A hybrid PC/PLC architecture for manufacturing-system control—theory and implementation

This paper presents a novel and generic PC/PLC-based software/hardware architecture for the control of flexible manufacturing workcells. The proposed implementation methodology is based on the utilization of any one of the available formal discrete-event-system control theories in conjunction with state-of-the-art industrial programmable-logic controllers (PLCs). The methodology has been illustrated to be a viable technique through its actual implementation in our laboratory using a robotic-workcell testbed. The specific control theory used is a combination of Extended Moore Automata and Ramadge-Wonham Automata that has been developed by our research group. The modular control software architecture has been developed for MS-Windows environments (running on one PC interfaced to the PLCs) and allows the use of different formal control theories as well as different commercial PLC hardware. The effective graphical user interface provides a transparent programming environment, where users are not expected to have a full knowledge of the formal control theory used.