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 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

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

Control of Time-Constrained Dual-Armed Cluster Tools Using (max, +) Algebra

International audienceThe problem studied in this paper is the control of discrete event systems subject to strict temporal constraints using (max, +) algebra. Initially we sought necessary and sufficient conditions for the existence of a causal control law guaranteeing the respect of the temporal constraints. Subsequently, a method for calculating the control law, if any, is proposed. The application which we are interested in is the control of a manufacturing semiconductor wafers process subject to strict temporal constraints

Modeling and formal verification of probabilistic reconfigurable systems

In this thesis, we propose a new approach for formal modeling and verification of adaptive probabilistic systems. 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 user and environmental requirements, such a dynamic reconfigurable system has to actively adjust its configuration at run-time by modifying its components and connections, while changes are detected in the internal/external execution environment. On the other hand, these changes may violate the memory usage, the required energy and the concerned real-time constraints since the behavior of the system is unpredictable. It might also make the system's functions unavailable for some time and make potential harm to human life or large financial investments. Thus, updating a system with any new configuration requires that the post reconfigurable system fully satisfies the related constraints. We introduce GR-TNCES formalism for the optimal functional and temporal specification of probabilistic reconfigurable systems under resource constraints. It enables the optimal specification of a probabilistic, energetic and memory constraints of such a system. To formally verify the correctness and the safety of such a probabilistic system specification, and the non-violation of its properties, an automatic transformation from GR-TNCES models into PRISM models is introduced. Moreover, a new approach XCTL is also proposed to formally verify reconfigurable systems. It enables the formal certification of uncompleted and reconfigurable systems. A new version of the software ZIZO is also proposed to model, simulate and verify such GR-TNCES model. To prove its relevance, the latter was applied to case studies; it was used to model and simulate the behavior of an IPV4 protocol to prevent the energy and memory resources violation. It was also used to optimize energy consumption of an automotive skid conveyor.In dieser Arbeit wird ein neuer Ansatz zur formalen Modellierung und Verifikation dynamisch rekonfigurierbarer Systeme vorgestellt. Dynamische rekonfigurierbare Systeme sind in vielen aktuellen und zukünftigen Anwendungen, wie beispielsweise Flugsteuerungssystemen, Fahrzeugelektronik und Fertigungssysteme zu finden. Diese Systeme weisen ein probabilistisches, adaptives Verhalten auf. Um die Benutzer- und Umgebungsbedingungen kontinuierlich zu erfüllen, muss ein solches System seine Konfiguration zur Laufzeit aktiv anpassen, indem es seine Komponenten, Verbindungen zwischen Komponenten und seine Daten modifiziert (adaptiv), sobald Änderungen in der internen oder externen Ausführungsumgebung erkannt werden (probabilistisch). Diese Anpassungen dürfen Beschränkungen bei der Speichernutzung, der erforderlichen Energie und bestehende Echtzeitbedingungen nicht verletzen. Eine nicht geprüfte Rekonfiguration könnte dazu führen, dass die Funktionen des Systems für einige Zeit nicht verfügbar wären und potenziell menschliches Leben gefährdet würde oder großer finanzieller Schaden entstünde. Somit erfordert das Aktualisieren eines Systems mit einer neuen Konfiguration, dass das rekonfigurierte System die zugehörigen Beschränkungen vollständig einhält. Um dies zu überprüfen, wird in dieser Arbeit der GR-TNCES-Formalismus, eine Erweiterung von Petrinetzen, für die optimale funktionale und zeitliche Spezifikation probabilistischer rekonfigurierbarer Systeme unter Ressourcenbeschränkungen vorgeschlagen. Die entstehenden Modelle sollen über probabilistische model checking verifiziert werden. Dazu eignet sich die etablierte Software PRISM. Um die Verifikation zu ermöglichen wird in dieser Arbeit ein Verfahren zur Transformation von GR-TNCES-Modellen in PRISM-Modelle beschrieben. Eine neu eingeführte Logik (XCTL) erlaubt zudem die einfache Beschreibung der zu prüfenden Eigenschaften. Die genannten Schritte wurden in einer Softwareumgebung für den automatisierten Entwurf, die Simulation und die formale Verifikation (durch eine automatische Transformation nach PRISM) umgesetzt. Eine Fallstudie zeigt die Anwendung des Verfahren

