The use of the Petri net reduction approach for an optimal deadlock prevention policy for flexible manufacturing systems

In a flexible manufacturing system (FMS) with multiple products, deadlocks can arise due to limited shared resources, such as machines, robots, buffers, fixtures etc. The development of efficient deadlock prevention policies, which can optimise the use of system resources, while preventing deadlocks from occurring, has long been an important issue to be addressed. In [1], an optimal deadlock prevention policy was proposed, based on the use of reachability graph (RG) analysis of the Petri net model (PNM) of a given FMS and the synthesis of a set of new net elements, namely places with initial marking and related arcs, to be added to the PNM, using the theory of regions. The policy proposed in [1] is optimal in the sense that it allows the maximal use of resources in the system according to the production requirements. For very big PNMs, the reachability graph of the PNMs becomes very large and the necessary computations to obtain an optimal deadlock prevention policy become more difficult. In this paper, we propose the use of the Petri net reduction approach to simplify very big PNMs so as to make necessary calculations easily in order to obtain an optimal deadlock prevention policy for FMSs. An example is provided for illustration.     

Deadlock avoidance control for manufacturing systems with multiple capacity resources

This paper addresses the problem of designing a control scheme capable of avoiding deadlock conditions for a class of manufacturing systems. The considered model for the system under control is based on Petri nets, and is formulated according to well-known modelling rules. A deadlock avoidance policy is proposed which is an extension of a previously presented one. The proofs of its main properties are briefly sketched. Finally, an example of an automated manufacturing system for which such a deadlock avoidance policy has been applied is discussed.     

A genetic algorithm for scheduling flexible manufacturing systems

General job shop scheduling and rescheduling with alternative route choices for an FMS environment is addressed in this paper. A genetic algorithm is proposed to derive an optimal combination of priority dispatching rules pdrs (independentpdrs one each for one Work Cell WC), to resolve the conflict among the contending jobs in the Giffler and Thompson GT procedure. The performance is compared with regard to makes-pan criteria and computational time. The optimal WCwise-pdr is proved to be efficient in providing optimal solutions in a reasonable computational time. Also, the proposed GA based heuristic method is extended to revise schedules on the arrival of new jobs, and on the failure of equipment to address the dynamic operation mode of flexible manufacturing systems. An iterative search technique is proposed to find the best route choice for all operations to provide a feasible and optimal solution. The applicability and usefulness of the proposed methodology for the operation and control of FMS in real-time are illustrated with examples. The scope of the genetic search process and future research directions are discussed.     

Modelling,simulation and scheduling of flexible assembly systems with coloured Petri nets

Scheduling in flexible assembly systems is a complicated phenomenon owing to the large variability in the operating parameters. In this paper, coloured Petri nets are shown to be useful in modelling, simulating and scheduling flexible assembly systems. Case studies from published literature are chosen to show its superiority over some of the heuristic and analytical tools. In addition, the tool is also shown to model and analyse systems with some realistic constraints.     

Real-time control and scheduling of flexible manufacturing systems: An ordinal optimisation based approach

A unique real-time control and scheduling framework for flexible manufacturing systems (FMS) is presented in this paper. The framework enables the adoption of different scheduling policies for short-term intervals when responding to the dynamic changes of the FMS shop floor status. Each time when rescheduling is called for, standard clock (SC) simulation is first employed to evaluate the performance of a set of scheduling policies for a short planning horizon. The ordinal optimisation concept is then used to choose quickly the most desirable scheduling policy. Owing to the use of the standard clock technique and the ordinal optimisation concept, this framework accomplishes a dramatic reduction in the time needed for decision making, the essential requirement for real-time control. It is also found that as the scale of the problem increases, the decision-making time increases linearly rather than exponentially. These two important features indicate that this framework has the potential for being successfully implemented in real FMS settings. Although the framework cannot always guarantee the global best performance, the case study indicates that satisfactory performance results are always achieved by using this framework.     

An integration architecture for flexible manufacturing cells

A modern flexible manufacturing cell (FMC) usually consists of several distributed control systems, including machining centres and material handling systems. Modelling an FMC to evaluate its design and performance, and translating the resulting models into operational programs are complex, but critical steps in implementing an FMC. This paper represents an architecture for the design, integration, and implementation of an FMC. The primary focus is on defining the process and functional requirements of the system, designing the system using high-level abstraction tools that ensure system integration and effective communication with users and implementors, and using efficient algorithms and effective interfaces for implementing real-time process control.     

