Manufacturing industries rely on automated manufacturing systems to improve the efficiency, quality and flexibility of production. Such systems typically consist of a variety of manufacturing machinery and control hardware, e.g. CNC machine tools, robots, PCs, Programmable Logic Controllers (PLCs) etc., which operate concurrently. The cost of developing and implementing an automated manufacturing system is high, and is particularly so if the control system is found to be unreliable or unsafe during operation. Distributed Control Systems are generally used to control complex concurrent systems,At present the methods used to develop DCSs tend to follow a sequence of steps, viz. a statement of the requirements of the DCS, a functional specification of the DCS, the design of the DCS, generation of the software code for the DCS, implementation of the software. This step approach is inadequate because of the dissimilarity of techniques used to represent each step, which leads to difficulties in ensuring equivalence between the final implementation of the DCS and the initial requirements, which in turn leads to errors in the final software. To overcome this, work has been conducted to unify the specification, design, and software coding phases of the DCS development procedure by ensuring formal equivalencies between them. One particular outcome of such previous work is a tool named Petri Net - Occam Methodology, developed by Dr. P. Gray, which produces dependable Occam code for DCSs. Gray's methodology produces readable designs, directly from the specification of systems, in a graphical but formal way, and results in a Petri Net graph which is equivalent to the final Occam code. However, his methodology is not for a complete DCS but only for one containing Transputers. The PLC is widely used in industry and an integral part of DCSs for Automated Manufacture. This research has developed a methodology, named PNPLC, which produces dependable PLC control programs, in a graphical but formal way, directly from a system's specification. It uses the same tool, Petri Nets, for both designing and simulating the control system, and specifies rules which ensure the correct design, simulation and encoding of PLC programs. The PN designs are a one-to-one equivalent to PLC code and can be directly translated into Ladder Diagrams. Therefore if the simulation shows the design to be correct, the final software will be correct. PNPLC works as a stand alone tool for developing dependable PLC control programs, and also unifies with Gray's methodology to produce a complete tool for developing a resilient DCS containing Transputers and PLCs. The unification of the two methodologies is also reported in this thesis. The research work presented in this thesis contributes to knowledge in the field of DCS development. Recommendations for further work regarding the applicability of the unified methodology on a wide scale industrial basis are also given.

An important consideration in discrete event dynamic systems control theory is the selection of a suitable modeling formalism that can capture the complex characteristics of the system and the capability to automatically synthesize a controller based on the system model. Net condition event systems are well suited for modeling complex discrete event dynamic systems owing to their input and output structure, which effectively captures the behavior of the physical devices to be monitored and/or controlled. To date, net condition event systems control models have not been extensively applied to highly automated manufacturing systems and there are few guidelines on how to automatically generate Programmable Logic Controller programming languages from net condition event systems models. This research automatically converted net condition event systems control models into Programmable Logic Controller programming language and evaluated the applicability of the proposed methodology in highly automated manufacturing systems using HAS-200 as a test bed.

