基于构件的可重构制造执行系统研究

制造执行系统是实现企业信息集成的关键技术，是企业信息化工程领域的研究热点之一。分析了制造执行系统的定义和功能，并提出基于软件构件的可重构制造执行系统的软件体系结构和实现方法。可重构制造执行系统的开发与运行实践表明，可重构制造执行系统的软件开发效率高、周期短、可扩展性好。     

Reconfigurable manufacturing systems: Key to future manufacturing

Presented in this article is a review of manufacturing techniques and introduction of reconfigurable manufacturing systems; a new paradigm in manufacturing which is designed for rapid adjustment of production capacity and functionality, in response to new market conditions. A definition of reconfigurable manufacturing systems is outlined and an overview of available manufacturing techniques, their key drivers and enablers, and their impacts, achievements and limitations is presented. A historical review of manufacturing from the point-of-view of the major developments in the market, technology and sciences issues affecting manufacturing is provided. The new requirements for manufacturing are discussed and characteristics of reconfigurable manufacturing systems and their key role in future manufacturing are explained. The paper is concluded with a brief review of specific technologies and research issues related to RMSs.     

Technical investment planning of flexible manufacturing systems—The application of practice-oriented methods

Flexible manufacturing systems (FMS) exhibit a high degree of automation of the machining system and of the workpiece, and for the information flow systems. Therefore, these systems are amongst the most complex production installations and their technical investment planning must be undertaken with great care.This paper introduces a strategic planning procedure and describes auxiliary aids for the selection of the components and for structuring of the overall system. Computer programs for the selection of machine tools and for the simulation of the manufacturing process sequence are part of this procedure. The application of the methods is illustrated by means of several problem situations arising from industrial production companies; the examples show the practical usefulness of the developed auxiliary techniques. The planning accuracy possible by these methods reduces the investment risk associated with the use of these complex manufacturing systems.Also described is an integrated system for the technical investment planning of flexible manufacturing systems which comprises both existing methods and new auxiliary means for planning the machining systems and the technical/organizational overall concept.     

A process-driven computing model for reconfigurable semiconductor manufacturing

Reconfigurability is essential for semiconductor manufacturing systems to remain competitive. Reconfigurable systems avoid costly modifications required to change and adapt to changes in product, production and services. A fully automated, collaborative, and integrated while reconfigurable manufacturing system proves cost-effective in the long term and is a promising strategy for the semiconductor manufacturing industry. However, there is a lack of computing models to facilitate the design and development of control and management systems in a truly reconfigurable manner. This paper presents an innovative computing model for reconfigurable systems and controlled manufacturing processes while allowing for the integration of modern technologies to facilitate reconfiguration, such as radio frequency identification (RFID) and reconfigurable field programmable gate array (FPGA). Shop floor manufacturing activities are modeled as processes from a business perspective. A process-driven formal method that builds on prior research on virtual production lines is proposed for the formation of a reconfigurable cross-facility manufacturing system. The trajectory of the controlled manufacturing systems is optimized for on-demand production services. Reconfigurable process controllers are introduced in support of the essential system reconfigurability of future semiconductor manufacturing systems. Implementation of this approach is also presented.     

A multiagent-based control system applied to an educational shop floor

This paper addresses the design and implementation of a multiagent-based control architecture to support modular reconfigurable production systems. The requirements for plugability of modules (manufacturing components) and product changes were considered and tested against an educational platform based on Fischertechnik, which resembles a production system composed of several workstations connected by a crane and conveyors.     

基于Agent的可重构装配线制造执行系统

针对制造执行系统存在的问题,根据可重构制造模式的理念,设计基于CORBA和多Agent的可重构装配线制造执行系统的体系结构,实现制造执行系统的可重构性和可集成性,构建系统的IDEF0功能模型,给出Agent结构模型及装配资源聚类方法。实际应用表明该系统具有良好的实用性,能满足企业需求。     

Distributed real-time embedded systems: Recent advances, future trends and their impact on manufacturing plant control

Real-time and embedded systems have historically been small scale. However, advances in microelectronics and software now allow embedded systems to be composed of a large set of processing elements, and the trend is towards significant enhanced functionality, complexity, and scalability, since those systems are increasingly being connected by wired and wireless networks to create large-scale distributed real-time embedded systems (DRES). Such embedded computing and information technologies have become at the same time an enabler for future manufacturing enterprises as well as a transformer of organizations and markets. This paper discusses opportunities for using recent advances in the DRES area in the deployment of intelligent, adaptive, and reconfigurable manufacturing plant control architectures.     

