Poisson, Satish Narayanan, Kevin Otto, John Burns, Igor Mezic, Marco Di Natale, Scott Bortoff… 2
AGENDA System Design Systems engineering: (1) requirements, (2) architecture, (3) model based design, (4) (design/development) process Platform Based Design – design flows (orthogonalize concerns; hierarchy) Opportunities & progress System level modeling – positive on reusabality, speed… Architecture exploration – not fully exploited - but enabled Requirements – potential to move between formal languages (in progress for embeddded systems) Model based development – positive on controls - MPC (and optimization), uncertainty (and use for robust design not there yet) Process – progress on integration of tool chains; level of abstraction change (slightly) with domain (but separate into main product development cycles) 3
DRIVERS System interactions (“emergent behavior”) Requirements & acceptance testing (verification) Safety (critical) (software intensive) systems Reusable architectures (modularity) Robustness (risk, lifing) 4
SYSTEMS ENGINEERING (DESIGN) Process From process to analysis (model based development) Bring forward in time the verification testing (SIL => HIL => acceptance) Orthogonalize requirements (requested behavior) and architecture (delivering services) 5
DESIGN PROCESS Status & Opportunities Sizing Analysis Installation Analysis Variation source Identification Failure Modes & Effects Analysis Model-Driven Variation Analysis Range of analyses Network Embedded Systems Analysis System Dynamics Analysis (views) Robust Control Design Critical Parameter Analysis Functional Architecture Requirements Instance #1 #1 Hierarchy (refinement) Physical Layer Abstraction Software Layer Layers Communications & Separation of concerns Control Layer (requirements, architecture, analysis) Analysis Abstraction Viewpoints Levels Functional Architecture Requirements Instance #2 #2 Analysis Viewpoints 6
SYSTEMS ENGINEERING (DESIGN) Definition Systems engineering is a methodology for product system level design, optimization and verification that: 1. Provides guarantees of performance and reliability against customer requirements while achieving business cost and time-to-market objectives; 2. Produces modular, extensible architectures for products incorporating mechanical components, embedded systems and application software; 3. Exploits model-based analytical tools and techniques to determine design choices and ensure robust system performance despite variations caused by product manufacturing, integration with other products and customer operation; and 4. achieves these objectives through the coordinated execution of a prescriptive, repeatable and measurable process. 7
REQUIREMENTS Status & Opportunities Enabler – formal language (not just equation based language) Status – strong for embedded systems; weak for continuous time (non-simulation based verification) Opportunity – robust 8 design/uncertainty
MODEL BASED DEVELOPMENT Status & Opportunities Enabler – equations; interconnection structure Status of use of equation based language – strong for optimization (MPC; Akesson- Optimica) ; not exploited for robust design; weak for architecture exploration Opportunity – robust design/uncertainty 9
ROBUST DESIGN Marciano Chart Process Mapping Voice of the Reliability Forecast & Plan C pk Forecast and Customer KJ Clustering Existing Product Performance New Design Targets Design element Corresponding Observed defects and failures 10X Quality Plan Improvement Current in new product design element in Improvement strategy Status By mode Total goals estimate existing design Failure modes (ppm) (ppm) Business 300 Drop-In Design 243 250 Opportunity Modular Approach Modular Approach, Obsolete A Series 200 QFD Quantity Proposal 150 135 Test 100 82 63 53 44 50 36 13 9 Planning 8 8 4 4 2 6 6 1 1 0 Coils Compressors Fans Fan Motors Fan Deck Total Statistical Verification Test Functional Modularity Plans & Number of Characterization FMEA Modleing Prototypes Experiments DFMA g Critical Parameter Management Pugh Process D & R Document Off-Nominal Capability Design Verification C pk Scorecards Reliability Experiment Tests Off-Nominal Verification Production Verification Experiment Tests Production Verification Experiment Tests Robustness & Scalability Experiments
ROBUST DESIGN & UNCERTAINTY Status & Opportunities: Exploit Structure Probability Distribution of input parameters Utilize Find interconnection Weak Interaction structure to tear system into strong & weak connections; propagate Exploit uncertainty (Meyn- Weak Interaction Mathew (and others) DARPA RUM 2008) 11
SUMMARY System Design Systems engineering : (1) requirements, (2) architecture, (3) model based design, (4) process Platform Based Design – design flows (orthogonalize concerns; hierarchy) Opportunities & progress System level modeling – positive on reusabality, speed… Architecture exploration – not fully exploited - but enabled Requirements – potential to move between formal languages (in progress for embeddded systems) Model based development – positive on controls - MPC (and optimization), uncertainty (and use for robust design not there yet) Process – progress on integration of tool chains; level of abstraction change (slightly) with domain (but separate into main product development cycles) Summary Big needs on uncertainty/robust design (much wider view of product development); Opportunity for realizing potential of tool integration (FMI) and with PLM (data management) 12
KEY POINTS System Design Systems engineering : (1) requirements, (2) architecture, (3) model based design, (4) process Platform Based Design – design flows (orthogonalize concerns; hierarchy) Opportunities & progress System level modeling – positive on reusabality, speed… Architecture exploration – not fully exploited - but enabled Requirements – potential to move between formal languages (in progress for embeddded systems) Model based development – MPC (and optimization), uncertainty (not there yet) Process – integration of tool chains; level of abstraction change (slightly) with domain (but separate into main product development cycles) Summary Big needs on uncertainty/robust design; Opportunity for realizing potential of integration (FMI) with tool chain and PLM 13
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