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.     

Decision making,computer attitudes and expert systems: What is our direction?

Expert systems have been concerned with applications dealing with medical diagnosis, mineral exploration, and computer configuration, with some efforts relatively successful in achieving results at least as good as human experts. Today, much is being written about these systems and managerial decision-making activities in organizations and the positive impact that they can have in these situations. However, it appears that expert systems could become somewhat of a panacea for some organizational ailments as research, development, and marketing of them continues at a fast pace. What may be forgotten in this technological thrust is the individual decision maker and his/her unique style of decision making which could affect acceptance and use of these systems. Another important consideration is the attitude people have toward computers and computer systems, which along with decision-making styles could certainly affect expert system effectiveness and ultimate success in organizations. This paper provides a discussion of potential problems that could occur regarding individual decision making and attitudes and their relationships to these systems.     

Mathematical modelling of a reverse flow reactor with catalytic surface dynamics

This paper studies a system of partial differential equations modelling the behaviour of a reverse flow reactor. For the parameters appropriate for the oxidation of ammonia on a Pt/Al₂O₃ catalyst in a typical laboratory set-up, the reactor may be split into regions where approximate formulas that determine its behaviour are deduced. Numerical calculations are presented and can be used to compare with the analytical formulas. The physical insight gained from the asymptotic analysis suggests a new switching strategy which is the subject of numerical experiments. The switching strategy is found to be efficient at minimising the ammonia exiting the reactor after reversal.     

Bottleneck Analysis of Assembly Lines with Characteristic Curves

Tuning the performance parameters of all stations of interlinked manufacturing and assembly systems to ensure the planned capacity is a major challenge. The application of system simulation for this task is little common, particularly in SMEs. A suitable tool for quickly assessing the specific influence of a standalone station on the entire system performance has been developed on the basis of the characteristic curve theory. The applied methodology and the results obtained are presented in this paper.     

Closed-loop automatic tuning of PID controller for nonlinear systems

In this paper, a robust control system is first proposed which is suitable for the control of a class of nonlinear systems. A parallel connection of a relay to a proportional integral derivative (PID) controller collectively forms the robust controller. The relay ensures robust control by providing a high feedback gain, but it also induces a control chattering phenomenon. Instead of viewing chattering as an undesirable yet inevitable feature, the chattering signals are used as natural excitation signals for identifying an equivalent PID controller using the recursive least squares algorithm. No other explicit input signal is required. Analysis is provided on the stability properties of the control scheme. Simulation results for the level control of fluid in a spherical tank using the scheme are presented.     

Comments on “Equivalence of characterizations of fixed models”

In this note we present a proof to the conjecture given in the above paper, and therefore establish the equivalence of characterizations of fixed modes for the general case.     

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.     

Should we be surprised at expert system success ?

Abstract. Expert systems proliferate. They are now a usable and used tool in a variety of organizations. However, little research has been undertaken on the quantification of success or failure of expert system projects. By and large the only test carried out for expert system validation is one of comparison of the conclusions of the system with those of an expert or team of experts. While questioning the validity, this paper accepts that this method is being used and analyses whether or not the results obtained from this type of test should be a surprise. That is, what sort of results should be expected and to what extent do the reported ones live up to these expectations? Earlier research from the field of human information processing casts doubts on the success claims made for current expert systems. The implications of this research are then analysed in order to explore the possible redeeming features of expert systems which are not taken into account in such comparisons. The use of linear models as comparators for expert systems may prove beneficial.     

From hospital to municipal cogeneration systems: an Italian case study

A mixed integer linear programming model combined with a more traditional design by scenarios is proposed to optimize facilities size and operation mode of a municipal energy system involving significant civil centres and a hospital. Moving from the need of a new heat and power station for the local hospital due to the construction of new pavilions, the opportunity of involving other centres in the neighbourhood in a distributed cogeneration system is analysed, increasing system complexity step by step. Smaller cogeneration units tailored to hospital needs are rewarding ventures with relatively low risks but, in a country whose traditional power generation systems heavily rely on fossil fuels and where energy policy and market conditions can make it profitable to sell surplus power, district heating systems foster the installation of larger cogenerators and lead thereby to higher profits and to better performance as for primary energy savings and greenhouse gases emission reduction. Copyright © 2006 John Wiley & Sons, Ltd.