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.     

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.     

Logic control law design for automated manufacturing systems

To respond rapidly to the highly volatile market, the reconfigurable manufacturing systems (RMS) have brought forward challenging issues. First of all there is a need to build a formal model of a manufacturing configuration. Second it has to be rather easy to derive the models associated to the manufacturing configuration changes (reconfiguration) from such an initial model. An off-line method of rapid design of an optimal logic control law (configuration) based on Petri net (PN) is presented in this paper. From a controlled system modeling point of view, the main characteristics of the level 1 of the CIM architecture are depicted. Subsequently, the formal tool used in the automated planning field is extended to provide a controlled system model. The concept of operation is structured in order to introduce the behavioral properties of the operations. A four-step method is then proposed to design a logic control law that satisfies several goals: reduction of the lead time, satisfaction of the work orders objectives, minimization of the time cycle. Finally, the proposed design method is illustrated on a manufacturing cell.     

基于改进的网重写系统途径的可重构制造单元故障恢复

提出了一种用于可重构制造单元故障恢复的策略与方法, 允许故障发生时, 通过对用于正常操作控制的Petri网形式的监督控制器进行局部、临时性的修改, 实现故障的恢复. 首先, 提出改进的网重写系统, 可用于动态改变Petri网模型结构. 然后,提出了基于改进的网重写系统的故障恢复方法, 其中改进的网重写系统用于操作、引导Petri网监督控制器由错误状态进入正确状态. 故障恢复后监督控制器的结构与期望属性维持不变. 最后, 以实例演示了该故障恢复方法的应用, 证实了方法的有效性.     

Scalability planning for reconfigurable manufacturing systems

Scalability is a key characteristic of reconfigurable manufacturing systems, which allows system throughput capacity to be rapidly and cost-effectively adjusted to abrupt changes in market demand. This paper presents a scalability planning methodology for reconfigurable manufacturing systems that can incrementally scale the system capacity by reconfiguring an existing system. An optimization algorithm based on Genetic Algorithm is developed to determine the most economical way to reconfigure an existing system. Adding or removing machines to match the new throughput requirements and concurrently rebalancing the system for each configuration, accomplishes the system reconfiguration. The proposed approach is validated through a case study of a CNC-based automotive cylinder head machining system.     

Reconfiguration point decision method based on dynamic complexity for reconfigurable manufacturing system (RMS)

To address the problem of how to identify the best time to implement reconfiguration for the reconfigurable manufacturing system (RMS), a dynamic complexity-based RMS reconfiguration point decision method is proposed. This method first identifies factors that affect RMS dynamic complexity (including both positive and negative complexity) at the machine tool and manufacturing cell levels. Next, based on information entropy theory, a quantitative model for RMS dynamic complexity is created, which is solved via state probability analysis for processing capability and the processing function. This model is combined with cusp catastrophe theory to establish an RMS reconfiguration decision model. Both positive and negative complexity are control variables for cusp catastrophe. Cusp catastrophe’s state condition is used to identify RMS state catastrophe at the final stage of production. This catastrophe point is the RMS reconfiguration point. Finally, the case study result shows that this method can effectively identify the RMS state catastrophe moment so that system reconfiguration is implemented promptly to improve RMS’s responsiveness to the market.     

可重构制造系统的多Agent模型

论文在介绍可重构制造系统重构方法的基础上,给出了可重构制造系统多Agent模型的结构,并详细描述了基于该模型的可重构车间加工系统的重构算法,最后对重构算法进行仿真验证了该算法的可行性。     

Decision-making method of reconfigurable manufacturing systems’ reconfiguration by a Gale-Shapley model

The companies need to rapid response to new product introduction, mix and demand changes to stay competitive. A reconfigurable manufacturing system can quickly react to changes in products and market. The control method to reconfigure the machines of a reconfigurable manufacturing system is crucial for the performance level. This paper proposes a reconfiguration decision-making method based on a Game-Theory algorithm, and in particular the Gale-Shapley model. A periodic review strategy is used to create two sets: one set of machine over-loaded and one set under-loaded. The Gale-Shapley model forms a coupled of over-loaded and under-loaded machines. The reconfiguration concerns the under-loaded machine of the coupled adding also the task performed by the over-loaded machine. This paper presents a simulation environment developed to evaluate the proposed method and highlight the main topics. The simulation results highlight how the game-theory approach developed improves all the performance measures with controlled number of machines’ reconfigurations.     

Reconfigurable Control Structure for Robots in Assembly

The increased use of changeable characteristics in modern manufacturing and robotic systems and applications call for improved system control design that offers some degree of reconfigurability. The need for control reconfiguration of robotic systems arises due to some inherent characteristics of the robotic system, variations of robot parameters due to environmental changes, major task changes typical in production changeover or manufacturing system reconfiguration, or geometry changes due to the reconfiguration of modular manipulators. In this paper, a reconfigurable controller, the Supervisory Control Switching System (SCSS), is proposed to meet the new on-line demands for changeability in robotic systems. The SCSS is capable of selecting the most suitable controller for a particular task or situation, from separate controllers designed a priori. The applicability and effectiveness of the developed switching control scheme have been illustrated through computer simulations of an AdeptOne SCARA manipulators carrying out assembly tasks.     

