Petri nets and flexible manufacturing

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.

Petri nets are used to design deadlock control strategies for flexible manufacturing systems (FMS), which typically involve the addition of monitors and the associated arcs to the FMS. The addition of several monitors and associated arcs to first constructed Petri net model significantly complicates the Petri net controller. This paper develops a two-step method for preventing deadlocks based on a colored Petri net and a structurally minimal approach that significantly reduces the number of monitors. In the first step, a vector covering technique is applied to generate a minimal covered sets of first-met bad markings (FBMs) and legal markings that are respectively smaller than the sets of FBMs and legal markings. At one iteration, place invariants (PIs) corresponding to monitors are constructed by solving an integer linear programming problem (ILPP) to prohibit the maximum number of FBMs, while allowing all legal markings in the minimal covering set. The purpose of the ILPP is to maximize the number of FBMs forbidden by the PIs. Then, based on a colored Petri net, all generated monitors are combined into a global control place. Therefore, a supervisor with minimal structural complexity can be constructed. The obtained net model is controlled after the addition of the designed supervisor. Two instances from the literature are considered to illustrate the proposed approach.

This paper presents a heuristic search approach for scheduling flexible manufacturing systems (FMS) with due dates based on the Petri net state equation. It is known that the state equation of a Petri net has a solution if the goal marking can be reached from the initial marking. In terms of scheduling, this denotes that the costs of jobs can be obtained from the solution. In this paper, the idea of jobwise Petri nets is introduced. A jobwise net is a part of the model of an FMS. It is only associated with one job and the resources that the job uses. A model of N jobs can be split into N jobwise net models. We combine jobwise Petri nets and the state equations to implement the search algorithm. The objective is to minimize weighted tardiness (lateness), which is the difference of the completion time of a job and its due date. In order to show that this scheduling method can get near-optimal solutions, we compare it with some commonly used dispatching rules by simulations.

Modelling Flexible Manufacturing Systems Based on Petri Nets

To simulate and debug or diagnose manufacturing systems is always challenging. This paper presents a hybrid PLC-controlled and PC Visual Basic (VB)-based Human-Machine Interface (HMI) platform based on Petri net (PN) theory for Manufacturing Systems. An augmented PN model was adopted to design and simulate the operational sequence of the Flexible Manufacturing System (FMS) at the National Kaohsiung First University of Science and Technology (NKFUST). With the simulated PN model, the control sequences were quickly translated into PLC programs. A PC-based HMI monitoring system based on the PN model was developed to provide an intuitive offline simulation and online diagnostic tools for the FMS. This hybrid system shows many of advantages by using the economical discrete control unit with PLC, and PC-based HMI using PN model as a base. The discrete event control sequence of an FMS can be easily modeled and evaluated before its build-up. More importantly, it can be diagnosed online when the system is malfunctioning. That is, the presented system provides an adequate means for offline system design, simulation, performance evaluation, and quick online system diagnostic.

In this paper, we use Petri nets to analyse flexible manufacturing systems (FMS) to achieve the following objectives. The first objective is to derive a theorem for checking the buffer overflows in an FMS. The second objective is to schedule the earliest starting times for a sequence of operations in an FMS by the timed Petri net. The FMS may involve many part types, machines, pallets and so on. The third objective is to detect the deadlock phenomenon by a corrected algorithm of the P-invariant theory for Petri nets. This method will enable us to know whether there exists any deadlock in an FMS. The algorithm is implemented in the Turbo Pascal language. The fourth objective is to search for the optimal scheduling rule in an FMS. The search procedure is also implemented in the Turbo Pascal language¨ The optimal machine scheduling rule can result in a better throughput.

In this paper we present an approach for modelling and analyzing flexible manufacturing systems (FMSs) using Petri nets. In this approach, we first build a Petri net model (PNM) of the given FMS in a bottom-up fashion and then analyze important qualitative aspects of FMS behaviour such as existence/absence of deadlocks and buffer overflows. The basis for our approach is a theorem we state and prove for computing the invariants of the union of a finite number of Petri nets when the invariants of the individual nets are known. We illustrate our approach using two typical manufacturing systems: an automated transfer line and a simple FMS.

