基于Petri网的牙膏研发柔性制造系统建模与开发
摘要
以Petri网作为小型/中型系统网络建模和分析工具的柔性制造系统设计、调度和优化是近年来工业自动化领域的一个热点研究方向。以宝洁公司牙膏产品研发柔性自动化系统实现为背景,本文有针对性地对多品种、小批量的研发型化工自动化生产系统设计与开发中的设计理论和若干关键技术展开研究,包括柔性制造系统的功能设计、系统化模型建立与分析、工厂自动化控制系统开发实施等。
通过分析现有大型化工企业中普遍使用的计算机集成生产系统技术现状和生产工艺要求,本文提出了针对具有多品种、小批量、高信息集成度等特点的研发型牙膏制备柔性生产系统的总体设计方案。方案涉及生产配方编辑以及现场批次生产的各个环节。通过系统化的基于对象的Petri网建模,配置了系统各主要操作单元的分布式职能,并规定其间的相互依赖关系。利用覆盖树分析方法,对制造系统OPN模型体系进行死锁探测和冲突分析,并提出相应的解决方案。在优化的OPN模型基础上,对本牙膏研发柔性制造系统进行硬件职能分配,并对液体装载分系统软件进行开发。分系统软件运行结果表明,Petri网建立的液体分析统模型具有实际指导意义。
在上述理论与实践研究基础上,论文实现了一个应用于化工产品研发过程的柔性自动化生产系统,该系统对于化工产品研发过程的理论研究和生产线研发都具有较重要的意义。
Petri net based research on FMS design, scheduling and optimization over small/ mid-scaled network is cutting-edge in current industrial automation area. With the background of dentifrice R&D flexible manufacturing system for P&G Corp, the key points on designing an automatic manufacturing system are studied in this dissertation, which include: systematic modeling & analysis, implement of plant automatic control.
Analyizing the popular CIMS technology and producing plan requirements in modern batch making companies, this dissertation gives a sound design of R&D flexible manufacturing system which is specialized in multi-types, small batch, high info-density. The design covers formula edition and management, and each functional unit in local batch making system. With systematic OPN modeling, fundermental operation units are entitied with required functions and the interrelations among all units are also defined. Coverability tree is used to analyize the OPN models, and certain deadlocks and interruptions are located, which suggested solutions are also illustrated. With optimized OPN model system, R&D flexible manufacturing system construction can offer come clue for mechanical design. Also based on optimized OPN models, the dissertation developed liquid loading sub-system software whose feasibility is proved. With partial proof from liquid loading subsystem, the FMS PN modeling is proved to be applicable in further relative research.
Based on all the theoretic and technical studies above, this dissertation develops an automatic batch flexible manufacturing system for pilot shop. It is meaningful for the equipment manufacturing and theoretic research of chemistry R&D process.
通过分析现有大型化工企业中普遍使用的计算机集成生产系统技术现状和生产工艺要求,本文提出了针对具有多品种、小批量、高信息集成度等特点的研发型牙膏制备柔性生产系统的总体设计方案。方案涉及生产配方编辑以及现场批次生产的各个环节。通过系统化的基于对象的Petri网建模,配置了系统各主要操作单元的分布式职能,并规定其间的相互依赖关系。利用覆盖树分析方法,对制造系统OPN模型体系进行死锁探测和冲突分析,并提出相应的解决方案。在优化的OPN模型基础上,对本牙膏研发柔性制造系统进行硬件职能分配,并对液体装载分系统软件进行开发。分系统软件运行结果表明,Petri网建立的液体分析统模型具有实际指导意义。
在上述理论与实践研究基础上,论文实现了一个应用于化工产品研发过程的柔性自动化生产系统,该系统对于化工产品研发过程的理论研究和生产线研发都具有较重要的意义。
Petri net based research on FMS design, scheduling and optimization over small/ mid-scaled network is cutting-edge in current industrial automation area. With the background of dentifrice R&D flexible manufacturing system for P&G Corp, the key points on designing an automatic manufacturing system are studied in this dissertation, which include: systematic modeling & analysis, implement of plant automatic control.
Analyizing the popular CIMS technology and producing plan requirements in modern batch making companies, this dissertation gives a sound design of R&D flexible manufacturing system which is specialized in multi-types, small batch, high info-density. The design covers formula edition and management, and each functional unit in local batch making system. With systematic OPN modeling, fundermental operation units are entitied with required functions and the interrelations among all units are also defined. Coverability tree is used to analyize the OPN models, and certain deadlocks and interruptions are located, which suggested solutions are also illustrated. With optimized OPN model system, R&D flexible manufacturing system construction can offer come clue for mechanical design. Also based on optimized OPN models, the dissertation developed liquid loading sub-system software whose feasibility is proved. With partial proof from liquid loading subsystem, the FMS PN modeling is proved to be applicable in further relative research.