Recent trends in flexible automated manufacturing

In recent years, an important change in developing and implementing manufacturing systems can be observed in all industrialized countries. Due to intense international competition and the growth of personnel costs, companies are forced to use systems with a higher level of automation. At the same time, an increasing number of product variation—caused by adapting the products to customer requirements—demand more flexibility of machine tools and manufacturing systems.Basic types of computer-controlled flexible automated manufacturing systems will be shown and characterized by their special ranges of application. A planning procedure is presented which includes selecting a suitable systems structure such as; transfer line or flexible manufacturing system or automated manufacturing cell, and for determinating every single machine tool within the system. Examples of several new computer-controlled manufacturing systems which have been planned by the above planning procedure are presented with special regard to the evaluation of the system's economic performance.Finally, some rules are given for measuring the economic performance of automated manufacturing or assembly systems including automation of the handling functions.     

Control architecture and design method of reconfigurable manufacturing systems

This paper proposes a control architecture for reconfigurable manufacturing systems and its design method based on Petri nets (Input Output Place Transition and Production Flow Schema), Service-Oriented Architecture and Holonic and Multi-Agent System techniques, among other good practices. The control architecture integrates value-added activities, information and resources. The method considers the exchange of knowledge among heterogeneous business workflow of manufacturing subsystems in different geographical locations, and allows modeling process, product, machine and device control. An example demonstrates advantages of the resulting control system.     

Modular machine tools: Design and barriers to industrial implementation

The Reconfigurable Manufacturing System (RMS) paradigm has been developed to address challenges in the design of manufacturing systems and equipment that will meet the demands of modern manufacturing. This research involved the development of Modular Reconfigurable Machines (MRMs); as an emerging technology in reconfigurable manufacturing. MRMs are mechanically modular machines. The modularity permits the kinematic architecture and processing functions of the machine to be reconfigured to meet changing production requirements. This paper will focus on aspects of the mechanical design and the development of a control system that supported the modularity and reconfigurability of the mechanical platform. A modular electronic system is presented that is characterized by a plug and play approach to control scalability. This is complemented by a software architecture that has been developed with a focus on hardware abstraction for the management of an augmented mechanical and electronic architecture. The implications of MRMs for RMSs are discussed and key inhibitors to industrial implementation are identified.     

Automatic Reconfiguration of Petri Net Controllers for Reconfigurable Manufacturing Systems With an Improved Net Rewriting System-Based Approach

The advent of reconfigurable manufacturing systems (RMSs) has given rise to a challenging problem, i.e., how to reconfigure rapidly and validly a RMS supervisory controller in response to frequent changes in the manufacturing system configuration driven by fluctuating market. This paper presents an improved net rewriting system (INRS)-based method for automatic reconfiguration of Petri net (PN) supervisory controllers for RMS. We begin with presenting the INRS which overcomes the limitations of the net rewriting system and can dynamically change the structure of a PN without damaging its important behavioral properties. Based on INRS, a method for design reconfigurable PN controllers of RMS is introduced. Subsequently, we presented an INRS-based method for rapidly automatic reconfiguration of this class of PN controllers. In the reconfiguration method, changes in a RMS configuration can be formalized and act on an existing controller to make it reconfigure rapidly into a new one. Noticeably, no matter the design or reconfiguration, the expected behavioral properties of the resultant PN controllers are guaranteed. Thus, efforts for verification of the results can be avoided naturally. We also illustrate the reconfiguration of a PN controller for a reconfigurable manufacturing cell.     

