Towards a new methodology for design, modelling, and verification of reconfigurable distributed control systems based on a new extension to the IEC 61499 standard

In order to meet user requirements and system environment changes, reconfigurable control systems must dynamically adapt their structure and behaviour without disrupting system operation. IEC 61499 standard provides limited support for the design and verification of such systems. In fact, handling different reconfiguration scenarios at runtime is difficult since function blocks in IEC 61499 cannot be changed at run-time. Hence, this thesis promotes an IEC 61499 extension called reconfigurable function block (RFB) that increases design readability and smoothly switches to the most appropriate behaviour when a reconfiguration event occurs. To ensure system feasibility after reconfiguration, in addition to the qualitative verification, quantitative verification based on probabilistic model checking is addressed in a new RFBA approach. The latter aims to transform the designed RFB model automatically into a generalised reconfigurable timed net condition/event system model (GRTNCES) using a newly developed environment called RFBTool. The GR-TNCES fits well with RFB and preserves its semantic. Using the probabilistic model checker PRISM, the generated GR-TNCES model is checked using defined properties specified in computation tree logic. As a result, an evaluation of system performance and an estimation of reconfiguration risks are obtained. The RFBA methodology is applied on a distributed power system case study.Dynamische Anforderungen und Umgebungen erfordern rekonfigurierbare Anlagen und Steuerungssysteme. Rekonfiguration ermöglicht es einem System, seine Struktur und sein Verhalten an interne oder externe Änderungen anzupassen. Die Norm IEC 61499 wurde entwickelt, um (verteilte) Steuerungssysteme auf Basis von Funktionsbausteinen zu entwickeln. Sie bietet jedoch wenig Unterstützung für Entwurf und Verifikation. Die Tatsache, dass eine Rekonfiguration das System-Ausführungsmodell verändert, erschwert die Entwicklung in IEC 61499 zusätzlich. Daher schlägt diese Dissertation rekonfigurierbare Funktionsbausteine (RFBs) als Erweiterung der Norm vor. Ein RFB verarbeitet über einen Master-Slave-Automaten Rekonfigurationsereignisse und löst das entsprechende Verhalten aus. Diese Hierarchie trennt das Rekonfigurationsmodell vom Steuerungsmodell und vereinfacht so den Entwurf. Die Funktionalität des Entwurfs muss verifiziert werden, damit die Ausführbarkeit des Systems nach einer Rekonfiguration gewährleistet ist. Hierzu wird das entworfene RFB-Modell automatisch in ein generalised reconfigurable timed net condition/event system übersetzt. Dieses wird mit dem Model-Checker PRISM auf qualitative und quantitative Eigenschaften überprüft. Somit wird eine Bewertung der Systemperformanz und eine Einschätzung der Rekonfigurationsrisiken erreicht. Die RFB-Methodik wurde in einem Softwarewerkzeug umgesetzt und in einer Fallstudie auf ein dezentrales Stromnetz angewendet

The DS-Pnet modeling formalism for cyber-physical system development

This work presents the DS-Pnet modeling formalism (Dataflow, Signals and Petri nets), designed for the development of cyber-physical systems, combining the characteristics of Petri nets and dataflows to support the modeling of mixed systems containing both reactive parts and data processing operations. Inheriting the features of the parent IOPT Petri net class, including an external interface composed of input and output signals and events, the addition of dataflow operations brings enhanced modeling capabilities to specify mathematical data transformations and graphically express the dependencies between signals. Data-centric systems, that do not require reactive controllers, are designed using pure dataflow models. Component based model composition enables reusing existing components, create libraries of previously tested components and hierarchically decompose complex systems into smaller sub-systems. A precise execution semantics was defined, considering the relationship between dataflow and Petri net nodes, providing an abstraction to define the interface between reactive controllers and input and output signals, including analog sensors and actuators. The new formalism is supported by the IOPT-Flow Web based tool framework, offering tools to design and edit models, simulate model execution on the Web browser, plus model-checking and software/hardware automatic code generation tools to implement controllers running on embedded devices (C,VHDL and JavaScript). A new communication protocol was created to permit the automatic implementation of distributed cyber-physical systems composed of networks of remote components communicating over the Internet. The editor tool connects directly to remote embedded devices running DS-Pnet models and may import remote components into new models, contributing to simplify the creation of distributed cyber-physical applications, where the communication between distributed components is specified just by drawing arcs. Several application examples were designed to validate the proposed formalism and the associated framework, ranging from hardware solutions, industrial applications to distributed software applications

