Temporized coloured Petri nets with changeable structure (CPN-CS) for performance modelling of dynamic production systems

One of the difficulties in modelling dynamic production systems is the representation of changes to the system along time. Coloured Petri nets with changeable structure (CPN-CS) are capable of modelling systems subject to change. However, this is restricted to functionality modelling of the system. In this paper, we extend CPN-CSs into temporized CPN-CS (TCPN-CS). The extension is carried out by associating relevant modelling elements with time parameters and modifying the mechanism for structure change of the CPN-CS model. TCPN-CS makes it possible to model a dynamic production system considering both functionality and performance. A case study is provided to show that TCPN-CS is effective for modelling dynamic production systems.     

Deadlock-free scheduling in flexible manufacturing systems using Petri nets

This paper addresses the deadlock-free scheduling problem in Flexible Manufacturing Systems. An efficient deadlock-free scheduling algorithm was developed, using timed Petri nets, for a class of FMSs called Systems of Sequential Systems with Shared Resources (S 4 R). The algorithm generates a partial reachability graph to find the optimal or near-optimal deadlock-free schedule in terms of the firing sequence of the transitions of the Petri net model. The objective is to minimize the mean flow time (MFT). An efficient truncation technique, based on the siphon concept, has been developed and used to generate the minimum necessary portion of the reachability graph to be searched. It has been shown experimentally that the developed siphon truncation technique enhances the ability to develop deadlock-free schedules of systems with a high number of deadlocks, which cannot be achieved using standard Petri net scheduling approaches. It may be necessary, in some cases, to relax the optimality condition for large FMSs in order to make the search effort reasonable. Hence, a User Control Factor (UCF) was defined and used in the scheduling algorithm. The objective of using the UCF is to achieve an acceptable trade-off between the solution quality and the search effort. Its effect on the MFT and the CPU time has been investigated. Randomly generated examples are used for illustration and comparison. Although the effect of UCF did not affect the mean flow time, it was shown that increasing it reduces the search effort (CPU time) significantly.     

Modelling of semiconductor wafer fabrication systems by extended object-oriented Petri nets

In this paper, extended object-oriented Petri nets (EOPNs) are proposed for the effective modelling of semiconductor wafer fabrication systems (SWFSs). To cope with their complexity in terms of the re-entrant process route and the mixed production mode, a special type of transition called main-bus gate is introduced, which may lead each kind of product to undergo every re-entrant processing stage. In addition, the hierarchical approach is also applied to cope with the complexity. An etching area that processes 0.25?µm logic IC products is taken as an illustration to present the detailed modelling procedures by EOPNs, and the resulting model validates that the EOPNs may cope well with complex SWFSs modelling.     

Deadlock-free genetic scheduling for flexible manufacturing systems using Petri nets and deadlock controllers

In this paper, a new deadlock-free scheduling method based on genetic algorithm and Petri net models of flexible manufacturing systems is proposed. The optimisation criterion is to minimise the makespan. In the proposed genetic scheduling algorithm, a candidate schedule is represented by a chromosome that consists of two sections: route selection and operation sequence. With the support of a deadlock controller, a repairing algorithm is proposed to check the feasibility of each chromosome and fix infeasible chromosomes to feasible ones. A feasible chromosome can be easily decoded to a deadlock-free schedule, which is a sequence of transitions without deadlocks. Different kinds of crossover and mutation operations are performed on two sections of the chromosome, respectively, to improve the performance of the presented algorithm. Computational results show that the proposed algorithm can get better schedules. Furthermore, the proposed scheduling method provides a new approach to evaluate the performance of different deadlock controllers.     

Industrial systems maintenance modelling using Petri nets

This article presents a new algorithm that we have developed to find the minimal cut-sets of a coherent fault tree. The model presented is based on Petri nets. We also show that for a large fault tree, we are faced with the complexity problem. We suggest the use of place fusion as well as a methodology that can allow us to overcome this difficulty.     

Petri nets and genetic algorithms for complex manufacturing systems scheduling

In this paper we propose the GAPN (genetic algorithms and Petri nets) approach, which combines the modelling power of Petri nets with the optimisation capability of genetic algorithms (GAs) for manufacturing systems scheduling. This approach uses both Petri nets to formulate the scheduling problem and GAs for scheduling. Its primary advantage is its ability to model a wide variety of manufacturing systems with no modifications either in the net structure or in the chromosomal representation. In this paper we tested the performance on both classical scheduling problems and on a real life setting of a manufacturer of car seat covers. In particular, such a manufacturing system involves features such as complex project-like routings, assembly operations, and workstations with unrelated parallel machines. The implementation of the algorithm at the company is also discussed. Experiments show the validity of the proposed approach.     