Perturbation analysis for production control and optimization of manufacturing systems

We use stochastic fluid models (SFM) to capture the operation of threshold-based production control policies in manufacturing systems without resorting to detailed discrete event models. By applying infinitesimal perturbation analysis (IPA) to a SFM of a workcenter, we derive gradient estimators of throughput and buffer overflow metrics with respect to production control parameters. It is shown that these gradient estimators are unbiased and independent of distributional information of supply and service processes involved. In addition, based on the fact that they can be evaluated using data from the observed actual (discrete event) system, we use them as approximate gradient estimators in simple iterative schemes for adjusting thresholds (hedging points) on line seeking to optimize an objective function that trades off throughput and buffer overflow costs.     

Rapid design and reconfiguration of Petri net models for reconfigurable manufacturing cells with improved net rewriting systems and activity diagrams

To respond rapidly to the highly volatile market, the emerging reconfigurable manufacturing systems (RMS) have brought forward two challenging issues, namely, how to build rapid a formal model of an initial manufacturing configuration and how to yield the goal model from the existing one along with manufacturing configuration changes (reconfiguration). As for the issues, we present in this paper a method for rapid design of Petri net (PN) formalized models of RMS, intended for supervisory control and logic control of RMS, as well as a method for automated reconfiguration of the models. Firstly, we present an improved net rewriting system (INRS) for dynamically operating net transformation, unlike its predecessor-net rewriting system, where the initial behavioral properties of the underlying PN rewritten can be preserved during the transformation. Subsequently, the paper proposes the three-phase method for rapid design of initial full PN models of reconfigurable manufacturing cells (RMCs). In this method, activity diagrams of Unified Modeling Languages version 2 (UML 2) are used to describe manufacturing configurations, firstly; then the sub-activity diagrams are transformed into PN sub-models; finally, the PN sub-models are automated synthesized into a full model by the approach of INRS. Further, we present a model reconfiguration method for this class of PN models. The method compares changes in activity diagrams of the existing and goal manufacturing configurations and converts them into net rewriting rules of INRS. By applying the rules obtained, the existing PN model can reconfigure into a new one for the goal manufacturing configuration. No matter the design method or the reconfiguration method, the behavioral properties of the obtained PN models, e.g., liveness, boundedness, or reversibility, can be guaranteed and thereby the efforts of verification can be avoided. Finally, rapid design of a PN model of a reconfigurable manufacturing cell, as well as its automated reconfiguration, is illustrated with the help of an example. The result indicates the validity of the methods.     

Decision support requirements in flexible manufacturing

Flexible manufacturing systems are being installed by many organizations in an effort to improve productivity. Because efficient operation of these systems is such a complex task, their capacity is often underutilized. The concept of computer-based decision support systems promises to remedy the situation. This paper defines the components of a decision support system which will enable the user to get the maximum benefit from a flexible manufacturing system. The structure of this decision support system parallels the organizational activities involved in running the flexible manufacturing system. This structure should be implemented using appropriate hardware and software components.     

网络化制造环境下一种面向能力的制造资源模型

制造资源管理是网络化制造中重要的一环。针对现有模型中共享资源在实现可行性方面存在的不足，提出建立一种面向能力的制造资源模型，并以XML格式进行描述。在此基础之上，建立了基于制造特征的任务定义模型。     

可重构制造系统监督控制器的自动重构

提出了基于改进的网重写系统(Improved net rewriting system, INRS)的可重构制造系统(Reconfigurable manufacturing systems, RMS) Petri网监督控制器的自动重构方法, 以快速适应由市场需求变化所引起的制造系统构形的频繁变化. INRS解决了网重写系统存在的问题, 可动态调整给定Petri网模型的结构而不改变其行为属性. 以集合和图的组合形式定义了RMS的构形, 并提出了基于INRS的一类模块化、可重构的Petri网控制器的设计方法. 针对这类Petri网控制器, 提出了基于INRS的自动重构方法. 方法可将RMS构形的变化转变为INRS的图重写规则, 并作用于当前Petri网控制器, 使其快速、自动地重构为所求的新控制器. 所提出的Petri网控制器的设计与重构方法, 均从理论上保证了结果的正确性, 免校验. 仿真研究验证了方法的有效性.     

