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

A model-based approach for supporting flexible automation production systems and an agent-based implementaction

158 p.En esta Tesis Doctoral se plantea una arquitectura de gestión genérica y personalizable, capaz de asegurar el cumplimiento de los requisitos de calidad de servicio (QoS) de un sistema de control industrial. Esta arquitectura permite la modificación de los mecanismos de detección y recuperación de los requisitos de QoS en función de diversos tipos de ésta. Como prueba de concepto, la arquitectura de gestión ha sido implementada mediante un middleware basado en sistemas multi-agente. Este middleware proporciona una serie de agentes distribuidos, los cuales se encargan de la monitorización y recuperación de las QoS en caso de su perdida.La incorporación de los mecanismos de reconfiguración incrementa la complejidad de los sistemas de control. Con el fin de facilitar el diseño de estos sistemas, se ha presentado un framework basado en modelos que guía y facilita el diseño de los sistemas de control reconfigurables. Este framework proporciona una serie de herramientas basadas en modelos que permiten la generación automática del código de control del sistema, así como de los mecanismos de monitorización y reconfiguración de los agentes del middleware.La implementación de la arquitectura ha sido validada mediante una serie de escenarios basados en una célula de montaje real

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

Description of Distributable Encapsulated Resource Package and Method for Orchestration of Distributed Automation Systems

Reconfiguration is critical to meet the current demands of manufacturing and production systems. Rapid reconfiguration can offer small batch sizes, customization and many product variants to the manufacturing companies. This thesis is to implement a novel concept of Resource Description and its Executable Capability. This is an implementation of theoretical concept by conceiving a use case scenario based on different stakeholders involved in the manufacturing system designing process. The stakeholders are vendors of physical production resource and system integrator who is the consumer of the physical production resource. The scenario is that the vendor provides the control software package along with resource and system integrator uses the software package to develop a control system. To implement this concept a set of requirements are extracted from resource description and its executable capability concept. Based on these requirements software packages are designed and test case resources are developed. These test case resources are then utilized to design a high-level control system. Realistic test case assembly system is developed and reconfigured. The obtained results present a realistic view of the concept of resource description in a limited scope. The qualitative analysis of test case scenarios proves the ease which can be achieved in reconfiguration of a manufacturing system if the concept of resource description is used in real-world environments

A model-based approach for supporting flexible automation production systems and an agent-based implementaction

158 p.En esta Tesis Doctoral se plantea una arquitectura de gestión genérica y personalizable, capaz de asegurar el cumplimiento de los requisitos de calidad de servicio (QoS) de un sistema de control industrial. Esta arquitectura permite la modificación de los mecanismos de detección y recuperación de los requisitos de QoS en función de diversos tipos de ésta. Como prueba de concepto, la arquitectura de gestión ha sido implementada mediante un middleware basado en sistemas multi-agente. Este middleware proporciona una serie de agentes distribuidos, los cuales se encargan de la monitorización y recuperación de las QoS en caso de su perdida.La incorporación de los mecanismos de reconfiguración incrementa la complejidad de los sistemas de control. Con el fin de facilitar el diseño de estos sistemas, se ha presentado un framework basado en modelos que guía y facilita el diseño de los sistemas de control reconfigurables. Este framework proporciona una serie de herramientas basadas en modelos que permiten la generación automática del código de control del sistema, así como de los mecanismos de monitorización y reconfiguración de los agentes del middleware.La implementación de la arquitectura ha sido validada mediante una serie de escenarios basados en una célula de montaje real

Agent-based middleware architecture for reconfigurable manufacturing systems

Modern manufacturing systems are expected to be flexible and efficient in order to cope with challenging market demands. Thus, they must be flexible enough as to meet changing requirements such as changes in production, energy efficiency, performance optimization, fault tolerance to process or controller faults, among others. Demanding requirements can be defined as a set of quality of service (QoS) requirements to be met. This paper proposes a generic and customizable multi-agent architecture that, making use of distributed agents, monitors QoS, triggering, if needed, a reconfiguration of the control system to recover QoS. As a proof of concept, the architecture has been implemented to provide availability of the control system understood as service continuity. The prototype has been tested in a case study consisting of an assembly cell where assessment of the approach has been conducted.This work was financed by the MINECO/FEDER under project DPI2015-68602-R

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

Engineering framework for service-oriented automation systems

Tese de doutoramento. Engenharia Informática. Universidade do Porto. Faculdade de Engenharia. 201