Based on all the theoretic and technical studies above, this dissertation develops an automatic batch flexible manufacturing system for pilot shop. It is meaningful for the equipment manufacturing and theoretic research of chemistry R&D process.
引文
[1] 宋国宁,蒋新松,刘宝义. 大型过程工业自动化全过程体系结构. 信息与控制, 1994, 23(2):65~70.
[2] 何坚,李秀媛. 实用日用化学品制造技术. 北京: 化学工业出版社, 1998.
[3] P&G 公司牙膏产品研发实验室试验配方.
[4] 日用化学品:性能,制备,配方. 北京: 化学工业出版社, 2002.
[5] P&G 公司北京研发中心考察纪录(2004~2005).
[6] 林闯. 随机 Petri 网和性能评价. 北京: 清华大学出版社, 2000.
[7] 蒋昌俊. Petri 网的行为理论及其应用. 北京: 高等教育出版社, 2003.
[8] Alan A. Desrochers and Robert Y. AI-Jaar. Applications of Petri Nets in Manufacturing systems, Modeling, control and Performance Analysis. IEEE Press, 1995.
[9] 林闯.计算机网络和计算机系统的性能评价. 北京: 清华大学出版社, 2001.
[10] Silva M, Valette R. Petri nets and flexible manufacturing. In Advances in Petri Nets’ 89, Lecture Notes in Computer Science, 1989, 424: 374~417.
[11] 徐心和,于海斌. 用于离散事件系统研究的代数方法, 信息与控制, 1990,Vol 3~6 连载.
[12] M. –K. Ghbri and P. Ladet. Dynamic Petri nets and their applications. IEEE Conference on Robotics and Automation. 1994, 1, P93-98.
[13] 原忠虎,基于 Petri 网的离散事件动态系统控制问题研究. [博士学位论文].黑龙江:东北大学,1994.
[14] 夏继强, 邢春香. 现场总线工业控制网络技术. 北京: 北京航空航天大学出版社, 2005
[15] 江芳泽,李昕. 现场总线体系结构的研究. 自动化仪表,1996,17(3):15-16.
[16] 陈小枫, 董景辰, 曹迎东等. 过程控制现场总线. 北京: 清华大学出版社, 2003
[17] 张大波,王光兴. 现场总线体系结构研究及通信栈的设计. 东北大学学报(自然科学版,1998, 19(2).
[18] 王恒. 日化产品间歇过程柔性制造系统的研究与实现. [博士后出站报告] 北京: 清华大学精仪系, 2006.
[19] 刘兴堂. 应用自适应控制. 西北工业大学出版社, 2003.5.
[20] 李会方. PROFIBUS 在数控车间 FMS 控制中的应用. 微计算机信息, 2001, 17(1):17~19.
[21] 袁崇义. 佩特里网. 南京: 东南大学出版社, 1989.
[22] Petri C A. Kommunikation mit automaten. Ph.D. dissertation. University of Bonn, Bonn, West Germany, 1962.
[23] Petri C A. Introduction to general net theory. LNCS, 1980, Vol 84.
[24] 胡燕祝,郎琦,张仲义. 间歇生产过程的控制系统. 现代化工, 2003,23(8):42-44.
[25] 胡峰,温熙森,孙国基. 离散事件动态系统理论及应用. 电脑与信息技术, 2001, (5):10-20.
[26] 蔡永生,王昕. 基于 OPN 的 FMS 建模及其控制软件的开发. 机电工程技术, 2005, 34(6):66-69.
[27] 胡春华,张智勇,程涛等. 基于 Petri 网的智能制造系统建模. 中国机械工程, 2001,12(12):1418-1422.
[28] 童国凡,邓建春,赵天奇等. 基于规则对象 Petri 网的柔性制造系统建模. 高技术通讯, 1997,(10):1-6.
[29] 舒海生,孟宪松,李庆芬. 基于面向对象技术和 Petri 网的 FMS 系统建模. 应用科技, 2001, 28(11):5-6.
[30] 艾矫燕,吴振彪,陈冬珍,杨敏. 基于面向对象技术与有色 Petri 网的 FMS 建模. 湖北工学院学报, 2000,15(1):14-17.
[31] 高春华. 基于面向对象智能 Petri 网的 FMS 单元控制模型. 中国机械工程. 2001,12(5):507-509.