模糊柔性制造系统的混杂Petri网建模与调度

对模糊柔性制造系统的建模和调度进行了研究.定义了一种具有模糊区间速率的混杂Petri网模型,提出了模型的迁移使能和迁移引发语义,定义了弱使能迁移的模糊使能规则,给出了模型动态演变算法.建立了模糊柔性制造系统调度的模糊线性规划模型,并对典型的工业实例进行了分析.研究结果表明,基于所定义的混杂Petri模型能够有效地描述和分析模糊柔性制造系统.     

Resource-requirements planning in flexible manufacturing systems

In this paper, we address the problem of planning the requirements of some of the important resources in flexible manufacturing systems. Specifically, we model the problem of estimating the required numbers and types of machines and tools in the context of a cellular layout. A two-stage procedure is developed which first forms the part families, using the complete-linkage clustering method based on a new similarity index defined in terms of the tooling requirements, and then subsequently estimates the resource requirements to manufacture the part families using an integer programming model. Several variations of the model are discussed and a numerical example is given.     

多资源服务处理系统的活性控制策略

为解决一类具有多资源服务处理制造系统中的死锁问题,提出了利用Petri网描述系统结构和动态特征的方法,以及循环结构的新概念,证明了循环结构是导致系统死锁的惟一结构特征。利用辅助系统Petri网模型,提出了计算系统的所有基本极大循环结构的方法。对每个基本极大循环结构增加一个控制位置及其相关弧以限制其资源的利用,从而有效地避免系统死锁的发生。     

柔性制造系统活性监督控制器设计的算法优化

针对区域法设计系统控制器时存在求解线性规划次数过多、算法复杂和状态爆炸等问题,提出了一个能有效降低计算复杂度的优化算法,解决了由状态爆炸引起的求解线性规划次数指数级递增的问题;证明了任何普通网系统需要添加的控制库所的数量不超过事件分离事例个数和|T|+1中的最小者。通过所提算法,最终获得结构简单、状态最大许可的柔性制造系统活性监督控制器。     

Knowledge-based workcell attribute oriented dynamic schedulers for flexible manufacturing systems

The economy of production in flexible manufacturing systems (FMS) depends mainly on how effectively the production is planned and how the resources are used. This requires efficient and dynamic factory scheduling and control procedures. This paper addresses two knowledge-based scheduling schemes (work cell attribute oriented dynamic schedulers WCAODSs) to control the flow of parts efficiently in real-time for FMS in which the part-mix varies continually with the planning horizon. The present work employs a hybrid optimisation approach in the generalised A1 framework. A genetic algorithm that provides an optimal combination of a set of priority dispatching rules, one for each work cell WC (WCwisepdr set), for each of the problem instances characterised by their WC attributes, is used for generating examples. The WC attributes reflect the information about the operating environment of each individual WC. Two inductive learning algorithms are employed to learn the examples, and scheduling rules are formulated as a knowledge base. The learning algorithms employed are: the Genetic CID3 (Continuous Interactive Dichotomister3 algorithm extended with genetic program for weight optimisation) and the Classification Decision Tree algorithm. The knowledge base obtained through the above learning schemes generates robust and effective schedules intelligently with respect to the part-mix changes in real-time, for makespan criteria. The comparison made with a GA-based scheduling methodology shows that WCAODSs provide solutions closer to the optimum.     

Object-oriented approach of MCTPN for modelling Flexible manufacturing systems

Manufacturing industry is facing a stricter challenge than ever before owing to the rapid change in market requirements. Flexible manufacturing systems (FMSs) have a much greater capability than traditional fixed-type production systems for coping with the rapid change. In this paper, a modified coloured-timed Petri net (MCTPN) is developed to model the dynamic activities in an FMS. The MCTPN provides an object-oriented and modular method of modelling manufacturing activities. It includes colour, time, modular and communication attributes. The features of object-oriented modelling allow the FMS to be modelled with the properties of classes, objects, and container trees. Since the system activities can be encapsulated and modularised by the proposed MCTPN, the manufacturing systems can be easily constructed and investigated by the system developers. It makes the concept of software IC possible for modelling complex FMSs. Once all of the MCTPN objects are well defined, the developers need to consider only the interfaces and operations relating to the MCTPN objects. In order to demonstrate the capability of the proposed MCTPN, the FMS in the Manufacturing Automation Technology Research Center (MATRC) of the National Taiwan University will be stimulated and justified by using the proposed MCTPN along with the G2 expert system.     

A decision-making approach to the operation of flexible manufacturing systems

This paper introduces a generic decision-making framework for assigning resources of a manufacturing system to production tasks. Resources are broadly defined production units, such as machines, human operators, or material handling vehicles; and tasks are activities performed by resources. In the specific context of FMS, resources correspond to individual machines; tasks correspond to operations to be performed on parts. The framework assumes a hierarchical structure of the system and calls for the execution of four consecutive steps to make a decision for the assignment of a resource to a task. These steps are 1) establishment of decision-making criteria, 2) formation of alternative assignments, 3) estimation of the consequences of the assignments, and 4) selection of the best alternative assignment. This framework has been applied to an existing FMS as an operational policy that decides what task will be executed on which resource of this FMS. Simulation runs provide some initial results of the application of this policy. It is shown that the policy provides flexibility in terms of system performance and computational effort.     

