Abstract— The aim of this paper is to present the application of There are three big challenges to face, in order to be able complex systems architecting approach in the development of to pursue this transformation: the digital twin through a use case of an industrial process: - Training: Industry 4.0’s transformation requires not phosphate mining site of Benguérir. We introduce the digital only to change equipment but also to change minds, twin concept and its influence on the development of operators should be aware of the new technologies manufacturing processes. Further, we present the complex and their use. systems engineering approach and its added value to the design - Test and verification: The operator needs to change and the manipulation of systems with a higher level of the configurations, edit the program, upgrade the complexity, and how this approach allows designing a digital system or maintain a new equipment, and this twin model of the mining site. Previous work undertook the digital twin concept and its benefits on industry without without any risk or failure, so, the operator must mentioning an efficient method to develop it. To realize our simulate and test the modification before vision to design the digital twin of the mining site of Benguérir, implementing it in the real process. we used SysML diagrams to model the solution based on the - R&D: Engineers and researchers need to develop three visions of the complex systems engineering: the algorithms and new methods based on the data operational vision, the functional vision and the constructional collected from the field and test the results and vision. algorithms. To face those challenges, and pursue the change, the Keywords- Industry 4.0; digital twin; simulators; complex Polytechnic University of Mohammed VI and the mining site systems engineering; mining site; fixed infrastructures. of the Office Chérifien des Phosphates (OCP) adopted the digital twin concept to deal with the issues discussed before. I. INTRODUCTION The digital twin is the virtual representation of a real process, product or service [1]; it contains of real time The fixed infrastructures of the mining site are a main simulators and this representation is a complex system since process in its value chain, whose function is the physical it must be a very close model of the real system. treatment of the extracted product. It consists in separating Furthermore, a well-defined design process should be used in rocks from valuable product and the transfer of this product order to collect all requirements from all stakeholders. The to the other sites (chemical treatments); this process is complex engineering system approach provides a structured composed of three units: and flexible modelling methodology in order to implement - Stone removal unit: The trucks bring the product and develop a clear functional architecture. (the phosphate) from the field, and put it into two The aim of this paper is to present the impact of complex hoppers, then it is screened, the rocks are crushed systems architecting approach in developing the digital twin and sent to a waste rock storage and the product is of the mining site. sent to the next unit via conveyors. After first describing the principles of systems - Screening unit: A second screen is necessary; the engineering approach and the digital twin concept, this paper unit contains five screens and five hoppers; the then demonstrates how this approach is an effective product is now sent via conveyors to the loading methodological support and allows an early detection of unit. possible weaknesses during initial design stages. - Loading unit: The product is stored and then loaded The paper is structured as follows: In Section 2, a state of in specific wagons depending on the quality, the type art will be presented, then Section 3 is dedicated to the and the quantity demanded from the customers. definition of digital twin concept and its advantages. The industrial manufacturing and, of course, the mining Furthermore, the complex systems architecting method is sites are getting into a deep transformation, which considers presented is Section 4, while Section 5 will present the digital technologies getting into industrial equipment. This is application of the complex systems architecting method in the fourth industrial revolution, called Industry4.0. It is the process of the mining site and results of this work, and characterized by the fusion of virtual world of internet and we conclude with a conclusion and perspectives of the work. the real industrial facilities.
SIMUL 2018 : The Tenth International Conference on Advances in System Simulation
II. STATE OF ART systems-design processes that accommodate the complexities
Different understandings of the digital twin can be of developing multi-disciplinary systems. Digital twins are at observed in industrial practice. In this regard, it has been the core of this development process [5]. argued that Parametric Technology Corporation (PTC) is The digital twin can allow companies to have a complete focusing on establishing a link between the virtual product digital footprint of their products from design and model and the physical part to increase the manufacturing development through the end of the product life cycle. flexibility and competitiveness, while Dassault Systèmes Digital twins are designed to model complicated assets or targets the product design performance. Moreover, the digital processes that interact in many ways with their environments twin understanding of General Electric focuses on for which it is difficult to predict outcomes over an entire forecasting the health and performance of their products over product life cycle, and to solve physical issues faster by lifetime, whereas SIEMENS strives for improved efficiency detecting them sooner, predict outcomes to a much higher and quality in manufacturing. TESLA aims at developing a degree of accuracy, design and build better products, and, digital twin for every built car, hence enabling synchronous ultimately, better serve their customers [6]. data transmission between the car and the factory, while IV. COMPLEX SYSTEMS ENGINEERING APPROACH other companies increasingly use complex product models to boost the immersion in virtual and augmented reality Complex systems engineering approach is the whole applications [2]. activity that allows to design an optimal system to meet a To develop a flexible digital twin framework and satisfy need. It is based on system vision that includes multiple the multiple understandings, a developed architecting parameters, the multidisciplinary aspect, the life cycle and method should be adopted, and as the system is complex and the use cases. It consists of establishing the functional and provides many parameters, this work proposes the complex physical compatibility of a system with the needs and the systems architecting method to model and implement the constraints digital twin based on simulators. Systems engineering approach enables engineering The design and development of a system indeed requires organizations to proceed toward the design of complex the contribution of various processes, stakeholders and systems