[32] 刘全胜,戴勇,龙波. 柔性制造系统中 OPN 模型的建立. 无锡职业技术学院学报. 2002, 1(1):22-25.
[33] 林宋. 制造系统得 Petri 网建模. 北方工业大学学报, 2002, 14(3):71-75.
[34] 江志斌. Petri 网及其在制造系统建模与控制中的应用. 北京: 机械工业出版社. 2004.
[35] Lakos C A. Object Petri nets: definiation and relationship to coloured nets. Technology Report R-94-3, University of Tasmania, Australia, 1994.
[36] Hack M. Decidability questions for Petri nets. Ph.D. dissertation, Department of Electrical Engineering. Massachusetts Institute of Technology, Cambridge, Massachusetts, 1975.
[37] Jensen K. High-level Petri nets: Applications and theory of Petri net. Informatik Fachberichte, 1983, Vol 66.
[38] Genrich H J. Predicate / transition nets. LNCS, 1986, Vol 254: 207~247.
[39] Ramchandani C. Analysis of asynchronous concurrent systems by timed Petri nets. Massachusetts Institute of Technology. Project MAC, Technology Report 120, 1974.
[40] Merlin P, Faber d J. Recoverability of Communicatioin protocols. IEEE Transactions on Communications, 1976, Vol 24, No. 9.
[41] Molloy M K. Performance analysis using stochastic Petri nets. IEEE Transactions on Computer, 1982, Vol 31, No.9.
[42] Krogh B H. Controlled Petri nets and maximally permissive feedback logic. Proceedings of the 25th Annual Allerton Conference, Unviersity Illinois Urbana, 1987: 317~326.
[43] Zhou M C, DiCesare F. A hybrid methodology for synthesis of Petri nets for manufacturing systems .IEEE Transactioins on Robotics and Automation, 1992, Vol 8: 350~361.
[44] 徐杜, 蒋永平, 张宪民. 柔性制造系统原理与实践. 北京: 机械工业出版社, 2001.9.
[45] Karp R, Miller R. Parallel program schemata. Journal of Computer and System Sciences, 1969, Vol 3, No 4.
[46] 蒋昌俊,吴哲辉. Petri 网的通项可达森林. 第四届全国过 Petri 会议论文, 1993.
[47] 蒋昌俊. Petri 网的行为理论及其应用. 北京: 高等教育出版社, 2003. 1.
[48] Peterson J. Petri Net Theory and the Modelling of Systems. Prentice-Hall, 1981. 吴哲辉译.徐州:中国矿业大学出版社,1989.
[49] Murata T. Stata equations, controllability and maximal matchings of Petri nets. IEEE Transactions on Automatic Control, 1977, Vol 22, No.3.
[50] Cheung S C, Kramer J. Enhancing compositional reachability analysis with context on straints. ACM Software Engineering Notes, 1993, Vol 18, No 5: 115~125.
[51] Zhou, M.C.; Dicesare, F. Adaptive design of Petri net controllers for error recovery in automated manufacturing systems. IEEE Transactions on Systems, Man and Cybernetics, 1989, Vol 19, Issue 5: 963~973.
[52] Zhou, M.C.; Dicesare, F. Parallel and sequential mutual exclusions for petri net modeling of manufacturing systems with shared resources. IEEE Transactions on Robotics and Automation, , Vol 7, Issue 4: 515 – 527.
[53] Banaszak Z A. Krogh B H. Deadlock Avoidance in Flexible Manufacturing systems with concurrently competing process flows. IEEE Transactions on Robotics and Automation, 1990, RA-6(6): 724-734.
[54] Atikimson N. Taking automation beyond process control. Process Engineering,1987,68(12):29~31.
[55] Hsieh F S, Chang Shichung. Dispatching driven deadlock avoidance controller synthesis for flexible manufacturing systems. IEEEE Trans. On Robotics and Automation, 1994, 10 (2): 196-208.
[56] Lewis F L, Gnrel A, Bogdan S, et al. Analysis of deadlock and circular waits using a matrix model for flexible manufacturinig systems. Automatic, 1997, 34 (9): 1083-1100.
[57] Viswanadham, Varahari Y, Johnson T L. Deadlock prevention and deadlock avoidance in flexible manufacturing systems using Petri net models. IEEE Transaction on Robotics and Automation, 1991, 6 (6): 713-723.
[58] Wu N Q. Necessary and sufficient conditions for deadlock-free operation in flexible manufacturing systems using a colored Petri nets model, IEEE transactions on Systems, Man and Cybernetics, Part C, 1999, 29 (2): 182-204
[59] 韩赞东,李基范. FMS 中资源共享导致的死锁状态及其避免方法. 中国机械工程,2004,15(10):887-891.
