Petri net model based specification and distributed control of robotic manufacturing systems

The methods of modeling and control of discrete event robotic manufacturing cells using Petri nets are considered, and a methodology of decomposition and coordination is presented for hierarchical and distributed control. Based on task specification, a conceptual Petri net model is transformed into the detailed Petri net model, and then decomposed into constituent local Petri net based controller tasks. The local controllers are coordinated by the coordinator through communication between the coordinator and the controllers. Simulation and implementation of the control system for a robotic workcell are described. By the proposed method, modeling, simulation, and control of large and complex manufacturing systems can be performed consistently using Petri nets.

The paper considers the methods of modeling and control of discrete event robotic manufacturing systems using Petri nets and proposes a methodology of decomposition and coordination for hierarchical and distributed control. First, a task specification is defined as a Petri net model at the conceptual level, and then transformed to the detailed Petri net representation of the subtasks. Finally, the overall Petri net is decomposed and the constituent subnets are assigned to local Petri net based controllers. The coordinator is introduced to coordinate the distributed controllers so that the behavior of the distributed system is the same as that of the original Petri net. A coordination algorithm by two control levels is developed for defining robot and machine activation conditions. Based on the proposed method, a distributed control system has been implemented for a robotic manufacturing cell.

This paper deals with the modeling and control of discrete event robotic manufacturing cells using Petri nets, and proposes a methodology of model based design and implementation of hierarchical and distributed control. Hierarchical Petri net models are adopted; conceptual Petri net model and detailed Petri net model. The overall detailed Petri net model is decomposed into local Petri net models which are used by the local machine controllers. The upper level station controller coordinates the distributed local controllers so that the aggregate behavior of decomposed subnets is the same as that of the original Petri net. The overall control system is implemented using multithreaded programming based on Petri net based multitask processing. Simulation experiments show that the distributed Petri net model based control system can perform the overall multitask processing control by coincidence of the behavior of the real system with the local Petri net models.

Modeling and Simulation of Flexible Manufacturing Systems Controlled by Petri Nets

The paper is a partial synthesis of the work that a team within the Faculty of Managerial and Technological Engineering has in the field of modeling and simulation of systems with Petri nets. The paper deals with three issues. The first part is Modeling and simulation of manufacturing systems with timed Petri nets. The first part presents the way in which the performances of some manufacturing systems are evaluated using timed Petri nets. The first example is a manufacturing system specific to the textile industry. The system has three production lines. In this case, the modeling with timed Petri nets allows the analysis of the operation of the flow lines and highlights the bottleneck. Another modeled manufacturing system is specific to a series production, more precisely it refers to the manufacture of gas cookers within a company from Oradea. The model with Petri nets also describes the supply sequences of the stocks of parts and subassemblies. The next modeled system is an automated manufacturing system for the packaging of detergents. The complexity of the Detergent Packing System and the high level of automation, require the use of efficient modeling and simulation methods to verify the validity of the solutions adopted. In this chapter is present the model of a robotic welding cell. The second part of the paper, the transition from timed Petri nets to hierarchical colored Petri nets, shows how Petri nets were developed for a robotic cell for metallographic analysis. The third part is dedicated to modeling with colored Petri nets timed with complex colors of the flexible manufacturing cell A007 within the Department of Industrial Engineering.

This paper presents a new approach for modeling discrete manufacturing systems using Petri nets. Starting with the literature review of the classical approaches, this paper describes the new approach known as Activity-Oriented Petri Nets (AOPN). The AOPN approach provides expressive Petri net models that are powerful enough for modeling complex and large-scale manufacturing systems. The AOPN approach provides compact Petri net model too when a large number of resources are used in the manufacturing system. GPenSIM is a software implementation of AOPN on MATLAB platform. Using a flexible manufacturing system as a running example, this paper also shows how a real-life manufacturing system can be modeled and simulated with the GPenSIM software using AOPN approach.

