PERT Approach & Supervisory

Control Flexible
Manufacturing System

Presented by,

Bhuvanesh J
MTAB Group of
Companies
Chennai.
 Outline
• General Talk on Flexibility
• What makes it Flexible
• Levels of Flexibility
• Types of Flexibility & systems
• Why PETRI NET (compatibility)
• An approach for Modelling & Analysing FMS
• Different FMS - Control system
• What is Supervisory control system & features
• Further scope on PETRI NET approach and Control system.
 What makes it Flexible
• Ability of a system to respond to potential internal or external
changes affecting its value delivery, in a timely and cost-effective
manner.

• Swift changeover of operation instructions.

• Swift changeover of physical setup.

• To qualify as being Flexible a manufacturing system should satisfy

several criteria’s.

1) Part variety 2) Schedule change

3) Error recovery 4) New part

 Levels of Flexibility – Manufacturing
systems
Typical categories are

– Dedicated FMS

– Random order FMS

• Dedicated FMS is designed to produce a limited variety of parts.

Another name is Special Manufacturing System, specific purpose
machines used. More production rate.

• Random order FMS is designed to produce wide range of part family.

Production schedule changes sometimes from day to day. More flexible
than dedicated FMS, more general purpose machines used.
 Types of Flexibility – Manufacturing
systems
• For manufacturing science eleven different classes of flexibility has been
identified [Browne, 1984], [Sethi and Sethi, 1990]:
• Machine flexibility - The different operation types that a machine can
perform.

• Material handling flexibility - The ability to move the products within a

manufacturing facility.

• Operation flexibility - The ability to produce a product in different ways.”

• Process flexibility - The set of products that the system can produce.

• Product flexibility - The ability to add new products in the system.

 Types of Flexibility – Manufacturing
systems
• Routing flexibility - The different routes (through machines and
workshops) that can be used to produce a product in the system.

• Volume flexibility - The ease to profitably increase or decrease the

output of an existing system.

• Expansion flexibility - The ability to build out the capacity of a

system.

• Program flexibility - The ability to run a system automatically.

• Production flexibility - The number of products a system currently

can produce.

.
 Types of Flexible Manufacturing
Systems
• Flexible manufacturing can be distinguished according to the
kind of operation
– Processing operation

– Assembly operation

• Generally FMS designed to perform either one, rarely both,

• Other ways to distinguished the systems

– By the number of the machines in the system

– By the level of flexibility

Modelling & Analysing

Flexible Manufacturing System

(Using PETRI NET Approach)

 An Approach
• In this approach, we first build a Petri net model of the given FMS
in a bottom-up fashion

• Then analyse important qualitative aspects of FMS behaviour such

as

– Existence/Absence of Deadlocks and

– Buffer overflows.

• We illustrate our approach using a typical manufacturing systems:

– Simple FMS layout.

– Automated transfer line.

 Brief on PETRI NET…
• Petri net models (PNM) fall into one of two classes namely,

– Timed PNMs and

– Untimed PNMs

• A Timed PNM of an FMS - captures the actual physical behaviour of the

FMS by assuming specific durations for various activities in the FMS.

• An Untimed PNM of an FMS - does not associate any times with the
activities and so models the physical behaviour of the FMS under all
possible time dependencies.

• Hence, analysis using untimed PNMs yields more conservative results

compared to those obtained using timed PNMs.
 Brief on PETRI NET…
• It is founded that,

– Untimed PNMs are mainly used for understanding

the qualitative aspects - such as existence/absence of
deadlocks, buffer overflows, and mutual exclusion.

• On the other side,

– Timed PNMs are useful in computing quantitative

performance measures such as throughput rate and
processing times.
Intro. on Petri nets
• A typical example of Petri Net (G)

• P = { p1, p2, p3.. Pn}, is a set of

places,

• T = { t1, t2, t3.. tm} is a set of

Transitions.

• IN: (P X T) Input fn. Defines

directed arcs from places to

IN
transitions.

• OUT: (P X T) Output fn. Defines

directed arcs from transitions to
places.
 Potential properties of Petri nets
• Consider a machine that processes
one job at a time. (Standard example).

