Petri net approaches for modeling, controlling, and validating flexible manufacturing systems

In this dissertation, we introduce the fundamental ideas and constructs of Petri net models such as ordinary, timed, colored, stochastic, control, and neural, and present some studies that emphasize Petri nets theories and applications as extended research fields that provide suitable platforms in modeling, controlling, validating, and evaluating concurrent systems, information systems, and a versatile dynamic system and manufacturing systems;We then suggest some of extensions that help make Petri nets useful for modeling and analyzing discrete event systems and manufacturing systems models based on the context of a versatile manufacturing system, and applies extended Petri nets models to several manufacturing systems such as an assembly cell, an Automated Palletized Conveyor System, and a tooling machine to show increased modeling power and efficient analysis methods;Finally, Validation methods are presented for these models and results of a performance analysis from a deterministic and stochastic model are used to reorganize and re-evaluate a manufacturing system in order to increase its flexibility

TOWARDS DIGITAL TWIN-DRIVEN PERFORMANCE EVALUATION METHODOLOGY OF FMS

The paper presents a method of automated modelling and performance evaluation of concurrent production flows carried out in Flexible Manufacturing Systems. The method allows for quick assessment of various variants of such systems, considering their structure and the organization of production flow of possible ways of their implementation. Its essence is the conditions imposed on the designed model, limiting the space of possible variants of the production flow only to deadlock-free variants. The practical usefulness of the model implemented in the proposed method illustrates the example, which describes the simultaneous assessment of alternative variants of the flexible machining module's structure and the planned multi-assortment production. The ability of the method to focus on feasible solutions offers attractive perspectives for guiding the Digital Twin-like scenario in situations caused by the need to change the production flow

A computer-aided simulation tool based on Petri nets for the design and analysis of FMSs

Discrete-event simulation has been recognized as an invaluable tool in analyzing and designing FMSs. In this dissertation, a computer-aided simulation tool based on Petri nets is presented to facilitate simulation projects in the manufacturing area. For modeling and simulation of FMSs, Conserved nets which are a subclass of Petri nets are proposed and implemented. The structural characteristics and liveness conditions of Conserved nets are investigated. While hardware components are modeled by hierarchically-classified Petri net objects, high-level, real-time control systems in FMSs are separately modeled and integrated with a Petri net model to resolve conflicts occurring in Petri net execution. The structure of the Petri net-based simulation tool is presented. Also, the use of the simulation tool is illustrated with several case studies including performance comparison of push- and pull-based AGV dispatching rules in an FMS. Finally, strengths and weaknesses of the developed simulation tool are discussed including areas for future study

Scheduling and discrete event control of flexible manufacturing systems based on Petri nets

A flexible manufacturing system (FMS) is a computerized production system that can simultaneously manufacture multiple types of products using various resources such as robots and multi-purpose machines. The central problems associated with design of flexible manufacturing systems are related to process planning, scheduling, coordination control, and monitoring. Many methods exist for scheduling and control of flexible manufacturing systems, although very few methods have addressed the complexity of whole FMS operations. This thesis presents a Petri net based method for deadlock-free scheduling and discrete event control of flexible manufacturing systems. A significant advantage of Petri net based methods is their powerful modeling capability. Petri nets can explicitly and concisely model the concurrent and asynchronous activities, multi-layer resource sharing, routing flexibility, limited buffers and precedence constraints in FMSs. Petri nets can also provide an explicit way for considering deadlock situations in FMSs, and thus facilitate significantly the design of a deadlock-free scheduling and control system. The contributions of this work are multifold. First, it develops a methodology for discrete event controller synthesis for flexible manufacturing systems in a timed Petri net framework. The resulting Petri nets have the desired qualitative properties of liveness, boundedness (safeness), and reversibility, which imply freedom from deadlock, no capacity overflow, and cyclic behavior, respectively. This precludes the costly mathematical analysis for these properties and reduces on-line computation overhead to avoid deadlocks. The performance and sensitivity of resulting Petri nets, thus corresponding control systems, are evaluated. Second, it introduces a hybrid heuristic search algorithm based on Petri nets for deadlock-free scheduling of flexible manufacturing systems. The issues such as deadlock, routing flexibility, multiple lot size, limited buffer size and material handling (loading/unloading) are explored. Third, it proposes a way to employ fuzzy dispatching rules in a Petri net framework for multi-criterion scheduling. Finally, it shows the effectiveness of the developed methods through several manufacturing system examples compared with benchmark dispatching rules, integer programming and Lagrangian relaxation approaches

