Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

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

A hormone regulation based approach for distributed and on-line scheduling of machines and automated guided vehicles

[EN] With the continuous innovation of technology, automated guided vehicles are playing an increasingly important role on manufacturing systems. Both the scheduling of operations on machines as well as the scheduling of automated guided vehicles are essential factors contributing to the efficiency of the overall manufacturing systems. In this article, a hormone regulation¿based approach for on-line scheduling of machines and automated guided vehicles within a distributed system is proposed. In a real-time environment, the proposed approach assigns emergent tasks and generates feasible schedules implementing a task allocation approach based on hormonal regulation mechanism. This approach is tested on two scheduling problems in literatures. The results from the evaluation show that the proposed approach improves the scheduling quality compared with state-of-the-art on-line and off-line approaches.The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This research was sponsored by the National Natural Science Foundation of China (NSFC) under grant nos 51175262 and 51575264 and the Jiangsu Province Science Foundation for Excellent Youths under grant no. BK2012032. This research was also sponsored by the CASES project which was supported by a Marie Curie International Research Staff Exchange Scheme Fellowship within the 7th European Community Framework Programme under grant agreement no. 294931.Zheng, K.; Tang, D.; Giret Boggino, AS.; Salido, MA.; Sang, Z. (2016). A hormone regulation based approach for distributed and on-line scheduling of machines and automated guided vehicles. Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture. 232(1):99-113. https://doi.org/10.1177/0954405416662078S99113232

Simulation in Automated Guided Vehicle System Design

The intense global competition that manufacturing companies face today results in an increase of product variety and shorter product life cycles. One response to this threat is agile manufacturing concepts. This requires materials handling systems that are agile and capable of reconfiguration. As competition in the world marketplace becomes increasingly customer-driven, manufacturing environments must be highly reconfigurable and responsive to accommodate product and process changes, with rigid, static automation systems giving way to more flexible types. Automated Guided Vehicle Systems (AGVS) have such capabilities and AGV functionality has been developed to improve flexibility and diminish the traditional disadvantages of AGV-systems. The AGV-system design is however a multi-faceted problem with a large number of design factors of which many are correlating and interdependent. Available methods and techniques exhibit problems in supporting the whole design process. A research review of the work reported on AGVS development in combination with simulation revealed that of 39 papers only four were industrially related. Most work was on the conceptual design phase, but little has been reported on the detailed simulation of AGVS. Semi-autonomous vehicles (SA V) are an innovative concept to overcome the problems of inflexible -systems and to improve materials handling functionality. The SA V concept introduces a higher degree of autonomy in industrial AGV -systems with the man-in-the-Ioop. The introduction of autonomy in industrial applications is approached by explicitly controlling the level of autonomy at different occasions. The SA V s are easy to program and easily reconfigurable regarding navigation systems and material handling equipment. Novel approaches to materials handling like the SA V -concept place new requirements on the AGVS development and the use of simulation as a part of the process. Traditional AGV -system simulation approaches do not fully meet these requirements and the improved functionality of AGVs is not used to its full power. There is a considerflble potential in shortening the AGV -system design-cycle, and thus the manufacturing system design-cycle, and still achieve more accurate solutions well suited for MRS tasks. Recent developments in simulation tools for manufacturing have improved production engineering development and the tools are being adopted more widely in industry. For the development of AGV -systems this has not fully been exploited. Previous research has focused on the conceptual part of the design process and many simulation approaches to AGV -system design lack in validity. In this thesis a methodology is proposed for the structured development of AGV -systems using simulation. Elements of this methodology address the development of novel functionality. The objective of the first research case of this research study was to identify factors for industrial AGV -system simulation. The second research case focuses on simulation in the design of Semi-autonomous vehicles, and the third case evaluates a simulation based design framework. This research study has advanced development by offering a framework for developing testing and evaluating AGV -systems, based on concurrent development using a virtual environment. The ability to exploit unique or novel features of AGVs based on a virtual environment improves the potential of AGV-systems considerably.University of Skovde. European Commission for funding the INCO/COPERNICUS Projec

Task Assignment and Path Planning for Autonomous Mobile Robots in Stochastic Warehouse Systems

The material handling industry is in the middle of a transformation from manual operations to automation due to the rapid growth in e-commerce. Autonomous mobile robots (AMRs) are being widely implemented to replace manually operated forklifts in warehouse systems to fulfil large shipping demand, extend warehouse operating hours, and mitigate safety concerns. Two open questions in AMR management are task assignment and path planning. This dissertation addresses the task assignment and path planning (TAPP) problem for autonomous mobile robots (AMR) in a warehouse environment. The goals are to maximize system productivity by avoiding AMR traffic and reducing travel time. The first topic in this dissertation is the development of a discrete event simulation modeling framework that can be used to evaluate alternative traffic control rules, task assignment methods, and path planning algorithms. The second topic, Risk Interval Path Planning (RIPP), is an algorithm designed to avoid conflicts among AMRs considering uncertainties in robot motion. The third topic is a deep reinforcement learning (DRL) model that is developed to solve task assignment and path planning problems, simultaneously. Experimental results demonstrate the effectiveness of these methods in stochastic warehouse systems