Modular Petri nets for simulation of flexible production systems

The use of Petri nets for modelling, analysing and simulating complex distributed production systems meets serious problems when the size of the model grows. Therefore, it would be very useful to decompose a Petri net based model into smaller models linked with one another. The aim of this paper is to suggest and discuss some possible definitions of Modular Petri nets. This is accomplished by introducing the concept of Petri subnet. Two possible definitions are proposed and the meaning and the usefulness with respect to both model definition and model executability for simulation are pointed out. All definitions are given for the basic model of Petri nets. The extension of modularity concepts to high level Petri nets is shown to be possible in the second part of the paper, where an application is illustrated. In particular an algorithm is given which allows automatic composition of subnets into a larger model     

Self-adaptive dynamic scheduling of virtual production systems

To enhance the agility of virtual production systems (VPSs) under today's dynamic and changing manufacturing environment, a self-adaptive dynamic scheduling method based on event-driven is proposed for VPSs in this paper. This method is composed of the mechanisms and algorithm of self-adaptive dynamic scheduling. In the mechanisms, the dynamic events faced by VPSs are determined through users’ inputs or supervisory controllers’ detections, the local effects made on the schedule are analysed according to the dynamic events, and the self-adaptive measures and rules are specified correspondingly. To implement the dynamic scheduling of VPSs under the guidance of self-adaptive rules, a modified heuristic rescheduling algorithm is proposed for affected operations. A case study illustrates that the proposed method can well accomplish the dynamic scheduling of VPSs in a self-adaptive manner.     

Real-time deadlock-free scheduling for semiconductor track systems based on colored timed Petri nets

This paper addresses the problem of real-time deadlock-free scheduling for a semiconductor track system. The system is required to process wafers continuously, cassette by cassette. The process is not necessarily a repeated one. In addition, the system is deadlock-prone and its modules are failure-prone. Thus, real-time scheduling approaches are required to achieve high-performance. The problem can be solved in a hierarchical way. A deadlock avoidance policy is developed for the system as a lower-layer controller. With the support of the deadlock avoidance policy, heuristic rules are proposed to schedule the system in real-time. An effective modeling tool, colored–timed resource-oriented Petri net, is presented. It is shown that with this model we can schedule a system to achieve satisfactory results in real-time. This method is tolerant to module failures.     

Maintenance integration in manufacturing systems by using stochastic Petri nets

Research into both increased performance and improvements in dependability of production systems involves maintenance integration, which allows one to protect their availability and their durability. In the case of large manufacturing systems, maintenance integration is essential from conception, and so it involves a particular development concerned with both model complexity and computing time. A modular modelling approach, based on a cellular decomposition of the system, using stochastic Petri nets and Markov chains has been adopted to implement various maintenance strategies in complex production workshops, with the aim of studying their influence on the system dependability and performance.     

Phased mission modelling of systems with maintenance-free operating periods using simulated Petri nets

A common scenario in engineering is that of a system which operates throughout several sequential and distinct periods of time, during which the modes and consequences of failure differ from one another. This type of operation is known as a phased mission, and for the mission to be a success the system must successfully operate throughout all of the phases. Examples include a rocket launch and an aeroplane flight. Component or sub-system failures may occur at any time during the mission, yet not affect the system performance until the phase in which their condition is critical. This may mean that the transition from one phase to the next is a critical event that leads to phase and mission failure, with the root cause being a component failure in a previous phase. A series of phased missions with no maintenance may be considered as a maintenance-free operating period (MFOP). This paper describes the use of a Petri net (PN) to model the reliability of the MFOP and phased missions scenario. The model uses Monte-Carlo simulation to obtain its results, and due to the modelling power of PNs, can consider complexities such as component failure rate interdependencies and mission abandonment. The model operates three different types of PN which interact to provide the overall system reliability modelling. The model is demonstrated and validated by considering two simple examples that can be solved analytically.     

Modelling reconfigurable manufacturing systems with coloured timed Petri nets

Reconfigurable manufacturing systems (RMSs) have been acknowledged as a promising means of providing manufacturing companies with the required production capacities and capabilities. This is accomplished through reconfiguring system elements over time for a diverse set of individualised products often required in small quantities and with short delivery lead times. Recognising the importance of dynamic modelling and visualisation in decision-making support in RMSs and the limitations of current research, we propose in this paper to model RMSs with Petri net (PN) techniques with focus on the process of reconfiguring system elements while considering constraints and system performance. In view of the modelling challenges, including variety handling, production variation accommodation, machine selection, and constraint satisfaction, we develop a new formalism of coloured timed PNs. In conjunction with coloured tokens and timing in coloured and timed PNs, we also define a reconfiguration mechanism to meet modelling challenges. An application case from an electronics company producing mobile phone vibration motors is presented. Also reported are system analysis and application results, which show how the proposed formalism can be used in the reconfiguration decision making process.     