Petri net modeling and analysis of an FMS cell

Petri nets have evolved into a powerful tool for the modeling, analysis and design of asynchronous, concurrent systems. This thesis presents the modeling and analysis of a flexible manufacturing system (FMS) cell using Petri nets. In order to improve the productivity of such systems, the building of mathematical models is a crucial step. In this thesis, the theory and application of Petri nets are presented with emphasis on their application to the modeling and analysis of practical automated manufacturing systems. The theory of Petri nets includes their basic notation and properties. In order to illustrate how a Petri net with desirable properties can be modeled, this thesis describes the detailed modeling process for an FMS cell. During the process, top-down refinement, system decomposition, and modular composition ideas are used to achieve the hierarchy and preservation of important system properties. These properties include liveness, boundedness, and reversibility. This thesis also presents two illustrations showing the method adopted to model any manufacturing systems using ordinary Petri nets. The first example deals with a typical resource sharing problem and the second the modeling of Fanuc Machining Center at New Jersey Institute of Technology. Furthermore, this thesis presents the analysis of a timed Petri net for cycle time, system throughput and equipment utilization. The timed (deterministic) Petri net is first converted into an equivalent timed marked graph. Then the standard procedure to find the cycle time for marked graphs is applied. Secondly, stochastic Petri net is analyzed using SPNP software package for obtaining the system throughput and equipment utilization. This thesis is of significance in the sense that it provides industrial engineers and academic researchers with a comprehensive real-life example of applying Petri net theory to modeling and analysis of FMS cells. This will help them develop their own applications

Extracting Petri Modules From Large and Legacy Petri Net Models

Petri nets, even though very useful for modeling of discrete event systems, suffer from some weaknesses such as huge size, huge state space, and slow in simulation. Due to the huge state space, model checking a Petri net is difficult. Also, due to the slowness in simulation, discrete-timed Petri nets cannot be used for real-time applications. Thus, modular Petri nets are suggested as a way of overcoming these difficulties. In modular Petri nets, modules are designed, developed, and run independently, and the modules communicate with each other via inter-modular connectors. This approach is suggested for developing newer Petri net models. However, there exists a large number of Petri net models of real-life systems, and these legacy models are enormous and non-modular. And, these models cannot be discarded as large amounts of time and money were spent to develop these models. This paper presents a unique algorithm for extracting modules from large and legacy Petri net models. The algorithm extracts modules (known as “Petri modules”) that are well-defined for inter-modular collaboration. Also, the extraction method preserves the structural properties. The goal of the paper is to introduce a methodology by which Petri nets can be moved to a new level in which a modular Petri net model can be made of Petri modules. The Petri modules are independent and can be hosted on different computers. These modules communicate via inter-modular components such as TCP/IP sockets. Since Petri modules are compact, also run faster, thus become suitable for supervisory control of real-time systems.publishedVersio

A petri-net based methodology for modeling, simulation, and control of flexible manufacturing systems

Global competition has made it necessary for manufacturers to introduce such advanced technologies as flexible and agile manufacturing, intelligent automation, and computer-integrated manufacturing. However, the application extent of these technologies varies from industry to industry and has met various degrees of success. One critical barrier leading to successful implementation of advanced manufacturing systems is the ever-increasing complexity in their modeling, analysis, simulation, and control. The purpose of this work is to introduce a set of Petri net-based tools and methods to address a variety of problems associated with the design and implementation of flexible manufacturing systems (FMSs). More specifically, this work proposes Petri nets as an integrated tool for modeling, simulation, and control of flexible manufacturing systems (FMSs). The contributions of this work are multifold. First, it demonstrates a new application of PNs for simulation by evaluating the performance of pull and push diagrams in manufacturing systems. Second, it introduces a class of PNs, Augmented-timed Petri nets (ATPNs) in order to increase the power of PNs to simulate and control flexible systems with breakdowns. Third, it proposes a new class of PNs called Realtime Petri nets (RTPNs) for discrete event control of FMS s. The detailed comparison between RTPNs and traditional discrete event methods such as ladder logic diagrams is presented to answer the basic question \u27Why is a PN better tool than ladder logic diagram?\u27 and to justify the PN method. Also, a conversion procedure that automatically generates PN models from a given class of logic control specifications is presented. Finally, a methodology that uses PNs for the development of object-oriented control software is proposed. The present work extends the PN state-of-the-art in two ways. First, it offers a wide scope for engineers and managers who are responsible for the design and the implementation of modem manufacturing systems to evaluate Petri nets for applications in their work. Second, it further develops Petri net-based methods for discrete event control of manufacturing systems

Modeling and analysis of semiconductor manufacturing processes using petri nets

This thesis addresses the issues in modeling and analysis of multichip module (MCM) manufacturing processes using Petri nets. Building such graphical and mathematical models is a crucial step to understand MCM technologies and to enhance their application scope. In this thesis, the application of Petri nets is presented with top-down and bottom-up approaches. The theory of Petri nets is summarized with its basic notations and properties at first. After that, the capability of calculating and analyzing Petri nets with deterministic timing information is extended to meet the requirements of the MCM models. Then, using top-down refining and system decomposition, MCM models are built from an abstract point to concrete systems with timing information. In this process, reduction theory based on a multiple-input-single-output modules for deterministic Petri nets is applied to analyze the cycle time of Petri net models. Besides, this thesis is of significance in its use of the reduction theory which is derived for timed marked graphs - an important class of Petri nets