Systematic development of virtual commissioning architectures using SPES methodology building blocks

Abstract The complexity of developing Virtual Commissioning (VC) architectures for modern automation systems requires a structured and adaptable methodology. This study addresses key challenges in applying the SPES (Software Platform Embedded Systems) methodology to VC, including limitations in decision support for technical configurations, a lack of clarity in control-level differentiation, and difficulty in integrating company-specific processes. To overcome these limitations, the SPES MBB (Methodological Building Blocks) framework is integrated with SPES, enhancing its capabilities through modular, reusable building blocks that provide clearer decision-making guidance, improve control-level task allocation, and support the integration of industry-specific knowledge. A case study from the iMOD project in aircraft manufacturing demonstrates the application of the SPES MBB framework to develop a more coherent and scalable VC architecture. The results highlight improvements in system integration, consistency across system viewpoints, and systematic configuration decision-making, leading to a more internally consistent and adaptable VC architecture, as demonstrated through a structured qualitative evaluation and a formal sensitivity analysis of expert judgments. The proposed approach addresses critical gaps in VC architecture development, demonstrating how SPES MBB can support the systematic design of VC architectures for complex automation systems.