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

Acyclic Transformation Technique for the Reachability Analysis of Petri Nets

Industrial Engineering and Managemen

Enhancing the performance of automated guided vehicles through reliability, operation and maintenance assessment

Automated guided vehicles (AGVs), a type of unmanned moving robots that move along fixed routes or are directed by laser navigation systems, are increasingly used in modern society to improve efficiency and lower the cost of production. A fleet of AGVs operate together to form a fully automatic transport system, which is known as an AGV system. To date, their added value in efficiency improvement and cost reduction has been sufficiently explored via conducting in-depth research on route optimisation, system layout configuration, and traffic control. However, their safe application has not received sufficient attention although the failure of AGVs may significantly impact the operation and efficiency of the entire system. This issue becomes more markable today particularly in the light of the fact that the size of AGV systems is becoming much larger and their operating environment is becoming more complex than ever before. This motivates the research into AGV reliability, availability and maintenance issues in this thesis, which aims to answer the following four fundamental questions: (1) How could AGVs fail? (2) How is the reliability of individual AGVs in the system assessed? (3) How does a failed AGV affect the operation of the other AGVs and the performance of the whole system? (4) How can an optimal maintenance strategy for AGV systems be achieved? In order to answer these questions, the method for identifying the critical subsystems and actions of AGVs is studied first in this thesis. Then based on the research results, mathematical models are developed in Python to simulate AGV systems and assess their performance in different scenarios. In the research of this thesis, Failure Mode, Effects and Criticality Analysis (FMECA) was adopted first to analyse the failure modes and effects of individual AGV subsystems. The interactions of these subsystems were studied via performing Fault Tree Analysis (FTA). Then, a mathematical model was developed to simulate the operation of a single AGV with the aid of Petri Nets (PNs). Since most existing AGV systems in modern industries and warehouses consist of multiple AGVs that operate synchronously to perform specific tasks, it is necessary to investigate the interactions between different AGVs in the same system. To facilitate the research of multi-AGV systems, the model of a three-AGV system with unidirectional paths was considered. In the model, an advanced concept PN, namely Coloured Petri Net (CPN), was creatively used to describe the movements of the AGVs. Attributing to the application of CPN, not only the movements of the AGVs but also the various operation and maintenance activities of the AGV systems (for example, item delivery, corrective maintenance, periodic maintenance, etc.) can be readily simulated. Such a unique technique provides us with an effective tool to investigate larger-scale AGV systems. To investigate the reliability, efficiency and maintenance of dynamic AGV systems which consist of multiple single-load and multi-load AGVs traveling along different bidirectional routes in different missions, an AGV system consisting of 9 stations was simulated using the CPN methods. Moreover, the automatic recycling of failed AGVs is studied as well in order to further reduce human participation in the operation of AGV systems. Finally, the simulation results were used to optimise the design, operation and maintenance of multi-AGV systems with the consideration of the throughputs and corresponding costs of them.The research reported in this thesis contributes to the design, reliability, operation, and maintenance of large-scale AGV systems in the modern and rapidly changing world.</div

A Petri net-occam based methodology for the development of dependable distributed control software.

Analysis of flexible manufacturing cells (FMCs) shows their requirement for flexible, correct, reliable, safe and distributed control. A comparison of the state of the art in software engineering for parallel systems, and an examination of safety related systems, reveal a need for formal and rigorous techniques at all stages in the software life cycle. However, parallel software, safety related software and formal techniques are complex. It is better to avoid faults rather than eliminate or tolerate them, and although less flexible, avoidance is often simpler to implement. There is a need for a tool which overcomes many of these complexities, and this thesis discusses and defines such a tool in the form of a methodology. The novelty of the work is in the combination of the core goals to manage these issues, and how the strategies guide the user to a solution which will not deadlock and which is comprehensible. Place-transition Petri nets are an ideal representation for designing and modelling the interaction of concurrent (and distributed) processes. Occam is a high level real time parallel language designed to execute on one or a network of transputers. Transputers are processing, memory and communication building blocks, and, together with occam, are shown to be suitable for controlling and communicating the control as the DCS in FMCs. The methodology developed in this thesis adopts the mathematically based tools of Petri nets, occam and transputers, and, by exploiting their structural similarities, incorporates them in a steps and tasks to improve the development of correct, reliable and hence safe occam code. The four steps: identify concurrent and sequential operations, produce Petri net graphs for all controllers, combine controller Petri net graphs and translate Petri net graphs into occam; are structured around three core goals: Petri net/occam equivalence, comprehensibility and pro-activity; which are manifest in four strategies: output-work-backwards, concurrent and sequential actions, structuralise and modularise, and deadlock avoidance. The methodology assists in all stages of the software development life cycle, and is applicable to small DCSs such as an FMC. The methodology begins by assisting in the creation of DCS requirements from the manufacturing requirements of the FMC, and guides the user to the production of dependable occam code. Petri nets allow the requirements to be specified as they are created, and the methodology's imposed restrictions enable the final Petri net design to be translated directly into occam. Thus the mathematics behind the formal tools is hidden from the user, which should be attractive to industry.The methodology is successfully applied to the example FMC, and occam code to simulate the FMC is produced. Due to the novelty of the research, many suggestions for further work are given