An Iterative Approach for Collision Feee Routing and Scheduling in Multirobot Stations

This work is inspired by the problem of planning sequences of operations, as welding, in car manufacturing stations where multiple industrial robots cooperate. The goal is to minimize the station cycle time, \emph{i.e.} the time it takes for the last robot to finish its cycle. This is done by dispatching the tasks among the robots, and by routing and scheduling the robots in a collision-free way, such that they perform all predefined tasks. We propose an iterative and decoupled approach in order to cope with the high complexity of the problem. First, collisions among robots are neglected, leading to a min-max Multiple Generalized Traveling Salesman Problem (MGTSP). Then, when the sets of robot loads have been obtained and fixed, we sequence and schedule their tasks, with the aim to avoid conflicts. The first problem (min-max MGTSP) is solved by an exact branch and bound method, where different lower bounds are presented by combining the solutions of a min-max set partitioning problem and of a Generalized Traveling Salesman Problem (GTSP). The second problem is approached by assuming that robots move synchronously: a novel transformation of this synchronous problem into a GTSP is presented. Eventually, in order to provide complete robot solutions, we include path planning functionalities, allowing the robots to avoid collisions with the static environment and among themselves. These steps are iterated until a satisfying solution is obtained. Experimental results are shown for both problems and for their combination. We even show the results of the iterative method, applied to an industrial test case adapted from a stud welding station in a car manufacturing line

Control of free-ranging automated guided vehicles in container terminals

Container terminal automation has come to the fore during the last 20 years to improve their efficiency. Whereas a high level of automation has already been achieved in vertical handling operations (stacking cranes), horizontal container transport still has disincentives to the adoption of automated guided vehicles (AGVs) due to a high degree of operational complexity of vehicles. This feature has led to the employment of simple AGV control techniques while hindering the vehicles to utilise their maximum operational capability. In AGV dispatching, vehicles cannot amend ongoing delivery assignments although they have yet to receive the corresponding containers. Therefore, better AGV allocation plans would be discarded that can only be achieved by task reassignment. Also, because of the adoption of predetermined guide paths, AGVs are forced to deploy a highly limited range of their movement abilities while increasing required travel distances for handling container delivery jobs. To handle the two main issues, an AGV dispatching model and a fleet trajectory planning algorithm are proposed. The dispatcher achieves job assignment flexibility by allowing AGVs towards to container origins to abandon their current duty and receive new tasks. The trajectory planner advances Dubins curves to suggest diverse optional paths per origin-destination pair. It also amends vehicular acceleration rates for resolving conflicts between AGVs. In both of the models, the framework of simulated annealing was applied to resolve inherent time complexity. To test and evaluate the sophisticated AGV control models for vehicle dispatching and fleet trajectory planning, a bespoke simulation model is also proposed. A series of simulation tests were performed based on a real container terminal with several performance indicators, and it is identified that the presented dispatcher outperforms conventional vehicle dispatching heuristics in AGV arrival delay time and setup travel time, and the fleet trajectory planner can suggest shorter paths than the corresponding Manhattan distances, especially with fewer AGVs.Open Acces

Reinforcement Learning Based Production Control of Semi-automated Manufacturing Systems

In an environment which is marked by an increasing speed of changes, industrial companies have to be able to quickly adapt to new market demands and innovative technologies. This leads to a need for continuous adaption of existing production systems and the optimization of their production control. To tackle this problem digitalization of production systems has become essential for new and existing systems. Digital twins based on simulations of real production systems allow the simplification of analysis processes and, thus, a better understanding of the systems, which leads to broad optimization possibilities. In parallel, machine learning methods can be integrated to process the numerical data and discover new production control strategies. In this work, these two methods are combined to derive a production control logic in a semi-automated production system based on the chaku-chaku principle. A reinforcement learning method is integrated into the digital twin to autonomously learn a superior production control logic for the distribution of tasks between the different workers on a production line. By analyzing the influence of different reward shaping and hyper-parameter optimization on the quality and stability of the results obtained, the use of a well-configured policy-based algorithm enables an efficient management of the workers and the deduction of an optimal production control logic for the production system. The algorithm manages to define a control logic that leads to an increase in productivity while having a stable task assignment so that a transfer to daily business is possible. The approach is validated in the digital twin of a real assembly line of an automotive supplier. The results obtained suggest a new approach to optimizing production control in production lines. Production control shall be centered directly on the workers’ routines and controlled by artificial intelligence infused with a global overview of the entire production system