• As soon as the processing is over,

another job is made available and the
machine starts processing again.

• In this example, it may be noted that the

places represent various conditions in the
system,

• whereas transitions represent the

commencement or conclusion of events.
 Potential properties of Petri nets

A PNM- processing of a Initial marking M0 Marking M1 reached after

job on a machine. of the PNM firing t1
 Potential properties of Petri nets
• A Petri net G = (P, T, IN, OUT) is
said to be pure or self-loop free if
there exists no pair P× T for which

– IN(p,t) != 0 and OUT(p,t)!= 0

A pure Petri net, p1’ is a dummy
• place, t1’ is a dummy transition.
In a pure Petri net, there exists no
place which is an input place and an
output place of the same transition.

An impure Petri net.

 Potential properties of Petri nets
• Similarly union of any finite number of Petri nets is also
defined likewise

• For example,

Two Petri nets Union of the Petri nets

 Relevance of
PETRI NET MODELLING TO FMS
Outline of Modelling
 Outline of Modelling
• FMS environment outlined in the figure is described as follows,

• FMS consists of two loading/unload station, storage/Retrieval systems, CNC

machines, AGV's, Inspection stations (Vision and CMM) and an assembly
station.

• Each machine has the temporary storages named input buffer and output buffer.
The capacities of these storages are finite.

• Loading and unloading of w/p between an AGV and a systems are executed by
Transfer conveyors. (T.C.R’s)

• AGV's move to one-way route with the specified paths.

• All these system are controlled by a centralised control system.

 Supervisory Control System
of
Flexible Manufacturing System
 Control system

• The control most widely used in industries

are mainly of three types,

– Cell Controller

– PLC Controlled

– Supervisory Controlled
 Cell Controller
• The cell controller is controller module, distributes the binary input/output
points from the I/O card to the machines.

• The communication between system and Cell controller is achieved through

serial port (RS232).

• This control structure is modular and flexible, allowing easily the expansion
of the Cell Controller if the number of machines in the cell grows up.

• When a new machine is added to the manufacturing cell, it’s only necessary
to add a Device Controller module and a Device Interface module,
customized to the new machine.
Cell Controller Structure
 Cell Controller
• Cell Controller structure has three hierarchical levels,
being each one responsible for the execution of control
functions.

– The first level is designated by Controller Module, and it is

responsible for the planning and the control of the machines.

– In the second level, I/O module has the responsibility to inter-

transaction of I/O data’s (machines to master, Master to
machine).

– Finally, the last level, Status display Module the Device.

 PLC / HMI
Control System for FMS
 PLC/ HMI Controls
– Programmable Logic Controller is a solid state
device designed to perform logic functions that
were previously accomplished by Electromagnetic
relays.

– PLC's are event driven devices, which implies that

an event taking place in the field will result in an
operation or output taking place.

– Any Applications that needs some type of electrical

control has a need for PLC
PLC / HMI Controlled
PC
PC
XLTURN XLMILL

L/U
L/U Arm
Control Arm Control
Box LATHE
MILL Box

Conveyor

Teach
Pendent

HOST
ASRS
CONTROLLE
R
CONTROL
HMI BOX
Controlle E Stop
r

USER
Architecture of PLC
 PLC / HMI Execution
 Testing input status. First, a PLC check each of the inputs status ON or OFF.

 In other words, it checks whether a sensor, or a switch etc.. Connected with an

input is activated or not.

 Information that processor thus obtains through this step is stored in memory in
order to be used in the following step.

• Program execution. Here a PLC executes a program, instruction by

instruction.

• Based on input as obtained in the preceding step, an appropriate action

is performed.

• Such as certain output, or results can be put on / off or stored in memory

to be retrieved later
 PLC / HMI Execution
• Check-up and correction of output status. Finally, a PLC checks up output status and
adjusts it as needed.

• This change is performed based on the input status (step 1) and

execution in (step 2),

• Following the execution of step 3 PLC returns to the beginning of this cycle and continually
repeats these steps.

• This time generally taken to execute the above three steps is known as Scan Time

of the PLC.