A model driven approach to analysis and synthesis of sequence diagrams

Software design is a vital phase in a software development life cycle as it creates a blueprint for the implementation of the software. It is crucial that software designs are error-free since any unresolved design-errors could lead to costly implementation errors. To minimize these errors, the software community adopted the concept of modelling from various other engineering disciplines. Modelling provides a platform to create and share abstract or conceptual representations of the software system – leading to various modelling languages, among them Unified Modelling Language (UML) and Petri Nets. While Petri Nets strong mathematical capability allows various formal analyses to be performed on the models, UMLs user-friendly nature presented a more appealing platform for system designers. Using Multi Paradigm Modelling, this thesis presents an approach where system designers may have the best of both worlds; SD2PN, a model transformation that maps UML Sequence Diagrams into Petri Nets allows system designers to perform modelling in UML while still using Petri Nets to perform the analysis. Multi Paradigm Modelling also provided a platform for a well-established theory in Petri Nets – synthesis to be adopted into Sequence Diagram as a method of putting-together different Sequence Diagrams based on a set of techniques and algorithms

Symbolic Supervisory Control of Resource Allocation Systems

<p>Supervisory control theory (SCT) is a formal model-based methodology for verification and synthesis of supervisors for discrete event systems (DES). The main goal is to guarantee that the closed-loop system fulfills given specifications. SCT has great promise to assist engineers with the generation of reliable control functions. This is, for instance, beneficial to manufacturing systems where both products and production equipment might change frequently.</p> <p>The industrial acceptance of SCT, however, has been limited for at least two reasons: (i) the analysis of DES involves an intrinsic difficulty known as the state-space explosion problem, which makes the explicit enumeration of enormous state-spaces for industrial systems intractable; (ii) the synthesized supervisor, represented as a deterministic finite automaton (FA) or an extended finite automaton (EFA), is not straightforward to implement in an industrial controller.</p> <p>In this thesis, to address the aforementioned issues, we study the modeling, synthesis and supervisor representation of DES using binary decision diagrams (BDDs), a compact data structure for representing DES models symbolically. We propose different kinds of BDD-based algorithms for exploring the symbolically represented state-spaces in an effort to improve the abilities of existing supervisor synthesis approaches to handle large-scale DES and represent the obtained supervisors appropriately.</p> <p>Following this spirit, we bring the efficiencies of BDD into a particular DES application domain -- deadlock avoidance for resource allocation systems (RAS) -- a problem that arises in many technological systems including flexible manufacturing systems and multi-threaded software. We propose a framework for the effective and computationally efficient development of the maximally permissive deadlock avoidance policy (DAP) for various RAS classes. Besides the employment of symbolic computation, special structural properties that are possessed by RAS are utilized by the symbolic algorithms to gain additional efficiencies in the computation of the sought DAP. Furthermore, to bridge the gap between the BDD-based representation of the target DAP and its actual industrial realization, we extend this work by introducing a procedure that generates a set of "guard" predicates to represent the resulting DAP.</p> <p>The work presented in this thesis has been implemented in the SCT tool Supremica. Computational benchmarks have manifested the superiority of the proposed algorithms with respect to the previously published results. Hence, the work holds a strong potential for providing robust, practical and efficient solutions to a broad range of supervisory control and deadlock avoidance problems that are experienced in the considered DES application domain.</p