A Petri net with controller is used to model discrete events in flexible job shop scheduling, the objective of scheduling problems is to minimize make-span, the scheduling results is obtained based on genetic and Tabu Search (TS) algorithm. It is proved capable of providing optimized schedule to the job-shop where the machine tool and manpower resources are both constrained. After crossover and mutation operations, an optimal or suboptimal scheduling plan can be found. The result of the test shows that this method is feasible and efficient. Job shop scheduling is the primary content and critical technology of the production management of CIMS, in the past during 30 years, a lot of researchers and results focus on it, but most of them deal with single objective and resource scheduling problems which are fixed processing route and constrained by machine, and production period is its optimal objective. Nevertheless, the production styles are variable and processing route is determined under the special condition. Moreover, job shop scheduling problem is the most difficult combined constraints optimal problem and typical NP hard problem which can't be solved in polynomial time by an effective algorithm. Up to date, there are some traditional algorithms to solve JSP problem (1-2). About paper (3), Petri net is used to construct JSP model and L1 which combines branch and bound algorithm with dynamic program is used to search its optimal solution. And paper (4), the job sequence is assigned by genetic code firstly, and then filtered beam search which based on breadth-first algorithm is adopted to search. In recent years, the Petri net as a discrete event dynamic system modeling and analysis tool(5), has been successfully applied to the flexible manufacturing system modeling, analysis and control. Some researchers put forward to be based on Petri network scheduling method, but only on the production line itself can not reflect the modeling, as in the production line of external control scheduling strategy influence. A hybrid algorithm is proposed to solve dual-resource scheduling problem in flexible production environment, and Petri net model with a controller, which can effectively model control. It combines the advantage of global search ability of GA with the self-adaptive merit of Tabu Search (TS) and improves its convergence. It is proved capable of global and part searching ability and efficient.

Deadlock/livelock problems can cause catastrophic results in flexible manufacturing systems (FMS) by forcing them to stop production processes at an unpredictable stage of production. Therefore, they must be handled properly in order to obtain flawless production in FMS. Petri net (PN) based deadlock/livelock studies for FMS have been widely carried out to obtain live PN models. When a PN model is live, this ensures that the modelled FMS is deadlock-free. Firstly, an uncontrolled (plant) PN model is constructed for the FMS suffering from deadlocks/livelocks. Then reachability graph (RG) analysis of this PN model is carried out to provide all possible reachable states of the modelled system. An RG of a PN model of an FMS suffering from deadlock/livelock problems can be split into the live zone (LZ) and the deadlock zone (DZ). The former is the set of system states considered to be legal (good), while the latter is the set of system states regarded to be illegal (bad). The LZ represents the optimal (maximally permissive) system behavior that must be provided by an optimal control policy. Generally, in PN based liveness studies, a liveness enforcing supervisor (LES) consisting of a set of control places (CP) is computed. Then the controlled (closed-loop) PN model is obtained by merging the plant PN model and the LES. If the number of reachable live states of the controlled PN model is the same as the ones that exist in the LZ, then the controlled model is optimal. Otherwise, it is suboptimal. The greater the number of live reachable states of the RG, the more products to be produced within the FMS. Therefore, the number of reachable live states of the controlled PN model is considered as a quality measure. It defines the behavioral permissiveness of the controlled model. In the literature, to verify the behavioral permissiveness of the PN models, the PN tool called INA (Integrated Net Analyzer) has been widely used. Recently, by means of INA, a method was proposed to compute the number of states within the LZ and the DZ of a given PN model suffering from deadlocks/livelocks. Unfortunately, INA cannot compute RGs of large PNs having a few millions of states. Therefore, in this paper by means of TINA (TIme petri Net Analyzer), an alternative faster and much more efficient method is proposed for the computation of the number of states within the LZ and the DZ for PN models with large RGs. In addition, in order to enable the development of new PN based deadlock prevention methods, further computations are also proposed. These include the computation of the set of states in the DZ, LZ and first met bad markings (FBMs) for a given PN model suffering from deadlocks/livelocks. The applicability and the effectiveness of the proposed methods are demonstrated by considering several well-known examples of FMS from the relevant literature.INDEX TERMS Flexible manufacturing systems (FMS), deadlock, deadlock prevention, Petri Nets (PN), liveness enforcing supervisor (LES), PN computation tools.

Supervisory control is usually considered as an external control mechanism to a system by controlling the occurrences of its controllable events. There exist Petri net models whose legal reachability spaces are nonconvex. In this case, they cannot be optimally controlled by the conjunctions of linear constraints. For Petri net models of flexible manufacturing systems, this work proposes a method to classify the legal markings into several subsets. Each subset is associated with a linear constraint that can forbid all first-met bad markings. Then, the disjunctions of the obtained constraints can make all legal markings reachable and forbid all first-met bad markings, i.e., the controlled net is live and maximally permissive. An integer linear programming model is formulated to minimize the number of the constraints. A supervisory structure is also proposed to implement the disjunctions of the constraints. Finally, examples are provided to illustrate the proposed method.

