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

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

Extracting Petri Modules From Large and Legacy Petri Net Models

Petri nets, even though very useful for modeling of discrete event systems, suffer from some weaknesses such as huge size, huge state space, and slow in simulation. Due to the huge state space, model checking a Petri net is difficult. Also, due to the slowness in simulation, discrete-timed Petri nets cannot be used for real-time applications. Thus, modular Petri nets are suggested as a way of overcoming these difficulties. In modular Petri nets, modules are designed, developed, and run independently, and the modules communicate with each other via inter-modular connectors. This approach is suggested for developing newer Petri net models. However, there exists a large number of Petri net models of real-life systems, and these legacy models are enormous and non-modular. And, these models cannot be discarded as large amounts of time and money were spent to develop these models. This paper presents a unique algorithm for extracting modules from large and legacy Petri net models. The algorithm extracts modules (known as “Petri modules”) that are well-defined for inter-modular collaboration. Also, the extraction method preserves the structural properties. The goal of the paper is to introduce a methodology by which Petri nets can be moved to a new level in which a modular Petri net model can be made of Petri modules. The Petri modules are independent and can be hosted on different computers. These modules communicate via inter-modular components such as TCP/IP sockets. Since Petri modules are compact, also run faster, thus become suitable for supervisory control of real-time systems.publishedVersio

Modeling production configuration using nested colored object-oriented Petri-nets with changeable structures

Configuring production processes based on process platforms has been well recognized as an effective means for companies to provide product variety while maintaining mass production efficiency. The production processes of product families involve diverse variations in manufacturing and assembly processes resulted from a large variety of component parts and assemblies. This paper develops a multilevel system of nested colored object-oriented Petri nets with changeable structures to model the configuration of production processes. To capture the semantics associated with production configuration decisions, some unique modeling mechanisms are employed, including colored Petri nets, object-oriented Petri nets, changeable Petri net structures, and net nesting. The modeling formalism comprises resource nets, manufacturing nets, assembly nets and process nets. The paper demonstrates how these net definitions are applied to the specification of production process variants at different levels of abstraction. Also reported is a case study in an electronics company. The system model is further analyzed with focus on conflict prevention and deadlock detection

Proceedings of the First NASA Formal Methods Symposium

Topics covered include: Model Checking - My 27-Year Quest to Overcome the State Explosion Problem; Applying Formal Methods to NASA Projects: Transition from Research to Practice; TLA+: Whence, Wherefore, and Whither; Formal Methods Applications in Air Transportation; Theorem Proving in Intel Hardware Design; Building a Formal Model of a Human-Interactive System: Insights into the Integration of Formal Methods and Human Factors Engineering; Model Checking for Autonomic Systems Specified with ASSL; A Game-Theoretic Approach to Branching Time Abstract-Check-Refine Process; Software Model Checking Without Source Code; Generalized Abstract Symbolic Summaries; A Comparative Study of Randomized Constraint Solvers for Random-Symbolic Testing; Component-Oriented Behavior Extraction for Autonomic System Design; Automated Verification of Design Patterns with LePUS3; A Module Language for Typing by Contracts; From Goal-Oriented Requirements to Event-B Specifications; Introduction of Virtualization Technology to Multi-Process Model Checking; Comparing Techniques for Certified Static Analysis; Towards a Framework for Generating Tests to Satisfy Complex Code Coverage in Java Pathfinder; jFuzz: A Concolic Whitebox Fuzzer for Java; Machine-Checkable Timed CSP; Stochastic Formal Correctness of Numerical Algorithms; Deductive Verification of Cryptographic Software; Coloured Petri Net Refinement Specification and Correctness Proof with Coq; Modeling Guidelines for Code Generation in the Railway Signaling Context; Tactical Synthesis Of Efficient Global Search Algorithms; Towards Co-Engineering Communicating Autonomous Cyber-Physical Systems; and Formal Methods for Automated Diagnosis of Autosub 6000

Scheduling of flexible manufacturing systems integrating petri nets and artificial intelligence methods.

The work undertaken in this thesis is about the integration of two well-known methodologies: Petri net (PN) model Ii ng/analysis of industrial production processes and Artificial Intelligence (AI) optimisation search techniques. The objective of this integration is to demonstrate its potential in solving a difficult and widely studied problem, the scheduling of Flexible Manufacturing Systems (FIVIS). This work builds on existing results that clearly show the convenience of PNs as a modelling tool for FIVIS. It addresses the problem of the integration of PN and Al based search methods. Whilst this is recognised as a potentially important approach to the scheduling of FIVIS there is a lack of any clear evidence that practical systems might be built. This thesis presents a novel scheduling methodology that takes forward the current state of the art in the area by: Firstly presenting a novel modelling procedure based on a new class of PN (cb-NETS) and a language to define the essential features of basic FIVIS, demonstrating that the inclusion of high level FIVIS constraints is straight forward. Secondly, we demonstrate that PN analysis is useful in reducing search complexity and presents two main results: a novel heuristic function based on PN analysis that is more efficient than existing methods and a novel reachability scheme that avoids futile exploration of candidate schedules. Thirdly a novel scheduling algorithm that overcomes the efficiency drawbacks of previous algorithms is presented. This algorithm satisfactorily overcomes the complexity issue while achieving very promising results in terms of optimality. Finally, this thesis presents a novel hybrid scheduler that demonstrates the convenience of the use of PN as a representation paradigm to support hybridisation between traditional OR methods, Al systematic search and stochastic optimisation algorithms. Initial results show that the approach is promising