An approach to open virtual commissioning for component-based automation

Increasing market demands for highly customised products with shorter time-to-market and at lower prices are forcing manufacturing systems to be built and operated in a more efficient ways. In order to overcome some of the limitations in traditional methods of automation system engineering, this thesis focuses on the creation of a new approach to Virtual Commissioning (VC). In current VC approaches, virtual models are driven by pre-programmed PLC control software. These approaches are still time-consuming and heavily control expertise-reliant as the required programming and debugging activities are mainly performed by control engineers. Another current limitation is that virtual models validated during VC are difficult to reuse due to a lack of tool-independent data models. Therefore, in order to maximise the potential of VC, there is a need for new VC approaches and tools to address these limitations. The main contributions of this research are: (1) to develop a new approach and the related engineering tool functionality for directly deploying PLC control software based on component-based VC models and reusable components; and (2) to build tool-independent common data models for describing component-based virtual automation systems in order to enable data reusability. [Continues.

Software framework for the development of context-aware reconfigurable systems

In this project we propose a new software framework for the development of context-aware and secure controlling software of distributed reconfigurable systems. Context-awareness is a key feature allowing the adaptation of systems behaviour according to the changing environment. We introduce a new definition of the term “context” for reconfigurable systems then we define a new context modelling and reasoning approach. Afterwards, we define a meta-model of context-aware reconfigurable applications that paves the way to the proposed framework. The proposed framework has a three-layer architecture: reconfiguration, context control, and services layer, where each layer has its well-defined role. We define also a new secure conversation protocol between distributed trustless parts based on the blockchain technology as well as the elliptic curve cryptography. To get better correctness and deployment guarantees of applications models in early development stages, we propose a new UML profile called GR-UML to add new semantics allowing the modelling of probabilistic scenarios running under memory and energy constraints, then we propose a methodology using transformations between the GR-UML, the GR-TNCES Petri nets formalism, and the IEC 61499 function blocks. A software tool implementing the methodology concepts is developed. To show the suitability of the mentioned contributions two case studies (baggage handling system and microgrids) are considered.In diesem Projekt schlagen wir ein Framework für die Entwicklung von kontextbewussten, sicheren Anwendungen von verteilten rekonfigurierbaren Systemen vor. Kontextbewusstheit ist eine Schlüsseleigenschaft, die die Anpassung des Systemverhaltens an die sich ändernde Umgebung ermöglicht. Wir führen eine Definition des Begriffs ``Kontext" für rekonfigurierbare Systeme ein und definieren dann einen Kontextmodellierungs- und Reasoning-Ansatz. Danach definieren wir ein Metamodell für kontextbewusste rekonfigurierbare Anwendungen, das den Weg zum vorgeschlagenen Framework ebnet. Das Framework hat eine dreischichtige Architektur: Rekonfigurations-, Kontextkontroll- und Dienste-Schicht, wobei jede Schicht ihre wohldefinierte Rolle hat. Wir definieren auch ein sicheres Konversationsprotokoll zwischen verteilten Teilen, das auf der Blockchain-Technologie sowie der elliptischen Kurven-Kryptographie basiert. Um bessere Korrektheits- und Einsatzgarantien für Anwendungsmodelle zu erhalten, schlagen wir ein UML-Profil namens GR-UML vor, um Semantik umzufassen, die die Modellierung probabilistischer Szenarien unter Speicher- und Energiebeschränkungen ermöglicht. Dann schlagen wir eine Methodik vor, die Transformationen zwischen GR-UML, dem GR-TNCES-Petrinetz-Formalismus und den IEC 61499-Funktionsblöcken verwendet. Es wird ein Software entwickelt, das die Konzepte der Methodik implementiert. Um die Eignung der genannten Beiträge zu zeigen, werden zwei Fallstudien betrachtet