and its impact across multiple engineering techniques. Each person often concentrates on a specific disciplines: mechanical, electrical, and software. With this aspect of the system without any perspective on the other approach, customer requirements are defined early in the aspects: designers have an architectural and functional vision development cycle and are implemented through design and of the system, the manufacturing team considers a system as system validation—from concept to operation [7]. This an element to be integrated in the assembly line, the approach is based on three essential visions: Operational procurement department views it as a list of supplies to be vision, functional vision and constructional vision. purchased. Complex systems engineering thus enables a - Operational Vision: The operational vision provides global view of the system to guarantee the consistency of “black box” models [8] of a given system where one specific contributions to the system; it takes into account the describes the interactions and the interfaces of a whole life cycle of the system including the definition of system of interest with its environment. Its core customer requirements, design, production, and marketing. It motivation is to understand the “Why” – of the defines the most effective methods and means for satisfying system. the technical and organizational requirements which, in - Functional Vision: The core notion of the functional practice, means satisfying cost, time and productivity vision is to understand the “what” of the system, it constraints. The challenge of complex systems engineering is functions, and the main mission is to understand to design and product the best system to meet a customer's deeply what does the system without however requirements with the most efficient control of deadlines and knowing at this point how it is concretely structured. costs. As system complexity continues to increase, systems - Constructional Vision: The aim is to describe all engineers now use modelling techniques to guarantee that concrete hardware, software and human-ware specification and design models are correctly built and can components of a system with their interactions; all be easily communicated to the development teams [3]. constructional concepts, such as configuration, The objective of the work described in this paper is to constructional scenarios or constructional objects are demonstrate the advantages of using recommended again uniquely referring to the system of interest methodology for the development of complex systems. without involving any external system [9].
III. DIGITAL TWIN CONCEPT V. APPLICATION & RESULTS
First, the project of the digital twin (DT) was originated In order to implement the complex systems engineering in the Institute of Automation, Measurement and Applied approach, we have employed the SysML modeling language Informatics of the faculty of Mechanical Engineering of the to develop different diagrams for each vision. Slovak University of Technology in Bratislava [4]. The DT The results of applying each vision are the operational, is one of the main concepts associated with the new the functional and the constructional diagrams; those industrial revolution, Industry 4.0. Manufacturers are taking diagrams will facilitate to develop the digital twin of the a more systems-design approach by implementing rigorous mining site. This method is characterized by high precision, accurate functioning and various configurations.
SIMUL 2018 : The Tenth International Conference on Advances in System Simulation
A. Operational vision Fig.1 below describes the use cases of our system. The The aim of the operational vision is to identify the digital twin of the OCP mining site will be used by multiple multiple users of our system and its environment, also to stakeholders which are: Operators, supervisors, production understand the stakeholders and the interactions between agents, maintenance agents and office managers. Its use them. It facilitates to design our system with high precision cases are: the test of the configurations, the optimization of because a misunderstanding or an error occurred during the process, the simulation of the process, prediction of the operational architecture process may lead to costly and system performance, real time monitoring and also for the disastrous consequences on our system under development. production management.
Figure.1: Use cases diagram of the digital twin
stacker needs to be automated; the provider of the solution
B. Functional vision may have different reflections and challenges to design the The results of the treatment of this vision are the right and exact solution for the problem. The aim of this functional requirements of our system (the digital twin) work is to identify the real needs of the operators, to model which are the functional needs of the operators from the those needs in a flexible way based on a system modeling field, agents, engineers and office managers. We will present language and use the requirements model to verify and the results of applying the functional vision of complex validate the solution proposed to implement the digital twin. system engineering to develop the functional diagrams that Fig.2 below describes the functional requirements of our will serve to develop the digital twin of the mining site. system. Those requirements have been identified from the As mentioned before, requirements engineering is an users of the digital twin. We classified them into four essential part of systems engineering. Indeed, understanding sections: Simulators, Research and development (R&D), the need facilitates designing the solution. Every requirement Training and test and validation. We have also set the should be S.M.A.R.T: Specific, Measurable, Achievable, requirements for each section in order to model those Relevant and Traceable [10]. requirements in a flexible way. Operators express their needs and the challenges they face by writing texts and classical sentences, e.g., The
SIMUL 2018 : The Tenth International Conference on Advances in System Simulation
Figure.2: Functional Requirements diagram of the digital twin
architecture or by the new possibilities brought by the
advances of technology [11]. C. Constructional vision Fig.3 shows the definition block diagram of the digital Constructional architecture is key since it consolidates all twin. This system is composed of n number of PLCs, motors, architectural analyses in a concrete vision of the considered actuators, sensors, panels and computers. The definition system. It makes in particular the synthesis between a top- block diagram shows the components of the digital twin, down design approach, as provided by the systems their parts, their values and the ports of the material and the architecting process, and a bottom-up one, which is typically energy of those components. induced by the constraints due to the existing product
SIMUL 2018 : The Tenth International Conference on Advances in System Simulation
Figure.3. Definition block diagram of the digital twin
Those diagrams will be used to establish the physical REFERENCES
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