Deadlock analysis and control using Petri net decomposition techniques

The work undertaken in this thesis is about the integration of two well-known methodologies: Petri net (PN) model Ii ng/analysis of industrial production processes and Artificial Intelligence (AI) optimisation search techniques. The objective of this integration is to demonstrate its potential in solving a difficult and widely studied problem, the scheduling of Flexible Manufacturing Systems (FIVIS). This work builds on existing results that clearly show the convenience of PNs as a modelling tool for FIVIS. It addresses the problem of the integration of PN and Al based search methods. Whilst this is recognised as a potentially important approach to the scheduling of FIVIS there is a lack of any clear evidence that practical systems might be built. This thesis presents a novel scheduling methodology that takes forward the current state of the art in the area by: Firstly presenting a novel modelling procedure based on a new class of PN (cb-NETS) and a language to define the essential features of basic FIVIS, demonstrating that the inclusion of high level FIVIS constraints is straight forward. Secondly, we demonstrate that PN analysis is useful in reducing search complexity and presents two main results: a novel heuristic function based on PN analysis that is more efficient than existing methods and a novel reachability scheme that avoids futile exploration of candidate schedules. Thirdly a novel scheduling algorithm that overcomes the efficiency drawbacks of previous algorithms is presented. This algorithm satisfactorily overcomes the complexity issue while achieving very promising results in terms of optimality. Finally, this thesis presents a novel hybrid scheduler that demonstrates the convenience of the use of PN as a representation paradigm to support hybridisation between traditional OR methods, Al systematic search and stochastic optimisation algorithms. Initial results show that the approach is promising.

Petri nets have been recognized as one of the most powerful tools for modeling flexible manufacturing systems (FMSs). Deadlock prevention policies are used to solve the deadlock problems of FMSs. It is well known that theory of regions is the efficient method for obtaining maximally permissive controllers. All legal and live maximal behavior of Petri net models can be preserved by using marking/transition-separation instances (MTSIs) or event-state-separation-problem (ESSP) methods. However, computing all sets of inequalities are an extremely time consuming problem due to the reachability graph of the deadlocked system. In our previous works, we proposed CMTSI method to improve the computational cost. In this paper, the selective siphon method is merged in our new deadlock prevention policy. The merit of the proposed policy is that the number of two types CMTSIs can then be simplified. Experimental results indicate that it is the most efficient policy to obtain maximal permissive behavior of Petri net models.

Agent-based FMS control

Petrinets are the suitable tool for modeling and analysis of discrete event systems. The effective methods of analyzing the discrete event systems (DES) are exhibited by Petri nets. The entire structure of the system is mathematically expressed using Petrinets and also all the properties are analysed by different methods. The properties of Petrinets are different in various systems, a Flexible Manufacturing System (FMS) requires production activities in which raw materials, energy, labour, and equipment are combined together in the modification process for the production of good quality goods.” The word “flexible” explains the capability of the system to relate productively to make changes in the system. These changes can be internal failure of the system or classification problems such as a sample or external changes in the structure of the model as well as demand for the process. The inherent limitations such as undecidable properties, complexity in checking, automatic verification of the modeled system are existing in FMS. This paper explains a study on FMS using Petri net reduction. A PN underlies event structures with casuality and compatibility relations. Partial order methods and reduction methods reduce the complexity of constructing the reachability graph. The determination of PN system through reduction methods in recent years focused by many researchers. The significance of reduction methods are highlighted to execute the faster analysis of a system. Instead of coverability trees and the graphical representation the incidence matrix of the PNs are used for the reduction methods. Reduction methods are used to simplify large scale PNs into “equivalent” smaller nets. Boundedness, liveness, simplification of implicit places, shared resources and elimination of self-loops are checked though equivalent smaller nets. The structure of FMS is preserved.

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.

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.

This paper describes the ways of using program tools for design and simulation of flexible manufacturing systems (FMS) for the purpose of teaching the undergraduate course Flexible Manufacturing Systems. The concept of the course is based on the synergism of theoretical knowledge and practical hands-on experience gained by studying numerous problem cases, using common tools for description of FMS (Petri nets, max-plus algebra and matrix modeling) and by working with more specialized program tools for FMS design and simulation. An emphasis is given to the description o the program tool FlexMan that enables elegant setting of an FMS configuration, supports automatic generation of a matrix-based FMS description and consequently, enables effective off-site design and simulation of the FMS by using virtual reality models and Internet-related technologies.