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

Petri Nets at Modelling and Control of Discrete-Event Systems with Nondeterminism - Part 2

Discrete-Event Systems (DES) are discrete in nature. Petri Nets (PN) are one of the most widespread tools for DES modelling, analyzing and control. Different kinds of PN can be used for such purposes. Some of them were described in [3], being the first part of this paper. Here, the applicability of Labelled PN (LbPN) and Interpreted PN (IPN) for modelling and control of nondeterministic DES, especially with uncontrollable and/or unobservable transitions in the models, will be pointed out. Moreover, another kinds of nondeterminism in DES (errors, failures) will be modelled, and the possibilities of the error recovery of failed system will be presented

Energy and Route Optimization of Moving Devices

This thesis highlights our efforts in energy and route optimization of moving devices. We have focused on three categories of such devices; industrial robots in a multi-robot environment, generic vehicles in a vehicle routing problem (VRP) context, automatedguided vehicles (AGVs) in a large-scale flexible manufacturing system (FMS). In the first category, the aim is to develop a non-intrusive energy optimization technique, based on a given set of paths and sequences of operations, such that the original cycle time is not exceeded. We develop an optimization procedure based on a mathematical programming model that aims to minimize the energy consumption and peak power. Our technique has several advantages. It is non-intrusive, i.e. it requires limited changes in the robot program and can be implemented easily. Moreover,it is model-free, in the sense that no particular, and perhaps secret, parameter or dynamic model is required. Furthermore, the optimization can be done offline, within seconds using a generic solver. Through careful experiments, we have shown that it is possible to reduce energy and peak-power up to about 30% and 50% respectively. The second category of moving devices comprises of generic vehicles in a VRP context. We have developed a hybrid optimization approach that integrates a distributed algorithm based on a gossip protocol with a column generation (CG) algorithm, which manages to solve the tested problems faster than the CG algorithm alone. The algorithm is developed for a VRP variation including time windows (VRPTW), which is meant to model the task of scheduling and routing of caregivers in the context of home healthcare routing and scheduling problems (HHRSPs). Moreover,the developed algorithm can easily be parallelized to further increase its efficiency. The last category deals with AGVs. The choice of AGVs was not arbitrary; by design, we decided to transfer our knowledge of energy optimization and routing algorithms to a class of moving devices in which both techniques are of interest. Initially, we improve an existing method of conflict-free AGV scheduling and routing, such that the new algorithm can manage larger problems. A heuristic version of the algorithm manages to solve the problem instances in a reasonable amount of time. Later, we develop strategies to reduce the energy consumption. The study is carried out using an AGV system installed at Volvo Cars. The results are promising; (1)the algorithm reduces performance measures such as makespan up to 50%, while reducing the total travelled distance of the vehicles about 14%, leading to an energy saving of roughly 14%, compared to the results obtained from the original traffic controller. (2) It is possible to reduce the cruise velocities such that more energy is saved, up to 20%, while the new makespan remains better than the original one

Timed petri net simulation of flexible manufacturing systems

Standard Petri nets have been used to model and analyze Flexible Manufacturing Systems. The timed Petri net, which can incorporate the time delay associated with manufacturing events, provides additional information about real time behavior of practical systems. The Timed Petri Net Simulation Tool, a highly interactive graphical tool, is applied to simulate the modeled flexible manufacturing systems. Timed Petri net models are experimented with. Machine utilization data and throughput are obtained. Analysis of the results shows that the system performance can be optimized by choosing proper parameters

Software development for analysis of stochastic petri nets using transfer functions

This thesis research is an implementation of a closed-form analytical technique for study, evaluation and analysis of Stochastic Petri Nets (SPN). The technique is based on a theorem that an isomorphism exists between an SPN and a Markov Chain. The procedure comprises five main steps: reachability graph generation of the underlying Petri net, transformation of the reachability graph to a state machine Petri net, calculation of transfer functions, computation of equivalent transfer functions via Mason\u27s rule, and computation of performance parameters of the SPN model from the equivalent transfer functions and their derivatives. The software is developed in UNIX using C and applied to various SPN models. Future research includes implementation of Mason\u27s rule for complex cases and symbolic derivation of equivalent transfer functions

Petri net modeling and performance analysis of can fieldbus

The CAN FB (Controller Area Network FieldBus) has been in existence for ten years. It supports automated manufacturing and process control environments to interconnect intelligent devices such as valves, sensors, and actuators. CAN FieldBus has a high bit rate and the ability to detect errors. It is immune to noise and resistant to shock, vibration, and heat. Two recently introduced mechanisms, Distributed Priority Queue (DPQ) and Priority Promotion (PP) enable CAN FieldBus networks to share out the system bandwidth and grant ail upper bound on the transmission times so as to meet the requirements in real-time communications. Modeling and analysis of such networks are an important research area for their wide applications in manufacturing automation. This thesis presents a Petri net methodology which models and analyzes CAN FieldBus access protocol. A Reachability Graph of the Petri net model is -utilized to study the behavioral properties of the protocol. A timed Petri net simulator is used to evaluate the performance of the protocol. Performance measures include the completion time for successful events and operations. Operational parameters investigated using the Petri Net model are FieldBus speed, the length of each frame, and the number of frames in a message