[60] 刘顺涛. 牙膏研发自动化生产系统的关键技术及其集成研究. [硕士学位论文]. 北京:清华大学精仪系, 2006.7.
[61] 宝洁牙膏研发柔性自动化制造系统(结题报告). 北京: 清华大学机器人及自动化实验室,2007.1.
[62] 朱韬. 牙膏研发制造中固体物料传输技术与系统研究. [硕士学位论文]. 北京: 清华大学精仪系, 2007. 1.
[2] 何坚,李秀媛. 实用日用化学品制造技术. 北京: 化学工业出版社, 1998.
[3] P&G 公司牙膏产品研发实验室试验配方.
[4] 日用化学品:性能,制备,配方. 北京: 化学工业出版社, 2002.
[5] P&G 公司北京研发中心考察纪录(2004~2005).
[6] 林闯. 随机 Petri 网和性能评价. 北京: 清华大学出版社, 2000.
[7] 蒋昌俊. Petri 网的行为理论及其应用. 北京: 高等教育出版社, 2003.
[8] Alan A. Desrochers and Robert Y. AI-Jaar. Applications of Petri Nets in Manufacturing systems, Modeling, control and Performance Analysis. IEEE Press, 1995.
[9] 林闯.计算机网络和计算机系统的性能评价. 北京: 清华大学出版社, 2001.
[10] Silva M, Valette R. Petri nets and flexible manufacturing. In Advances in Petri Nets’ 89, Lecture Notes in Computer Science, 1989, 424: 374~417.
[11] 徐心和,于海斌. 用于离散事件系统研究的代数方法, 信息与控制, 1990,Vol 3~6 连载.
[12] M. –K. Ghbri and P. Ladet. Dynamic Petri nets and their applications. IEEE Conference on Robotics and Automation. 1994, 1, P93-98.
[13] 原忠虎,基于 Petri 网的离散事件动态系统控制问题研究. [博士学位论文].黑龙江:东北大学,1994.
[14] 夏继强, 邢春香. 现场总线工业控制网络技术. 北京: 北京航空航天大学出版社, 2005
[15] 江芳泽,李昕. 现场总线体系结构的研究. 自动化仪表,1996,17(3):15-16.
[16] 陈小枫, 董景辰, 曹迎东等. 过程控制现场总线. 北京: 清华大学出版社, 2003
[17] 张大波,王光兴. 现场总线体系结构研究及通信栈的设计. 东北大学学报(自然科学版,1998, 19(2).
[18] 王恒. 日化产品间歇过程柔性制造系统的研究与实现. [博士后出站报告] 北京: 清华大学精仪系, 2006.
[19] 刘兴堂. 应用自适应控制. 西北工业大学出版社, 2003.5.
[20] 李会方. PROFIBUS 在数控车间 FMS 控制中的应用. 微计算机信息, 2001, 17(1):17~19.
[21] 袁崇义. 佩特里网. 南京: 东南大学出版社, 1989.
[22] Petri C A. Kommunikation mit automaten. Ph.D. dissertation. University of Bonn, Bonn, West Germany, 1962.
[23] Petri C A. Introduction to general net theory. LNCS, 1980, Vol 84.
[24] 胡燕祝,郎琦,张仲义. 间歇生产过程的控制系统. 现代化工, 2003,23(8):42-44.
[25] 胡峰,温熙森,孙国基. 离散事件动态系统理论及应用. 电脑与信息技术, 2001, (5):10-20.
[26] 蔡永生,王昕. 基于 OPN 的 FMS 建模及其控制软件的开发. 机电工程技术, 2005, 34(6):66-69.
[27] 胡春华,张智勇,程涛等. 基于 Petri 网的智能制造系统建模. 中国机械工程, 2001,12(12):1418-1422.
[28] 童国凡,邓建春,赵天奇等. 基于规则对象 Petri 网的柔性制造系统建模. 高技术通讯, 1997,(10):1-6.
[29] 舒海生,孟宪松,李庆芬. 基于面向对象技术和 Petri 网的 FMS 系统建模. 应用科技, 2001, 28(11):5-6.
[30] 艾矫燕,吴振彪,陈冬珍,杨敏. 基于面向对象技术与有色 Petri 网的 FMS 建模. 湖北工学院学报, 2000,15(1):14-17.
[31] 高春华. 基于面向对象智能 Petri 网的 FMS 单元控制模型. 中国机械工程. 2001,12(5):507-509.