Deadlock modeling and control of semiconductor track systems using resource-oriented Petri nets

This paper addresses the deadlock avoidance problem in track systems in semiconductor fabrication. For the system without buffer space in it, the existing deadlock avoidance policies tend to be too conservative. Routing flexibility provides a chance to develop better ones, but makes their computation more complex. This paper models a track system using coloured resource-oriented Petri net (CROPN). Based on the model, a sufficient condition for deadlock-free operation and the corresponding control law are presented. This proposed policy is shown computationally efficient and less conservative than existing methods. An example is presented to demonstrate its application.     

Reliability analysis of discrete event dynamic systems with Petri nets

This paper deals with dynamic reliability of embedded systems. It presents a method for deriving feared scenarios (which might lead the system to a critical situation) in Petri nets. A classical way to obtain scenarios in Petri nets is to generate the reachability graph. However, for complex systems, it leads to the state space explosion. To avoid this problem, in our approach, Petri net reachability is translated into provability of linear logic sequents. Linear logic bases are introduced and used to formally define scenarios and minimality of scenarios. These definitions allow the method to produce only pertinent scenarios. The steps of the method are described and illustrated through a landing-gear system example.     

Transient inter-production scheduling based on Petri nets and constraint programming

In this article, we focus on the transient inter-production scheduling problem between two cyclic productions in the framework of flexible manufacturing systems. This problem is first formulated as a reachability problem in timed Petri nets (TPN), then solved using a methodology based on constraint programming. Our work is based on the controlled executions proposed by Chretienne to model the sequence of transition firing dates. Our methodology is based on a preliminary resolution of the state equation between initial and final states in the underlying non-TPN. Then, we choose a duration T _max corresponding to the maximal duration time of the scheduling. For each solution S of the state equation, we build a controlled execution from the sequence of firings in S. After the propagation of firing date constraints and reachability constraints in the TPN, we use constraint programming to enumerate the set of feasible controlled executions.     

Modelling and simulation of manufacturing systems with first-order hybrid Petri nets

First-order hybrid Petri nets are models that consist of continuous places holding fluid, discrete places containing a non-negative integer number of tokens, and transitions, either discrete or continuous. In the first part of the paper, we provide a framework to describe the overall hybrid net behaviour that combines both time-driven and event-driven dynamics. The resulting model is a linear discrete-time, time-varying state variable model that can be directly used by an efficient simulation tool. In the second part of the paper, we focus on manufacturing systems. Manufacturing systems are discrete-event dynamic systems whose number of reachable states is typically very large, hence approximating fluid models have often been used in this context. We describe the net models of the elementary components of a flexible manufacturing system (machines and buffers) and we show in a final example how these modules can be put together in a bottom-up fashion.     

Performance evaluation of tandem and conventional AGV systems using generalized stochastic Petri nets

This paper investigates the different policies and concepts followed in the traffic management of automated guided vehicle (AGV) systems, and develops the controls for automatically eliminating potential vehicle conflicts in an AGV system. The planning of the AGV system is performed in such a way that there are no conflicts or deadlocks for the vehicles using stochastic Petri nets (SPNs). The major effort is devoted to determining the benefits of the tandem AGV control in comparison with the conventional AGV control method. SPNs have been used to model the different designs of flexible manufacturing systems (FMSs) and with different policies for the movement of material, vehicle path control, inventory planning and tool control. The SPN model is solved and the performance of the system can be evaluated. In this study, the effort is directed to model an FMS with two different types of AGV traffic management methods, namely the conventional and tandem AGV control. A SPN program is used which takes the FMS Petri net model as the input and evaluates the different properties of the Petri net. Finally the performance measures are obtained, which helps in evaluating and comparing the two different AGV traffic management methods.     

Modelling and simulation of energy consumption of ceramic production chains with mixed flows using hybrid Petri nets

Ceramic production chain consisting of discrete flow and continuous flow energy-intensive processes consumes substantial amounts of energy. This study aims to evaluate energy consumption performance and energy-saving potentials of the ceramic production chain. According to the energy consumption characteristics of manufacturing processes and process interaction constraints in a ceramic production chain, an approach integrating the first-order hybrid Petri net (FOHPN) model, an objective linear programming model and a sensitivity analysis is proposed. The FOHPN model will simulate the energy consumption patterns of the ceramic production chain. Meanwhile, multi-objective linear programming model and sensitivity analysis will suggest the optimal specific energy consumption (SEC) of the production chain and identify the influences of input parameters (i.e. production rate of a process) on the SEC in the optimal production scheme. Finally, a real case study from bathroom ceramic plant validates the approach. It provides a tool for modelling and simulation of energy consumption of ceramic production chains with mixed flows and helps operators to perform energy-saving actions in the ceramic enterprise.