A Novel Method for Adaptive Control of Manufacturing Equipment in Cloud Environments

The ability to adaptively control manufacturing equipment, both in local and distributed environments, is becoming increasingly more important for many manufacturing companies. One important reason for this is that manufacturing companies are facing increasing levels of changes, variations and uncertainty, caused by both internal and external factors, which can negatively impact their performance. Frequently changing consumer requirements and market demands usually lead to variations in manufacturing quantities, product design and shorter product life-cycles. Variations in manufacturing capability and functionality, such as equipment breakdowns, missing/worn/broken tools and delays, also contribute to a high level of uncertainty. The result is unpredictable manufacturing system performance, with an increased number of unforeseen events occurring in these systems. Events which are difficult for traditional planning and control systems to satisfactorily manage. For manufacturing scenarios such as these, the use of real-time manufacturing information and intelligence is necessary to enable manufacturing activities to be performed according to actual manufacturing conditions and requirements, and not according to a pre-determined process plan. Therefore, there is a need for an event-driven control approach to facilitate adaptive decision-making and dynamic control capabilities. Another reason driving the move for adaptive control of manufacturing equipment is the trend of increasing globalization, which forces manufacturing industry to focus on more cost-effective manufacturing systems and collaboration within global supply chains and manufacturing networks. Cloud Manufacturing is evolving as a new manufacturing paradigm to match this trend, enabling the mutually advantageous sharing of resources, knowledge and information between distributed companies and manufacturing units. One of the crucial objectives for Cloud Manufacturing is the coordinated planning, control and execution of discrete manufacturing operations in collaborative and networked environments. Therefore, there is also a need that such an event-driven control approach supports the control of distributed manufacturing equipment. The aim of this research study is to define and verify a novel and comprehensive method for adaptive control of manufacturing equipment in cloud environments. The presented research follows the Design Science Research methodology. From a review of research literature, problems regarding adaptive manufacturing equipment control have been identified. A control approach, building on a structure of event-driven Manufacturing Feature Function Blocks, supported by an Information Framework, has been formulated. The Function Block structure is constructed to generate real-time control instructions, triggered by events from the manufacturing environment. The Information Framework uses the concept of Ontologies and The Semantic Web to enable description and matching of manufacturing resource capabilities and manufacturing task requests in distributed environments, e.g. within Cloud Manufacturing. The suggested control approach has been designed and instantiated, implemented as prototype systems for both local and distributed manufacturing scenarios, in both real and virtual applications. In these systems, event-driven Assembly Feature Function Blocks for adaptive control of robotic assembly tasks have been used to demonstrate the applicability of the control approach. The utility and performance of these prototype systems have been tested, verified and evaluated for different assembly scenarios. The proposed control approach has many promising characteristics for use within both local and distributed environments, such as cloud environments. The biggest advantage compared to traditional control is that the required control is created at run-time according to actual manufacturing conditions. The biggest obstacle for being applicable to its full extent is manufacturing equipment controlled by proprietary control systems, with native control languages. To take the full advantage of the IEC Function Block control approach, controllers which can interface, interpret and execute these Function Blocks directly, are necessary

An AutomationML model for plug-and-produce assembly systems

This paper aims to support the creation of high performance ‘Plug-and-Produce’ systems by proposing a new semantic model that targets the use of AutomationML (AML). In this direction, the focus is narrowed to the self-description of equipment modules that highlights the use of ‘Skill’ concept. An insight description on how the concept of ‘Skill Recipe’ can be used to execute the equipment ‘Skills’ to fulfil the product's assembly requirements is also provided. This is viewed as a critical concept to achieve high performance in ‘Plug-and-Produce’. To translate the base semantic definitions, we have developed new libraries that are fully compliant with the AML standard. The main purpose of using AML in this context is to bridge production and other engineering domains. An overview of the literature that covers the past and current trends in data exchange and standards is presented, while pointing out the existing challenges and limitations. The vision of this paper is to support the standardization effort of integrating information for design, build, ramp-up and operation of production systems. Hence, this approach elucidates the use of existing AML concepts to model and instantiate Product, Process and Resource (PPR), and the underlying definitions such as: ‘Skills’, ‘Skill Recipes’ and ‘Skill Requirements’. Finally, this paper illustrates the implementation of this approach in AML with a help of an industrial case study demonstrated within the openMOS project