[32] 刘全胜,戴勇,龙波. 柔性制造系统中 OPN 模型的建立. 无锡职业技术学院学报. 2002, 1(1):22-25.
[33] 林宋. 制造系统得 Petri 网建模. 北方工业大学学报, 2002, 14(3):71-75.
[34] 江志斌. Petri 网及其在制造系统建模与控制中的应用. 北京: 机械工业出版社. 2004.
[35] Lakos C A. Object Petri nets: definiation and relationship to coloured nets. Technology Report R-94-3, University of Tasmania, Australia, 1994.
[36] Hack M. Decidability questions for Petri nets. Ph.D. dissertation, Department of Electrical Engineering. Massachusetts Institute of Technology, Cambridge, Massachusetts, 1975.
[37] Jensen K. High-level Petri nets: Applications and theory of Petri net. Informatik Fachberichte, 1983, Vol 66.
[38] Genrich H J. Predicate / transition nets. LNCS, 1986, Vol 254: 207~247.
[39] Ramchandani C. Analysis of asynchronous concurrent systems by timed Petri nets. Massachusetts Institute of Technology. Project MAC, Technology Report 120, 1974.
[40] Merlin P, Faber d J. Recoverability of Communicatioin protocols. IEEE Transactions on Communications, 1976, Vol 24, No. 9.
[41] Molloy M K. Performance analysis using stochastic Petri nets. IEEE Transactions on Computer, 1982, Vol 31, No.9.
[42] Krogh B H. Controlled Petri nets and maximally permissive feedback logic. Proceedings of the 25th Annual Allerton Conference, Unviersity Illinois Urbana, 1987: 317~326.
[43] Zhou M C, DiCesare F. A hybrid methodology for synthesis of Petri nets for manufacturing systems .IEEE Transactioins on Robotics and Automation, 1992, Vol 8: 350~361.
[44] 徐杜, 蒋永平, 张宪民. 柔性制造系统原理与实践. 北京: 机械工业出版社, 2001.9.
[45] Karp R, Miller R. Parallel program schemata. Journal of Computer and System Sciences, 1969, Vol 3, No 4.
[46] 蒋昌俊,吴哲辉. Petri 网的通项可达森林. 第四届全国过 Petri 会议论文, 1993.
[47] 蒋昌俊. Petri 网的行为理论及其应用. 北京: 高等教育出版社, 2003. 1.
[48] Peterson J. Petri Net Theory and the Modelling of Systems. Prentice-Hall, 1981. 吴哲辉译.徐州:中国矿业大学出版社,1989.
[49] Murata T. Stata equations, controllability and maximal matchings of Petri nets. IEEE Transactions on Automatic Control, 1977, Vol 22, No.3.
[50] Cheung S C, Kramer J. Enhancing compositional reachability analysis with context on straints. ACM Software Engineering Notes, 1993, Vol 18, No 5: 115~125.
[51] Zhou, M.C.; Dicesare, F. Adaptive design of Petri net controllers for error recovery in automated manufacturing systems. IEEE Transactions on Systems, Man and Cybernetics, 1989, Vol 19, Issue 5: 963~973.
[52] Zhou, M.C.; Dicesare, F. Parallel and sequential mutual exclusions for petri net modeling of manufacturing systems with shared resources. IEEE Transactions on Robotics and Automation, , Vol 7, Issue 4: 515 – 527.
[53] Banaszak Z A. Krogh B H. Deadlock Avoidance in Flexible Manufacturing systems with concurrently competing process flows. IEEE Transactions on Robotics and Automation, 1990, RA-6(6): 724-734.
[54] Atikimson N. Taking automation beyond process control. Process Engineering,1987,68(12):29~31.
[55] Hsieh F S, Chang Shichung. Dispatching driven deadlock avoidance controller synthesis for flexible manufacturing systems. IEEEE Trans. On Robotics and Automation, 1994, 10 (2): 196-208.
[56] Lewis F L, Gnrel A, Bogdan S, et al. Analysis of deadlock and circular waits using a matrix model for flexible manufacturinig systems. Automatic, 1997, 34 (9): 1083-1100.
[57] Viswanadham, Varahari Y, Johnson T L. Deadlock prevention and deadlock avoidance in flexible manufacturing systems using Petri net models. IEEE Transaction on Robotics and Automation, 1991, 6 (6): 713-723.
[58] Wu N Q. Necessary and sufficient conditions for deadlock-free operation in flexible manufacturing systems using a colored Petri nets model, IEEE transactions on Systems, Man and Cybernetics, Part C, 1999, 29 (2): 182-204
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