(Depends upon type of PLC)

 Supervisory
Control System for FMS
 Supervisory Control System (SCADA)
• One or more field Data interface devices, usually RTU's, or PLC’s,
which interface to field sensing devices and local control switchboxes
and valve actuators.

• A communications system used to transfer data between field data

interface devices and control units and the computers in the SCADA
central host. The system can be radio, telephone, cable, satellite, etc.,
or any combination of these.

• A central host computer server or servers (sometimes called a

SCADA Center, master station, or Master Terminal Unit (MTU)
Supervisory Control System (SCADA)
• SCADA acts as a system that collects, displays and stores data
received from various devices at a factory, plant or in other
remote locations

• Then sends this data to a Master computer which then

manages and controls the data.

• Every PLC/RTU is controlled through

a SCADA Master.
 SCADA-Control System
• The Field and sub devices are connected to the PLC/RTU’s via interfacing
cables.
• These PLC are inturn connected to the Main system (SCADA) via PPI
cables.

• Ladder Layout:

― Parts can be sent to any machine in any sequence

― Parts not limited to particular part families

 Architecture
User Interface

ActiveX, OCX, DLL

Trends, Reports, Recipes

Screens Logics Alarms

Kernel
Tag Database

Data LoggersLog, TraceI/O Manager Networking

ODBC ODBC ODBC ODBC I/O OPC TCP, UDP, HTTP

DB
Clients
DB Dispositivi Web Clients
DB
DB In campo
SQL Server, Devices Remote Clients
Oracle, Access…
 Control Features
• Online monitoring & Simulation of the real-time process from a remote
location,

• Datalogging report involving the Persons, time of handling etc,

• Historical trending report of all the activities carried in the system,

• Online messaging about the sequence of processes carrying out in the

machine,

• Effortless Data handling with the database and

• Voice Alarm message on diagnosing a fault in the system.

Online monitoring & Simulation
Online monitoring & Simulation
Online / Offline Simulation
Online / Offline Simulation
Online / Offline Simulation
Online / Offline Simulation
Online / Offline Simulation
 Datalogging

Note : Different Security Levels in handing the database

 Historical trending
• Trending is used for displaying plant
system variables and those recorded by
the Data Logger in charts.

• This acts as a tool for filing, printing and

graphically analysing the plant value
behavior.

• The Trends also allows operator to

historicize data in .CSV format for
MSExcel interpretation or linked to the
Dataloggers ODBC register engines.
Historical trending
Online messaging
 Data Loggers
• The Data Logger resource in the ODBC

Tags Manager.

• The Data Logger is at the base of the graph

representation potentialities of recorded data.

Data Loggers Included among these potentialities are

Reports, Grid, Recipes, Trends, Reports and Recipes.
Trends
• The database objects created from the Data
ODBC Manager
Logger can be declared as ‘Templates’ and
saved in the Movicon graphic libraries.
Relational
Relational • By using the Data Logger makes it easy to
Database
Database
Relational manage DB archives in standard formats that
Database are normally complex to manage in Scada
applications.
 Data handling - Tags Database
• It is real-time database is based
on extremely efficient and
enhanced technologies.

• The Movicon X tags have

numerous properties, which
make them operating centers in
their own right.

• They can be associated with

Properties commands to be executed on
The tag property window
allows you to configure the threshold values. They can be
properties of the entire tag set with a scaling.
DB or of individual tags.
The complete list of tags • They can be connected in real-
can be displayed from the
toolbar. time to the database, OPC client
or server and set with networking
Tag Database
modes.
tags can be displayed,
imported or inserted within
the project structure.
Voice Alarm message
 Alarm Viewer
• The Alarm viewer can be linked to any
network station (Network Server) to
display the alarms of one or more remote
stations, also with support to OPC A&E
server.

• The beeper sounds, which support

the .WAV format, can also be
customized.

• In addition to the normal guide texts, for

example Help files (HLP or HTML) can
Alarm Viewer be linked in hypermedia mode to manage
The alarm Viewer is
found in the ToolBox images, movies, hypertexts linked
and can be used in any
screen to display driectly to any individual alarm.
active alarms.
End of Session