Recursive newton-euler formulation for flexible dynamic manufacturing analysis of open-loop robotic systems

The main objective of this paper is to develop a recursive formulation for the flexible dynamic manufacturing analysis of open-loop robotic systems. The nonlinear generalized Newton-Euler equations are used for flexible bodies that undergo large translational and rotational displacements. These equations are formulated in terms of a set of time invariant scalars, vectors and matrices that depend on the spatial coordinates as well as the assumed displacement fields. These time invariant quantities represent the dynamic manufacturing couplings between the rigid body motion and elastic deformation. This formulation applies recursive procedures with the generalized Newton-Euler equations for flexible bodies to obtain a large, loosely coupled system equation describing motion in flexible manufacturing systems. The techniques used to solve the system equations can be implemented in any computer system. The algorithms presented in this investigation are illustrated using cylindrical joints for open-loop robotic systems, which can be easily extended to revolute, slider and rigid joints. The recursive Newton-Euler formulation developed in this paper is demonstrated with a robotic system using cylindrical mechanical joints.     

Analysis of the number of automated guided vehicles required in flexible manufacturing systems

In this paper we examine some of the general principles and analysis methods that are used to design an automated material handling system. The paper focuses on one type of automated handling system that seems especially suitable for automation in discrete-product manufacturing. These types of automated handling systems are called automated guided vehicle systems. These systems are most applicable for the automation of low-and medium-volume handling situations, where the routeing of materials is more individualised. For guided vehicles, a new quantitative method for analysing these systems is developed in the paper. Examples are presented to demonstrate the method.     

AGV schedule integrated with production in flexible manufacturing systems

Flexible manufacturing systems (FMS) comprise, automated machine tools, automated material handling, and automated storage and automated retrieval systems (AS/RS) as essential components. Effective sequencing and scheduling of the material handling systems (MHS) can have a major impact on the productivity of the manufacturing system. The material handling cannot be neglected while scheduling the production tasks. It is necessary to take into account the interaction between machines, material handling systems and computer. In this context, this paper attempts to link the operation of automated guided vehicles (AGV) with the production schedule and suggests a heuristic algorithm that employs vehicle dispatching rules (vdr) for conflict resolution. The vdrs considered in this paper are: shortest operation time (SPT), longest operation time (LPT), longest travel time (LTT) and shortest travel time (STT). The performance of the vdrs in the proposed heuristic is compared with makespan criteria. The results show that the STT provides the best solutions compared to other vdrs.     

柔性装配制造系统中生产优化的Petri网方法

本文在基本Ｐｅｔｒｉ网的基础上,给出了一种进行周期性生产的柔性装配制造系统的模型;同时,针对该系统,给出了一个求稳定需求下最佳生产指量的启发式调度方法。     

Deadlock prevention and avoidance in FMS: A Petri net based approach

The use of structure theory of Petri nets to develop efficient deadlock prevention and deadlock avoidance methods for flexible manufacturing systems (FMSs) modelled by S⁴R nets is demonstrated. Major synchronisation patterns, such as generalised parallel and sequential mutual exclusion, frequently observed in FMS contexts can be represented by this class. The liveness property of a given S⁴R net (deadlock-freeness in the context of FMSs) is characterised in terms of structural Petri net elements called siphons. An efficient method for controlling minimal siphons of a given S⁴R net is developed where local control places are added to the net. A sufficient condition for liveness of the augmented net is provided. This constitutes a deadlock prevention approach. When the net liveness condition is not satisfied, an on-line controller, using a dynamic resource allocation policy, is developed for the augmented net. The performance of the proposed approaches is illustrated using several examples.     

自动制造系统中的迭代式死锁预防策略

为解决自动制造系统中的死锁问题,提出一种将混合整数规划算法和Petri网相结合的迭代式预防策略。在该策略中,混合整数规划算法中的0／1变量用来表示Petri网模型中的库所和变迁是否与一个最大的可被清空的信标相关。由于从一个最大的可被清空的信标中可以容易地计算出一个严格极小信标,就可以在不遍历所有的严格极小信标的情况下,直接求得一组基本信标,从而大大地降低了策略的时间算法复杂度。同时,控制该组基本信标可以确保目标系统具有简单的控制器结构和尽可能多的许可行为。实验结果表明了该控制策略的有效性和高效性。