Worker-robot cooperation and integration into the manufacturing workcell via the holonic control architecture

Cooperative manufacturing is a new field of research, which addresses new challenges beyond the physical safety of the worker. Those new challenges appear due to the need to connect the worker and the cobot from the informatics point of view in one cooperative workcell. This requires developing an appropriate manufacturing control system, which fits the nature of both the worker and the cobot. Furthermore, the manufacturing control system must be able to understand the production variations, to guide the cooperation between worker and the cobot and adapt with the production variations.Die kooperative Fertigung ist ein neues Forschungsgebiet, das sich neuen Herausforderungen stellt. Diese neuen Herausforderungen ergeben sich aus der Notwendigkeit, den Arbeiter und den Cobot aus der Sicht der Informatik in einem kooperativen Arbeitsplatz zu verbinden. Dies erfordert die Entwicklung eines geeigneten Produktionskontrollsystems, das sowohl der Natur des Arbeiters als auch der des Cobots entspricht. Darüber hinaus muss die Fertigungssteuerung in der Lage sein, die Produktionsschwankungen zu verstehen, um die Zusammenarbeit zwischen Arbeiter und Cobot zu steuern

Innovative configurable and collaborative approach to automation systems engineering for automotive powertrain assembly

Presently the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Both, agility and reconfiguration are widely recognised as important attributes for manufacturing systems to satisfy the needs of competitive global markets. To facilitate and accommodate unforeseen business changes within the automotive industry, a new proactive methodology is urgently required for the design, build, assembly and reconfiguration of automation systems. There is also need for the promotion of new technologies and engineering methods to enable true engineering concurrency between product and process development. Virtual construction and testing of new automation systems prior to build is now identified as a crucial requirement to enable system verification and to allow the investigation of design alternatives prior to building and testing physical systems. The main focus of this research was to design and develop reconfigurable assembly systems within the powertrain sector of the automotive industry by capturing and modelling relevant business and engineering processes. This research has proposed and developed a more process-efficient and robust automation system design, build and implementation approach via new engineering services and a standard library of reusable mechanisms. Existing research at Loughborough had created the basic technology for a component based approach to automation. However, no research had been previously undertaken on the application of this approach in a user engineering and business context. The objective of this research was therefore to utilise this prototype method and associated engineering tools and to devise novel business and engineering processes to enable the component-based approach to be applied in industry. This new approach has been named Configurable and Collaborative Automation Systems (CO AS). In particular this new research has studied the implications of migration to a COAS approach in terms of I) necessary changes to the end-users business processes, 2) potential to improve the robustness of the resultant system and 3) potential for improved efficiency and greater collaboration across the supply chain... cont'

