A model-based design methodology for the development of mechatronic systems

•We propose an integrated MBD approach for the design of mechatronic systems.•SysML is selected as the tool to support the whole design process.•The methodology is based on the W model.•The W model is applied at different levels of abstraction: hierarchical approach.•We tested the method in the rationalization of a mechatronic system. The development of mechatronic systems involves the use of multiple disciplines, from mechanical engineering to electronics engineering and computer science. Traditionally, every discipline was developed independently and then integrated to generate the final system. However, high-quality designs cannot be achieved without simultaneously considering all the engineering disciplines. This integrated approach carries an intrinsic complexity into system design process and numerous researches are on-going in order to find out optimal methods. This article illustrates a methodology based on Model-Based System Engineering to support the integrated development of complex mechatronic devices. The main contribution is the introduction of a design methodology based on the W model and the identification of SysML as the tool to support the whole process. This method will also address the problem of “devices interchangeability”, that means the possibility to develop the functionality of a system with different operation principles, at a very early stage of the development process (i.e. during the conceptual development). To achieve this goal, the methodology treats the problem of linking the conceptual with executable models to enable the validation by simulation. Main advantages of this methodology are in providing, to the mechatronic systems designers, a fixed schedule which does not limit their intuition and reduces complexity through a hierarchical approach. The process has been tested through the rationalization of the choices that have brought to the current solution of the filling system of an automatic filling machine for liquid foodstuff.