On Minimum-time Control of Continuous Petri nets: Centralized and Decentralized Perspectives

Muchos sistemas artificiales, como los sistemas de manufactura, de logística, de telecomunicaciones o de tráfico, pueden ser vistos "de manera natural" como Sistemas Dinámicos de Eventos Discretos (DEDS). Desafortunadamente, cuando tienen grandes poblaciones, estos sistemas pueden sufrir del clásico problema de la explosión de estados. Con la intención de evitar este problema, se pueden aplicar técnicas de fluidificación, obteniendo una relajación fluida del modelo original discreto. Las redes de Petri continuas (CPNs) son una aproximación fluida de las redes de Petri discretas, un conocido formalismo para los DEDS. Una ventaja clave del empleo de las CPNs es que, a menudo, llevan a una substancial reducción del coste computacional. Esta tesis se centra en el control de Redes de Petri continuas temporizadas (TCPNs), donde las transiciones tienen una interpretación temporal asociada. Se asume que los sistemas siguen una semántica de servidores infinitos (velocidad variable) y que las acciones de control aplicables son la disminución de la velocidad del disparo de las transiciones. Se consideran dos interesantes problemas de control en esta tesis: 1) control del marcado objetivo, donde el objetivo es conducir el sistema (tan rápido como sea posible) desde un estado inicial a un estado final deseado, y es similar al problema de control set-point para cualquier sistema de estado continuo; 2) control del flujo óptimo, donde el objetivo es conducir el sistema a un flujo óptimo sin conocimiento a priori del estado final. En particular, estamos interesados en alcanzar el flujo máximo tan rápido como sea posible, lo cual suele ser deseable en la mayoría de sistemas prácticos. El problema de control del marcado objetivo se considera desde las perspectivas centralizada y descentralizada. Proponemos varios controladores centralizados en tiempo mínimo, y todos ellos están basados en una estrategia ON/OFF. Para algunas subclases, como las redes Choice-Free (CF), se garantiza la evolución en tiempo mínimo; mientras que para redes generales, los controladores propuestos son heurísticos. Respecto del problema de control descentralizado, proponemos en primer lugar un controlador descentralizado en tiempo mínimo para redes CF. Para redes generales, proponemos una aproximación distribuida del método Model Predictive Control (MPC); sin embargo en este método no se considera evolución en tiempo mínimo. El problema de control de flujo óptimo (en nuestro caso, flujo máximo) en tiempo mínimo se considera para redes CF. Proponemos un algoritmo heurístico en el que calculamos los "mejores" firing count vectors que llevan al sistema al flujo máximo, y aplicamos una estrategia de disparo ON/OFF. También demostramos que, debido a que las redes CF son persistentes, podemos reducir el tiempo que tarda en alcanzar el flujo máximo con algunos disparos adicionales. Los métodos de control propuestos se han implementado e integrado en una herramienta para Redes de Petri híbridas basada en Matlab, llamada SimHPN

Module-based architecture for a periodic job-shop scheduling problem

AbstractThis paper addresses the Petri net (PN) based design and modeling approach for a periodic job-shop scheduling problem. Asynchronous synthesis for net-modules of the jobs is suggested in this paper for optimal allocation of shared resources to different operations. To make sure the completion of all the jobs in a single iteration of a production cycle and the correct calculation of a makespan, the synchronization problem among jobs is tackled by introducing the special synchronizing transition in the model. A timed-place PN is adopted for the purpose of finding the feasible schedule in terms of the firing sequence of the transitions of the PN model by using the heuristic search method. Further, the characterization of the PN model is performed and it is shown that the PN model for a periodic job-shop scheduling problem is equivalent to a class of PN known as parallel process net with resources (PPNRs). The modeling approach is demonstrated with a practical example and a makespan is calculated for the example