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

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

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

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

Transient analysis of manufacturing system performance

Includes bibliographical references (p. 28-34).Supported by the INDO-US Science and Technology Fellowship Program.Y. Narahari, N. Viswanadham

TOWARDS DIGITAL TWIN-DRIVEN PERFORMANCE EVALUATION METHODOLOGY OF FMS

The paper presents a method of automated modelling and performance evaluation of concurrent production flows carried out in Flexible Manufacturing Systems. The method allows for quick assessment of various variants of such systems, considering their structure and the organization of production flow of possible ways of their implementation. Its essence is the conditions imposed on the designed model, limiting the space of possible variants of the production flow only to deadlock-free variants. The practical usefulness of the model implemented in the proposed method illustrates the example, which describes the simultaneous assessment of alternative variants of the flexible machining module's structure and the planned multi-assortment production. The ability of the method to focus on feasible solutions offers attractive perspectives for guiding the Digital Twin-like scenario in situations caused by the need to change the production flow

Decision systems : the relation between problem specification and mathematical analysis

In this paper it is demonstrated that automated support for decision making of a tactical or strategic nature requires a solver-independent medium for describing decision situations. Such a medium may be specific for one environment, but it is also possible to develop media for certain types of environments. By using such a medium one obtains a decoupling of problem formulation and method of analysis. This makes it possible to use (parts of) the problem formulation as input for different types of models. Such problem formulations may provide mathematical models themselves, although they might also contain some less formal features. The decoupling makes it possible to choose problem formulations which are much closer to the original decision situation than would otherwise be possible with formulations in terms of a preselected solver. The argumentation is illustrated by treating a language for specifying goods flow problems in some detail. This language is based on timed coloured Petri-nets