Robotic systems are complex cyber-physical systems (CPS) commonly equipped with multiple sensors and effectors. Recent simulation methods enable the Digital Twin (DT) concept realisation. However, DT employment in robotic system development, e.g. in-development testing, is unclear. During the system development, its parts evolve from simulated mockups to physical parts which run software deployed on the actual hardware. Therefore, a design tool and a flexible development procedure ensuring the integrity of the simulated and physical parts are required. We aim to maximise the integration between a CPS's simulated and physical parts in various setups. The better integration, the better simulation-based testing coverage of the physical part (hardware and software). We propose a Domain Specification Language (DSL) based on Systems Modeling Language (SysML) that we refer to as SPSysML (Simulation-Physical System Modeling Language). SPSysML defines the taxonomy of a Simulation-Physical System (SPSys), being a CPS consisting of at least a physical or simulated part. In particular, the simulated ones can be DTs. We propose a SPSys Development Procedure (SPSysDP) that enables the maximisation of the simulation-physical integrity of SPSys by evaluating the proposed factors. SPSysDP is used to develop a complex robotic system for the INCARE project. In subsequent iterations of SPSysDP, the simulation-physical integrity of the system is maximised. As a result, the system model consists of fewer components, and a greater fraction of the system components are shared between various system setups. We implement and test the system with popular frameworks, Robot Operating System (ROS) and Gazebo simulator. SPSysML with SPSysDP enables the design of SPSys (including DT and CPS), multi-setup system development featuring maximised integrity between simulation and physical parts in its setups.

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