Performance evaluation for manufacturing systems under control-limit maintenance policy

Maintenance decision-making in large manufacturing systems is complex as it requires the integration of various information. A control-limit policy is popular in practice, where maintenance is carried out when the degradation state of a machine reaches a threshold value. In this paper, by developing a framework based on discrete-time Markov chain models, we evaluate the system performance under the control-limit policy, in manufacturing systems that consist of multi-state machines and intermediate buffers. An exact analysis is performed for a two-machine-one-buffer system and an approximation method based on system decomposition is developed for multi-stage systems. Both steady-state and transient performance is analyzed. Numerical examples are presented to demonstrate the accuracy of the proposed method and the impact of different parameters (e.g., buffer capacity, uncertainty in the maintenance duration) on the system performance.     

An integrated modelling framework to support manufacturing system diagnosis for continuous improvement

This paper proposes an integrated modelling framework for the analysis of manufacturing systems that can increase the capacity of modelling tools for rapidly creating a structured database with multiple detail levels and thus obtain key performance indicators (KPIs) that highlight possible areas for improvement. The method combines five important concepts: hierarchical structure, quantitative/qualitative analysis, data modelling, manufacturing database and performance indicators. It enables methods to build a full information model of the manufacturing system, from the shopfloor functional structure to the basic production activities (operations, transport, inspection, etc.). The proposed method is based on a modified IDEF model that stores all kind of quantitative and qualitative information. A computer-based support tool has been developed to connect with the IDEF model, creating automatically a relational database through a set of algorithms. This manufacturing datawarehouse is oriented towards obtaining a rapid global vision of the system through multiple indicators. The developed tool has been provided with different scorecard panels to make use of KPIs to decide the best actions for continuous improvement. To demonstrate and validate both the proposed method and the developed tools, a case study has been carried out for a complex manufacturing system.     

Trends and perspectives in flexible and reconfigurable manufacturing systems

To better understand future needs in manufacturing and their enabling technologies, a survey of experts in manufacturing has been conducted. The survey instrument (i.e., questionnaire) tries to assess the experience to date with the use of flexible manufacturing systems (FMS) and to examine the potential roles and enabling technologies for reconfigurable manufacturing systems (RMS). The results show that two-thirds of respondents stated that FMSs are not living up to their full potential, and well over half reported purchasing FMS with excess capacity (which was eventually used) and excess features (which in many cases were not eventually used). They identified a variety of problems associated with FMS, including training, reconfigurability, reliability and maintenance, software and communications, and initial cost. However, despite these issues, nearly 75% of respondent expressed their desire to purchase additional, or expand existing FMSs. The experts agreed that RMS (which can provide exactly the capacity and functionality needed, exactly when needed) is a desirable next step in the evolution of production systems. The key enabling technologies for RMS were identified as modular machines, open-architecture controls, high-speed machining, and methods, training and education for the operation of manufacturing systems.     

An adapted NSGA-2 algorithm based dynamic process plan generation for a reconfigurable manufacturing system

With burgeoning global markets and increasing customer demand, it is imperative for companies to respond quickly and cost effectively to be present and to take the lead among the competitors. Overall, this requires a changeable structure of the organization to cater to a wide product variety. It can be attained through adoption of the concept of reconfigurable manufacturing system (RMS) that comprises of reconfigurable machines, controllers and software support systems. In this paper, we propose a new approach to generate the dynamic process plan for reconfigurable manufacturing system. Initially, the requirements of the parts/products are assessed which are then compared with the functionality offered by machines comprising manufacturing system. If the production is feasible an optimal process plan is generated, otherwise the system shows an error message showing lack of functionality. Using an adapted NSGA-2 algorithm, a multi-objective scenario is considered with the aim of reducing the manufacturing cost and time. With the help of a numerical example, the efficacy of the proposed approach is demonstrated.