Extended structured adaptive supervisory control model of shop floor controls for an e-Manufacturing system

Abstract

The high cost and long development cycle of shop floor control systems and the lack of true system integration capabilities are identified as one of the most challenging obstacles in deploying e-Manufacturing systems. Overcoming these obstacles is essential for manufacturers to execute a make-to-order business model in order to stay competitive and remain profitable in the future. We propose a formal method to generate the desired control trajectories and provide true integration mechanisms for shop floor control systems. Using the proposed architecture can result in the development of an e-Manufacturing system capable of achieving a substantial reduction of both the high cost and long development cycle currently required to engineer shop floor control systems. By taking advantage of both the linear growth of the complexity function in a structured adaptive supervisory control model and the information-centric characteristics of a virtual production line in a manufacturing execution system, a formal model, which we call an extended structured adaptive supervisory control, for a discrete manufacturing system is introduced. A shop floor control system based on the extended structured adaptive supervisory control model is built for an industrial testbed system. The shop floor control system is fully tested and evaluated.