Modelling and control of manufacturing systems using fuzzy petri nets

Modelling and analysis of kanban-controlled (just-in-time) production systems under realistic assumptions presents a number of challenges, including the ability to conduct both qualitative and quantitative analysis, and the ability to model control policies. These challenges are due, in part, to station interdependence, blocking and starvation due to limited buffer spaces, and the necessity of modelling both material and kanban flows. Petri nets (PNs) have recently emerged as a promising approach for modelling manufacturing systems. PNs are a graphical and mathematical technique useful for modelling concurrent, asynchronous, distributed, parallel, non-deterministic and stochastic systems. PN models can be analysed to determine both their qualitative and quantitative properties. In this paper, we develop stochastic, coloured PN (SCPN) models of a JIT system utilizing two different kanban control policies: a traditional kanban system (TKS) policy and a flexible kanban system (FKS) policy. The resulting models can be used to represent JIT systems of arbitrary size, producing single or multiple types of products, with fixed order points 1. The models are shown to be live and bounded, and can be simulated to produce quantitative results. Sample simulation results are presented to illustrate the models' capabilities.

Decentralized supervisory structure has drawn much attention in recent years to address the computational complexity in designing supervisory structures for large Petri net model. Many studies are reported in the paradigm of automata while few can be found in the Petri net paradigm. The decentralized supervisory structure can address the computational complexity, but it adds the structural complexity of supervisory structure. This paper proposed a new method of designing a global controller for decentralized systems of a large Petri net model for flexible manufacturing systems. The proposed method can both reduce the computational complexity by decomposition of large Petri net models into several subnets and structural complexity by designing a global supervisory structure that can greatly reduce the cost at the implementation stage. Two efficient algorithms are developed in the proposed method. Algorithm 1 is used to compute decentralized working zones from the given Petri net model for flexible manufacturing systems. Algorithm 2 is used to compute the global controller that enforces the liveness to the decentralized working zones. The ring assembling method is used to reconnect and controlled the working zones via a global controller. The proposed method can be applied to large Petri nets size and, in general, it has less computational and structural complexity. Experimental examples are presented to explore the applicability of the proposed method.

A class of Petri nets, called extended Petri nets, with multiple types of places, multiple classes of tokens and multiple arcs is proposed. It is utilized for the hierarchical modeling of flexible manufacturing systems, ensuring a priori that the extended Petri net system model obtained is live, bounded, consistent and error free. The proposed method views the operation of the flexible manufacturing system as a process that is decomposed into operations with specified precedence relations. For each operation the required resources are identified, and on the basis of these requirements the overall system is decomposed into a set of finite subsystems. The operation of each subsystem is modeled as an event graph representing a single resource activity cycle. The extended Petri net system model is synthesized from these component nets using certain synthesis rules. A software package has been developed to simulate the execution of the model obtained. >

In this paper a hybrid approach is proposed for supervisory control of discrete event systems (DES) subject to forbidden states. Assuming that an uncontrolled bounded Petri net (PN) model of a (plant) DES and a set of forbidden state specifications are given, the proposed approach computes a maximally permissive and nonblocking closed-loop hybrid model. The first step is to simplify the given PN model by means of PN reduction rules. The simplified model and the specifications are then represented as buffers, and supervisory control theory (SCT) is applied to obtain a Ramadge–Wonham (RW) supervisor in the form of an automaton. After reduction of the latter’s state size by a ‘control congruence’, the simplified RW supervisor is represented by a so-called auto-net and coupled to the given uncontrolled PN plant model by means of inhibitor arcs to represent the disabling actions. The plant model and supervisor auto-net run concurrently, synchronizing on shared events. This procedure provides a maximally permissive and nonblocking ‘hybrid’ (mixed PN/automaton) closed-loop controlled system. The method is straightforward logically, graphically, and technologically. Its applicability is shown by two examples, one of them a workcell from the PN control literature.

Modelling Flexible Manufacturing Systems Based on Petri Nets