An approach to regulating machine sharing in reconfigurable back-end semiconductor manufacturing

By complying with the operational philosophy of virtual production lines, a back-end semiconductor manufacturing system can be controlled and managed with better reconfigurability. However, due to the absence of a fully-integrated information system and the gaining popularity of distributed computing, machine reconfiguration decisions are made by machine controllers on the shop floor where heterarchical control architecture is typically used. This research investigates how non-cooperative game theory could be applied for facilitating the decision process reconfiguration decision-making at the machine controller level as machines are competed by multiple jobs streams. This paper presents how material flow traffic can be better regulated in a reconfigurable manufacturing environment. A study using an industrial pilot system is discussed to demonstrate the applicability of the proposed approach, in which heuristics are used to determine the game specification.     

FPGA远程动态重构技术的研究

提出了一种FPGA远程动态重构的方法,结合FPGA动态重构技术和GSM通信技术来实现。利用GSM技术实现配置数据的无线传输,在单片机控制下将数据存储于CF卡中。在内嵌硬核微处理器PowerPC405控制下,FPGA通过内部配置存取端口读取CF卡中新的配置数据,对可重构区进行配置以实现新的功能。     

Designs of Bisimilar Petri Net Controllers With Fault Tolerance Capabilities

This paper proposes an approach for providing tolerance against faults that may compromise the functionality of a given controller modeled by a Petri net. The method is based on embedding the given Petri net controller into a larger (redundant) Petri net controller that retains the original functionality and properties, and uses additional places, connections, and tokens to impose invariant conditions that allow the systematic detection and identification of faults via linear parity checks. In particular, this paper considers two types of redundant Petri net controllers: 1) nonseparate redundant Petri net controllers have the same functionality as the given Petri net controller and allow for fault detection and identification, but do not necessarily retain the given controller intact; and 2) separate redundant Petri net controllers are a special case of the nonseparate redundant controllers that retain the given Petri net controller intact but enhance it with additional places to enable fault detection and identification. The work in this paper obtains complete characterizations of both types of redundant controllers along with necessary and sufficient conditions for them to be bisimulation equivalent to the given original Petri net controller. In addition, this paper discusses how each type of redundant controllers can be designed to have desirable fault detection and identification capabilities. When the bisimulation equivalence requirement is not directly enforced, nonseparate redundant controllers can potentially have advantages over separate ones (e.g., they can use fewer connections to detect and identify the same number of faults). An example of a Petri net controller for a production cell and its fault tolerance capabilities using separate and nonseparate embeddings is used to illustrate the approach.     

结构化三层次Petri网及在MPS监控系统中的应用

基于模块化制造系统(MPS)的监控问题，提出了一种扩展的结构化三层次Petri网建模方法，把MPS系统从整体、局部再到细节进行不同层次的描述；使用消息库所来解决Petri子网间的通信问题。该建模方法，有效地降低了系统建模的复杂度，增强了开发的相应监控系统可靠性与可重用性。根据此模型开发MPS监控软件，验证了该建模方法的有效性。     

The real-time supervisory control of an experimental manufacturing system based on a hybrid method

In this paper, the real-time supervisory control of an experimental manufacturing system is reported based on a recently proposed hybrid (mixed PN/automaton) approach. Assuming that an uncontrolled bounded Petri net (PN) model of a (plant) discrete event system (DES) and a set of forbidden state specifications are given, the proposed approach computes a maximally permissive and nonblocking closed-loop hybrid model. The method is straightforward logically, graphically and technologically. This paper particularly shows the applicability of a hybrid (mixed PN/automaton) approach to low-level real-time DES control. To do this, programmable logic controller (PLC) based real-time control of an experimental manufacturing system is considered.     

基于JBits的一种可重构数据处理系统可靠性研究

空间太阳望远镜(SST)是一颗对太阳进行观测的科学卫星,它使用FPGA芯片对每天采集的大量数据进行预处理.高昂的建造费用和恶劣的工作环境,确保SST数据的高可靠性成为一项艰巨任务.改进了常规TMR结构,提出一种基于配置数据的可重构硬件故障检测和修复方法,使用JBits工具简化对配置数据的各种操作.此结构和方法能及时检测到故障,通过硬件重构消除故障,提高系统可靠性.采用Markov过程理论对系统可靠性进行分析,结果表明可靠性可得到显著提高.     