Analysing the impact of rescheduling time in hybrid manufacturing control

Hybrid manufacturing control architectures merge the benefits of hierarchical and heterarchical approaches. Disturbances can be handled at upper or lower decision levels, depending on the type of disturbance, its impact and the time the control system has to react. This paper focuses particularly on a disturbance handling mechanism at upper decision levels using a rescheduling manufacturing method. Such rescheduling is more complex that the offline scheduling since the control system must take into account the current system status, obtain a satisfactory performance under the new conditions, and also come up with a new schedule in a restricted amount of time. Then, this paper proposes a simple and generic rescheduling method which, based on the satisfying principle, analyses the trade-off between the rescheduling time and the performance achieved after a perturbation. The proposed approach is validated on a simulation model of a realistic assembly cell and results demonstrate that adaptation of the rescheduling time might be beneficial in terms of overall performance and reactivity.info:eu-repo/semantics/publishedVersio

Contributions to the deadlock problem in multithreaded software applications observed as Resource Allocation Systems

Desde el punto de vista de la competencia por recursos compartidos sucesivamente reutilizables, se dice que un sistema concurrente compuesto por procesos secuenciales está en situación de bloqueo si existe en él un conjunto de procesos que están indefinidamente esperando la liberación de ciertos recursos retenidos por miembros del mismo conjunto de procesos. En sistemas razonablemente complejos o distribuidos, establecer una política de asignación de recursos que sea libre de bloqueos puede ser un problema muy difícil de resolver de forma eficiente. En este sentido, los modelos formales, y particularmente las redes de Petri, se han ido afianzando como herramientas fructíferas que permiten abstraer el problema de asignación de recursos en este tipo de sistemas, con el fin de abordarlo analíticamente y proveer métodos eficientes para la correcta construcción o corrección de estos sistemas. En particular, la teoría estructural de redes de Petri se postula como un potente aliado para lidiar con el problema de la explosión de estados inherente a aquéllos. En este fértil contexto han florecido una serie de trabajos que defienden una propuesta metodológica de diseño orientada al estudio estructural y la correspondiente corrección física del problema de asignación de recursos en familias de sistemas muy significativas en determinados contextos de aplicación, como el de los Sistemas de Fabricación Flexible. Las clases de modelos de redes de Petri resultantes asumen ciertas restricciones, con significado físico en el contexto de aplicación para el que están destinadas, que alivian en buena medida la complejidad del problema. En la presente tesis, se intenta acercar ese tipo de aproximación metodológica al diseño de aplicaciones software multihilo libres de bloqueos. A tal efecto, se pone de manifiesto cómo aquellas restricciones procedentes del mundo de los Sistemas de Fabricación Flexible se muestran demasiado severas para aprehender la versatilidad inherente a los sistemas software en lo que respecta a la interacción de los procesos con los recursos compartidos. En particular, se han de resaltar dos necesidades de modelado fundamentales que obstaculizan la mera adopción de antiguas aproximaciones surgidas bajo el prisma de otros dominios: (1) la necesidad de soportar el anidamiento de bucles no desplegables en el interior de los procesos, y (2) la posible compartición de recursos no disponibles en el arranque del sistema pero que son creados o declarados por un proceso en ejecución. A resultas, se identifica una serie de requerimientos básicos para la definición de un tipo de modelos orientado al estudio de sistemas software multihilo y se presenta una clase de redes de Petri, llamada PC2R, que cumple dicha lista de requerimientos, manteniéndose a su vez respetuosa con la filosofía de diseño de anteriores subclases enfocadas a otros contextos de aplicación. Junto con la revisión e integración de anteriores resultados en el nuevo marco conceptual, se aborda el estudio de propiedades inherentes a los sistemas resultantes y su relación profunda con otros tipos de modelos, la confección de resultados y algoritmos eficientes para el análisis estructural de vivacidad en la nueva clase, así como la revisión y propuesta de métodos de resolución de los problemas de bloqueo adaptadas a las particularidades físicas del dominio de aplicación. Asimismo, se estudia la complejidad computacional de ciertas vertientes relacionadas con el problema de asignación de recursos en el nuevo contexto, así como la traslación de los resultados anteriormente mencionados sobre el dominio de la ingeniería de software multihilo, donde la nueva clase de redes permite afrontar problemas inabordables considerando el marco teórico y las herramientas suministradas para subclases anteriormente explotadas

Scheduling of flexible manufacturing systems with automated guided vehicles using petri net models

In this thesis, Petri net models for Flexible Manufacturing Systems (EMS) are constructed. A firing sequence of the Petri net from the initial marking to the final marking can be seen as a schedule of the modeled FMS. By using the branch-and-bound algorithm, an optimal schedule of the FMS can be obtained. Automated Guided Vehicle Systems (AGVS) are increasingly used for material handling in factories and warehouses. An AGVS can reduce labor costs and is ready to be integrated into an automated factory. This thesis presents two AGVS models (shared and duty) which integrate the control of AGVS with the control of part processing facilities. Both types of AGVS are modeled by Petri nets. We want to compare the two AGVS in terms of systems performance and discuss which application is more suitable for each AGVS type. We also want to consider and solve AGV jam problems. The objective of the AGV jam-free control module is to guarantee a jam-free condition among AGVs in an EMS. Results have been obtained and analyzed