Nos travaux portent sur l'analyse des systèmes de production automatisée à l'aide de réseaux de Petri. Le problème posé est de savoir si un système peut se bloquer complètement ou partiellement et si besoin de calculer un contrôleur garantissant son bon fonctionnement. Les systèmes de production se modélisent naturellement à l'aide d'une sous-classe des réseaux de Petri, les S3PRs. Ce modèle a été très largement étudie par le passe conduisant à des méthodes basées uniquement sur la structure du modèle. Dans ce travail, nous généralisons ces travaux aux modèles des WS3PR, une extension des S3PR ou la réalisation d'une active nécessite non par une ressource mais plusieurs ressources d'un même type et pour lesquels nous proposons des techniques originales combinant des éléments de Théorie des graphes et de théorie des nombres, améliorant même les méthodes du passe sur le modèle simple des S3PR.On présente une caractérisation fine de la vivacité d'un tel modèle basée la notion d'attente circulaire. Une attente circulaire peut être vue comme une composante connexe du sous graphe réduit aux transitions et aux places ressources du modèle. Puis nous démontrons que la non vivacité d'un WS3PR est équivalente a l'existence d' ≪ un blocage circulaire dans une attente circulaire ≫. Ce résultat généralise finement la caractérisation de la vivacité d'un S3PR. Apres avoir introduit la notion de ≪ circuits du graphe de ressources ≫ (WSDC), on construit une méthode de contrôle de ces verrous garantissant la vivacité du modèle d'autant plus efficace qu'une méthode de décomposition du réseau est proposée. Enfin, une traduction de traduit la condition de vivacité des WS3PR sous la forme d'un programme linéaire en nombres entiers est établie et des expérimentations ont démontré l'intérêt de la méthode pour contrôle de systèmes l'allocation des ressources. / As an indispensable component of contemporary advanced manufacturing systems, flexible manufacturing systems (FMSs) possess flexibility and agility that traditional manufacturing systems lack. An FMS usually consists of picking and placing robots, machining centers, logistic systems, and advanced control systems. Some of them can be recognized as its shared resources, which result in its flexibility but may lead to its deadlocks. As a classic problem in resource allocation systems, deadlocks may arise in a fully automated FMS and bring about a series of disturbing issues, from degraded and deteriorated system productivity and performance to low utilization of some critical and expensive resources and even long system downtime. Therefore, the analysis of and solution to deadlock problems are imperative for both a theoretical investigation and practical application of FMSs. Deadlock-freedom means that concurrent produc-tion processes in an FMS will never stagnate. Furthermore, liveness, another significant behavioral property, means that every production process can always be finished. Liveness implies deadlock-freedom, but not vice versa. The liveness-enforcement is a higher requirement than deadlock-freedom.From the perspective of the behavioral logic, the thesis focuses on the intrinsicallylive structures and deadlock control of generalized Petri nets modeling flexible manufacturing systems. Being different from the existing siphon-based methods, a concept of intrinsically live structures becomes the starting point to design, analyze, and optimize a series of novel deadlock control and liveness-enforcing methods in the work.The characteristics and essence of intrinsically live structures are identified and derived from subclasses of generalized Petri nets modeling FMSs with complex resource usage styles. In addition, the numerical relationship between initial markings and weights of connecting arcs is investigated and used to design restrictions that ensure the intrinsical liveness of global or local structures.With the structural theory, graph theory, and number theory, the thesis work achieves the goals of deadlock control and liveness-enforcement.The proposed methods are superior over the traditional siphon-based oneswith a lower computational complexity (or a higher computational efficiency),a lower structural complexity, and a better behavioral permissiveness of the controlled system.

Made available in DSpace on 2016-06-02T19:05:32Z (GMT). No. of bitstreams: 1 2127.pdf: 1371924 bytes, checksum: 9875e1d607356e12cb2a118b33474a4e (MD5) Previous issue date: 2008-09-12 / The production scheduling problem of products with simultaneous use of machines and transportation systems in manufacturing systems invloves the system modeling task and the application of a technique to solve it. This scheduling type is characterized by the great amount of possible solutions and several researches indicates the Adaptive Genetic Algorithms as search method to solve this problem, where these algorithms have the capacity of globally explore the search space and to find good solutions quickly. In this dissertation, it is proposed a method that uses an adaptive genetic algorithm to solve this scheduling problem. The aim of this dissertation is to obtain good scheduling of product production, in order to reach good makespan values and response obtaining time. The makespan values are obtained by adaptive genetic algorithm and the response obtaining time is the processing time of the adaptive genetic algorithm. The results were validated in small and large scenerios and compared with the results of two other approaches. These results are presented and discussed in this dissertation. / O problema da programação da produção de produtos com uso simultâneo de máquinas e sistemas de transporte em sistemas de manufatura envolvem questões como a modelagem do problema e a técnica utilizada para resolvê-lo. Este tipo de programação é caracterizado pela grande quantidade de soluções possíveis, em que várias pesquisas apontam para o uso de Algoritmos Genéticos Adaptativos como método de busca, uma vez que estes algoritmos possuem a capacidade de percorrer de forma global o espaço da busca, a fim de encontrar boas soluções rapidamente. Neste trabalho, é proposto um método com uso de um algoritmo genético adaptativo para resolver este tipo de problema de programação. O objetivo deste trabalho é obter uma boa programação da produção de produtos, a fim de atingir um bom compromisso entre valores de makespan e de tempo de obtenção da resposta. Os valores de makespan são obtidos a partir da aplicação do algoritmo genético adaptativo e o tempo de obtenção da resposta é referente ao tempo de processamento do algoritmo genético adaptativo. Os resultados deste trabalho foram validados para cenários pe quenos e grandes e comparados com os resultados de outras duas abordagens. Estes resultados são apresentados e discutidos neste trabalho.