Dependability through Assured Reconfiguration in Embedded System Software

In many software systems, properties necessary for dependable operation are only a small subset of all desirable system properties. Assuring properties over the simpler subset can provide assurance of critical properties over the entire system. This work provides a method for constructing systems to be dependably reconfigurable. A system's primary function can have less demanding dependability requirements than the overall system because the system can reconfigure to some simpler function. Reconfiguration thus controls the effective complexity of the system without forcing that system to sacrifice desired, but unassurable, capabilities. Focusing a system's dependability argument on reconfiguration means that reconfiguration must proceed correctly with very high assurance. The system construction approach in this work also provides a method through which system dependability properties can be shown. To illustrate the ideas in this work, we have built part of a hypothetical avionics system that is typical of what might be found on an unmanned aerial vehicle.     

Towards a generic design method for reconfigurable manufacturing systems: Analysis and synthesis of current design methods and evaluation of supportive tools

In today’s global manufacturing environment, changes are inevitable and something that every manufacturer must respond to and take advantage of, whether it is in regards to technology changes, product changes, or changes in the manufacturing processes. The reconfigurable manufacturing system (RMS) meets this challenge through the ability to rapidly and efficiently change capacity and functionality, which is the reason why it has been widely labelled the manufacturing paradigm of the future. However, design of the RMS represents a significant challenge compared to the design of traditional manufacturing systems, as it should be designed for efficient production of multiple variants, as well as multiple product generations over its lifetime. Thus, critical decisions regarding the degree of scalability and convertibility of the system must be considered in the design phase, which affects the abilities to reconfigure the system in accordance with changes during its operating lifetime. However, in current research it is indicated that conventional manufacturing system design methods do not support the design of an RMS and that a systematic RMS design method is lacking, despite the fact that numerous contributions exist. Moreover, there is currently only limited evidence for the breakthrough of reconfigurability in industry. Therefore, the research presented in this paper aims at synthesizing current contributions into a generic method for RMS design. Initially, currently available design methods for RMS are reviewed, in terms of classifying and comparing their content, structure, and scope, which leads to a synthesis of the reviewed methods into a generic design method. In continuation of this, the paper includes a discussion of practical implications related to carrying out the design, including an identification of potential challenges and an assessment of which tools that can be applied to support the design. Conclusively, further areas for research are indicated, which provides valuable knowledge of how to develop and realize the benefits of reconfigurability in industry.     

A non-dominated sorting genetic algorithm based approach for optimal machines selection in reconfigurable manufacturing environment

This paper deals with a problem of reconfigurable manufacturing systems (RMSs) design based on products specifications and reconfigurable machines capabilities. A reconfigurable manufacturing environment includes machines, tools, system layout, etc. Moreover, the machine can be reconfigured to meet the changing needs in terms of capacity and functionality, which means that the same machine can be modified in order to perform different tasks depending on the offered axes of motion in each configuration and the availability of tools. This problem is related to the selection of candidate reconfigurable machines among an available set, which will be then used to carry out a certain product based on the product characteristics. The selection of the machines considers two main objectives respectively the minimization of the total cost (production cost, reconfiguration cost, tool changing cost and tool using cost) and the total completion time. An adapted version of the non- dominated sorting genetic algorithm (NSGA-II) is proposed to solve the problem. To demonstrate the effectiveness of the proposed approach on RMS design problem, a numerical example is presented and the obtained results are discussed with suggested future research.     

Agile MPC system linking manufacturing and market strategies

Increasing complexity and interdependency in manufacturing enterprises require an agile manufacturing paradigm. This paper considers a dynamic control approach for linking manufacturing strategy with market strategy through a reconfigurable manufacturing planning and control (MPC) system to support agility in this context. A comprehensive MPC model capable of adopting different MPC strategies through distributed controllers of inventory, capacity, and WIP is presented. A hierarchical supervisory controller (referred to as decision logic unit, DLU) that intakes the high-level strategic market decisions and constraints together with feedback of the current manufacturing system state (WIP, production, and inventory levels) and optimally manages the distributed controllers is introduced. The DLU architecture with its three layers and their different functionalities is discussed showing how they link the higher management level to the operational level to satisfy the required demand. A case study for an automatic PCB assembly factory is implemented to demonstrate the applicability of the whole approach. In addition, a comparative cost analysis study is carried out to compare between the developed agile MPC system and classical-inventory- and capacity-based MPC policies in response to different demand patterns. Results showed that the developed agile MPC policy is as cost effective as the inventory-based MPC policy in demand patterns with steady trends, as cost effective as capacity-based MPC in turbulent demand patterns, and far superior than both classical MPC polices in mixed-demand patterns.     

A distributed method for reconfiguration of a three-dimensional homogeneous structure

A distributed reconfiguration method is proposed for a theree-dimensional reconfigurable structure, composed of many identical mechanical units. The method aims to enable the structure to transform itself into a desired structure from an arbitrary initial configuration. The proposed method is implemented in such a way that each unit has identical software as well as hardware, so that any unit can play any role in the system. It is also featured by a stochastic relaxation process, which allows the system to converge to a given target structure by searching for a proper unit motion over many degrees of freedom. Furthermore, the method is extended for the structure to reconfigure itself dynamically according to the environment. The effectiveness of the method is confirmed by computer simulations.