Intelligent workstation controller for computer-integrated manufacturing: Problems and models

Abstract

A shop floor control system (SFCS), an integrated part of computer-integrated manufacturing, oversees the production required to fill orders. To effectively control these activities, it is necessary to define a control architecture and functional perspective of how a SFCS operates. In this paper, a hierarchical SFCS (shop, workstation, equipment) is adopted. The paper presents the problems and models necessary to develop an intelligent workstation controller (IWC) at the middle level of a SFCS. The IWC is responsible for selecting a specific process routing, allocating resources, scheduling and coordinating activities across the equipment, monitoring the progress of activities, detecting and recovering from errors, and preparing reports. The IWC fulfills this responsibility using three functions—planning, scheduling, and execution. Requirements for the development of the IWC are to create a process plan representation model, specify the evolution of a process plan from the shop down to the equipment, and define all of the functions to be integrated into an intelligent controller. A deadlock detection and resolution model is also presented to maintain the system in a deadlock-free state. Finally, the IWC software is created to demonstrate the architectural linkages with other controllers. As a result, the development of the IWC will save cost and time in developing control software for automated manufacturing systems.