A Modeling and Analysis Framework To Support Monitoring, Assessment, and Control of Manufacturing Systems Using Hybrid Models

The manufacturing industry has constantly been challenged to improve productivity, adapt to continuous changes in demand, and reduce cost. The need for a competitive advantage has motivated research for new modeling and control strategies able to support reconfiguration considering the coupling between different aspects of plant floor operations. However, models of manufacturing systems usually capture the process flow and machine capabilities while neglecting the machine dynamics. The disjoint analysis of system-level interactions and machine-level dynamics limits the effectiveness of performance assessment and control strategies. This dissertation addresses the enhancement of productivity and adaptability of manufacturing systems by monitoring and controlling both the behavior of independent machines and their interactions. A novel control framework is introduced to support performance monitoring and decision making using real-time simulation, anomaly detection, and multi-objective optimization. The intellectual merit of this dissertation lies in (1) the development a mathematical framework to create hybrid models of both machines and systems capable of running in real-time, (2) the algorithms to improve anomaly detection and diagnosis using context-sensitive adaptive threshold limits combined with context-specific classification models, and (3) the construction of a simulation-based optimization strategy to support decision making considering the inherent trade-offs between productivity, quality, reliability, and energy usage. The result is a framework that transforms the state-of-the-art of manufacturing by enabling real-time performance monitoring, assessment, and control of plant floor operations. The control strategy aims to improve the productivity and sustainability of manufacturing systems using multi-objective optimization. The outcomes of this dissertation were implemented in an experimental testbed. Results demonstrate the potential to support maintenance actions, productivity analysis, and decision making in manufacturing systems. Furthermore, the proposed framework lays the foundation for a seamless integration of real systems and virtual models. The broader impact of this dissertation is the advancement of manufacturing science that is crucial to support economic growth. The implementation of the framework proposed in this dissertation can result in higher productivity, lower downtime, and energy savings. Although the project focuses on discrete manufacturing with a flow shop configuration, the control framework, modeling strategy, and optimization approach can be translated to job shop configurations or batch processes. Moreover, the algorithms and infrastructure implemented in the testbed at the University of Michigan can be integrated into automation and control products for wide availability.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/147657/1/migsae_1.pd

Symbolic planning for heterogeneous robots through composition of their motion description languages

This dissertation introduces a new formalism to define compositions of interacting heterogeneous systems, described by extended motion description languages (MDLes). The properties of the composition system are analyzed and an automatic process to generate sequential atom plan is introduced. The novelty of the formalism is in producing a composed system with a behavior that could be a superset of the union of the behaviors of its generators. As robotic systems perform increasingly complex tasks, people resort increasingly to switching or hybrid control algorithms. A need arises for a formalism to compose different robotic behaviors and meet a final target. The significant work produced to date on various aspects of robotics arguably has not yet effectively captured the interaction between systems. Another problem in motion control is automating the process of planning and it has been recognized that there is a gap between high level planning algorithms and low level motion control implementation. This dissertation is an attempt to address these problems. A new composition system is given and the properties are checked. We allow systems to have additional cooperative transitions and become active only when the systems are composed with other systems appropriately. We distinguish between events associated with transitions a push-down automaton representing an MDLe can take autonomously, and events that cannot initiate transitions. Among the latter, there can be events that when synchronized with some of another push-down automaton, become active and do initiate transitions. We identify MDLes as recursive systems in some basic process algebra (BPA) written in Greibach Normal Form. By identifying MDLes as a subclass of BPAs, we are able to borrow the syntax and semantics of the BPAs merge operator (instead of defining a new MDLe operator), and thus establish closeness and decidability properties for MDLe compositions. We introduce an instance of the sliding block puzzle as a multi-robot hybrid system. We automate the process of planning and dictate how the behaviors are sequentially synthesized into plans that drive the system into a desired state. The decidability result gives us hope to abstract the system to the point that some of the available model checkers can be used to construct motion plans. The new notion of system composition allows us to capture the interaction between systems and we realize that the whole system can do more than the sum of its parts. The framework can be used on groups of heterogeneous robotic systems to communicate and allocate tasks among themselves, and sort through possible solutions to find a plan of action without human intervention or guidance

An agile and adaptive holonic architecture for manufacturing control

Tese de doutoramento. Engenharia Electrotécnica e de Computadores. 2004. Faculdade de Engenharia. Universidade do Port