Modeling and verification of reconfigurable discrete event control systems

Most modern technological systems rely on complicated control technologies, computer technologies, and networked communication technologies. Their dynamic behavior is intricate due to the concurrence and conflict of various signals. Such complex systems are studied as discrete event control systems (DECSs), while the detailed continuous variable processes are abstracted. Dynamic reconfigurable systems are the trend of all future technological systems, such as flight control systems, vehicle electronic systems, and manufacturing systems. In order to meet control requirements continuously, such a dynamic reconfigurable system is able to actively adjust its configuration at runtime by modifying ist components, connections among components and data, while changes are detected in the internal/external execution environment. Model based design methodologies attract wide attention since they can detect system defect earlier, increase system reliability, and decrease time and cost on system development. An accurate, compact, and easy formal model to be analyzed is the first step of model based design methods. Formal verification is an expected effective method to completely check if a designed system meets all requirements and to improve the system design scheme. Considering the potential benefits of Timed Net Condition/Event Systems (TNCESs) in modeling and analyzing reconfigurable systems, this dissertation deals with formal modeling and verification of reconfigurable discrete event control systems (RDECSs) based on them.Die meisten modernen technologischen Systeme benötigen aufwändige Steuerungs-, Rechner- und Kommunikationstechnologien. Aufgrund von Nebenläufigkeit und Konflikten ergibt sich ein kompliziertes dynamisches Verhalten. Derartige komplexe Systeme werden dadurch untersucht, dass man sie als ereignisdiskrete Steuerungssysteme (Discrete Event Control Systems, DECSs) betrachtet und dabei die detaillierten unterlagerten kontinuierlichen Prozesse abstrahiert. Um die Anforderungen an die Steuerung durchgängig erfüllen zu können adaptieren sich dynamische rekonfigurierbare Systeme zur Laufzeit durch Modifikation ihrer Komponenten, deren Verbindungen untereinander und der gespeicherten Daten, sobald Änderungen in der internen oder externen Umgebung festgestellt werden. Beispiele für dynamische Rekonfigurierbare Systeme finden sich in der Luftfahrt, im Automobilbereich aber auch in Fertigungssystemen. Modellbasierte Entwicklungsmethoden erfreuen sich zunehmender Beliebtheit, da sie es erlauben Fehler früher im Entwicklungsprozess aufzudecken und damit zu höherer Systemverfügbarkeit bei verkürzter Entwicklungszeit führen. Ein formales Modell des Systems bildet hierbei den ersten wichtigen Schritt. Durch formale Verifikation kann dieses Modell effektiv und vollständig überprüft und ggf. verbessert werden. Eine geeignete Modellform hierfür sind Timed Net Condition/Event Systems (TNCESs). Die vorliegende Dissertation befasst sich mit der Anwendung von TNCES zur Modellierung und Verifikation rekonfigurierbarer ereignisdiskreter Steuerungssysteme (RDECSs)

Multi-Agent Modelling of Industrial Cyber-Physical Systems for IEC 61499 Based Distributed Intelligent Automation

Traditional industrial automation systems developed under IEC 61131-3 in centralized architectures are statically programmed with determined procedures to perform predefined tasks in structured environments. Major challenges are that these systems designed under traditional engineering techniques and running on legacy automation platforms are unable to automatically discover alternative solutions, flexibly coordinate reconfigurable modules, and actively deploy corresponding functions, to quickly respond to frequent changes and intelligently adapt to evolving requirements in dynamic environments. The core objective of this research is to explore the design of multi-layer automation architectures to enable real-time adaptation at the device level and run-time intelligence throughout the whole system under a well-integrated modelling framework. Central to this goal is the research on the integration of multi-agent modelling and IEC 61499 function block modelling to form a new automation infrastructure for industrial cyber-physical systems. Multi-agent modelling uses autonomous and cooperative agents to achieve run-time intelligence in system design and module reconfiguration. IEC 61499 function block modelling applies object-oriented and event-driven function blocks to realize real-time adaption of automation logic and control algorithms. In this thesis, the design focuses on a two-layer self-manageable architecture modelling: a) the high-level cyber module designed as multi-agent computing model consisting of Monitoring Agent, Analysis Agent, Self-Learning Agent, Planning Agent, Execution Agent, and Knowledge Agent; and b) the low-level physical module designed as agent-embedded IEC 61499 function block model with Self-Manageable Service Execution Agent, Self-Configuration Agent, Self-Healing Agent, Self-Optimization Agent, and Self-Protection Agent. The design results in a new computing module for high-level multi-agent based automation architectures and a new design pattern for low-level function block modelled control solutions. The architecture modelling framework is demonstrated through various tests on the multi-agent simulation model developed in the agent modelling environment NetLogo and the experimental testbed designed on the Jetson Nano and Raspberry Pi platforms. The performance evaluation of regular execution time and adaptation time in two typical conditions for systems designed under three different architectures are also analyzed. The results demonstrate the ability of the proposed architecture to respond to major challenges in Industry 4.0