A system-level digital twin behavioral modeling paradigm with multi-model integration: architecture, methodology and verification

Purpose Achieving high-fidelity modeling of physical dynamic behavior distinguishes digital twin (DT) from simulation. Physical manufacturing systems or processes are complex aggregates of information composed of different elements. The DT behavioral model (DT_BM) constructed based on single-model makes research fall into the dilemma of “model islands.” Therefore, this article aims to propose a system-level DT_BM modeling paradigm with multi-model integration to enable more intelligent DT applications in the manufacturing. Design/methodology/approach A modeling reference architecture for DT_BM is proposed to accelerate technical standardization and promote consensus among stakeholders. A modeling method of DT_BM is proposed based on systems modeling language (SysML), which is used to realize the description of information interaction and dynamic collaboration between sub-models in DT_BM. Based on timed automaton (TA), a formal transformation framework and toolchain for DT_BM verification are designed to ensure the correctness and reliability of modelling. Findings The proposed modeling paradigm shows good ability in expressing complex dynamic interactions between sub-models. A case study of processing quality control proves its practicability. The results show that the proposed method can accurately, effectively and verifiably characterize the behavior of complex physical manufacturing systems or processes. Originality/value This article innovatively proposes a DT_BM modeling paradigm that covers the entire process of architecture, modeling and verification. Unlike traditional single-model method, it supports multi-model collaboration, dynamic interaction and correctness assurance, providing theoretical and technical support for the realization of intelligent and reliable DT systems.