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Agent-based Manufacturing Workshop - Autonomous Agents’98 - Minneapolis/St.

Paul, May 9-13, 1998

Agent-based Intelligent Control System Design


For Real-time Distributed Manufacturing Environments
Lihui Wang, Sivaram Balasubramanian and Douglas H. Norrie

Division of Manufacturing Engineering, University of Calgary


2500 University Drive N.W., Calgary, Alberta, Canada T2N 1N4
Phone: (403)220-5787 Fax: (403)282-8406
Email: [lhwang | balasubr | norrie]@enme.ucalgary.ca

ABSTRACT hence reconfiguration of the factory requires physical


wiring changes and manual reprogramming of controllers.
This research focuses on development of a generic
The era of present day manufacturing systems with its
agent-based intelligent control system designer for real-
hard-wired interconnection of manufacturing cells is
time distributed manufacturing environments. The paper
passing and will be gradually phased out, because these
first describes related research into distributed
conventional manufacturing systems are insufficiently
manufacturing and real-time control system, then reports
flexible due, in part, to their rigid system control structure.
on the intelligent control function design interface and
Future manufacturing systems will be required to be agile,
automatic control code generation.
flexible and fault-tolerant. The next-generation intelligent
Keywords: Multi-agent, manufacturing, real-time control, manufacturing systems (IMS) will be multi-agent systems
function block, automatic code generation. containing distributed control and application entities that
dynamically collaborate to satisfy both local and global
objectives. They will be implemented within dynamically
1. INTRODUCTION re-configurable factories having decentralized and virtual
Over the last several decades, computer control of organization structure. The constituent resources will be
manufacturing systems has been the focus of extensive capable of addressing both the knowledge processing and
research. Advances in microprocessor, computing, material processing requirements simultaneously. In such
networking and interfacing technologies have improved a real-time distributed manufacturing environment, the
capabilities of industrial automation and control systems control relationships among resources will be ever-
substantially over this period. However, these control changing, and the control codes will need to be updated in
systems are proprietary and still have problems in areas real-time due to the changes of control relationship.
such as interoperability, scalability, and lack of standard The presently reported research focuses on
user interfaces. The development of open architecture development of a generic agent-based intelligent control
control systems addresses some of these problems, in system designer for real-time distributed manufacturing
varying degrees. Open architecture control systems shift environments. This paper first describes related research
the focus of automation from being hardware centric to into distributed manufacturing and real-time control
software centric, providing further flexibility. The focus is system, then reports on the intelligent control function
now shifting to distributed control systems, which is the design interface and automatic control code generation.
central concern of this research work.
The conventional way to control the complex of 2. BACKGROUND
manufacturing machines in a modern factory is to When considering the design of a manufacturing
distribute the control instructions through a hierarchy of control system, one of the main goals is to achieve a design
control computers. This hierarchy is hard-wired, and that is flexible enough to adapt to changes in the

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manufacturing environment. A brief review of the In an HMS, the constitution of holons change and the
background and the approaches that have been taken will functional elements evolve over time according to system
be discussed in this section. level requirements. For instance, a turning center holon
may be augmented with certain milling operations or a
2.1 Holonic Manufacturing Systems holonic robot may be provided with additional vision
In the last decade, the change in market requirements system capabilities. Hence the ability to reconfigure on
towards a larger variety of products in smaller batch sizes, demand is an important requirement for holonic systems.
has lead to the concept of next generation intelligent This and related capabilities of holonic systems will
manufacturing systems (IMS) being an integrated network largely be dependent on their Intelligent Control Systems.
of distributed resources simultaneously capable of
combined knowledge processing and material processing. 2.2 Intelligent Control in HMS
The control relationships among these distributed In a holonic manufacturing system, the objective is to
resources need to be reconfigured on the fly according to achieve a complete spectrum of manufacturing control
the changing requirements. Earlier research in the area of functions ranging from production planning and control at
IMS has established that such resources can be realised the highest level, to process/machine control at the lowest
through the concepts of the holonic paradigm [1-3]. Based level. Intelligent control involves not only the achievement
on holonic concepts, the next-generation of IMS could of these control functions, but seamless integration of them
form distributed re-configurable virtual factories, in which as well. A holon-based decentralized and distributed HMS
humans, machines and control modules interact in uses autonomy and cooperation as the primary means to
dynamically formed virtual clusters. Such a system could achieve system wide integration of control functions. In
be built from intelligent, autonomous and cooperative other words, the control objectives which need to be
elements or holons [2-4]. achieved at the individual holon level need also to be
A holon is defined as an autonomous and cooperative achieved at the system level. Obviously, the ability of a
building block within a manufacturing system for holon to achieve these control functions is directly
transforming, transporting, storing and/or validating dependent on its control system. An intelligent control
information and physical objects [3]. A holon has the system (ICS) in next generation of HMS has been
autonomy to create and control the execution of its own identified to be comprised of four major components [3] as
plans, and can cooperate with other holons to develop shown in Fig.2.
mutually acceptable plans for achieving system goals.
Cooperation among holons is accomplished through an
evolutionary self-organizing holarchy (a system of holons). Inter-Holon
A holarchy which integrates the entire range of Interface
manufacturing activities (e.g. order booking, design,
production, and marketing, etc.) is defined as a holonic
Human Process/Machine
manufacturing system (HMS). Interface Control
Figure 1 illustrates the major functional elements and
interfaces of a holon. A holon exchanges information,
Process/Machine
material, or resources with other holons via its interfaces.
Interface
It can also form a part of another holon.

Inter-Holon Negotiation/Cooperation
Fig.2 Major components of ICS in HMS

System 1) Process/Machine Control:


Human Inter-Holon
Engineering
Interface Interface
Interface
Responsible for execution of the control plan for the
process being controlled.
Intra-Holon Coordination 2) Process/Machine Interface:
Representing the physical and logical interfaces
(sensors and actuators) to the process being controlled.
Intelligent Sensors/Actuators 3) Human Interface:
Representing the interfaces to the human resources.
Process/Product 4) Inter-Holon Interface:
Providing for the exchange of information, negotiation
Fig.1 Holonic elements and interfaces and cooperation with other holons in the system.

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2.3 Metamorphic Control Requirements such situations. A new generation of real-time distributed
A holonic system is inherently distributed and intelligent control systems is required. The control system
metamorphic, which has important implications for its under development in this research is aiming at meeting
control system. As shown in Fig.3, a typical distributed these metamorphic requirements by adopting the partial-
control system of this nature makes use of a real-time dynamic control hierarchy [4] and IEC-1499 function
network for communication among spatially distributed block architecture [5].
controller nodes. The centralized application level control
program that previously would have been executed on a 3. CONTROL ARCHITECTURE
single CPU is now distributed among the controller nodes. 3.1 Partial Dynamic Control Hierarchy
The distributed programs synchronize by communicating When considering the design of a control system, one
through message passing under real time constraints to of the main goals is to achieve a design that is flexible
meet application requirements. The microcomputer serves enough to adapt to the changes under a real-time and
to program, configure and monitor the distributed control distributed manufacturing environment. Ideally, the
system. Metamorphic control requires numerous changes control system will have this flexibility embodied in its
in form, substance and allocation to be accommodated design. When changes do occur on the shop floor (e.g., the
within system lifetime. Its control requirements are the addition or deletion of equipment), changes do not have to
unique combination and interaction of those of real time be made to the control software, or the changes that have
control, distributed control, event-driven control as well as to be made are minimal. Although the decentralized
intelligent control. approach that involves the use of a number of interacting
decision-makers in place of a single centralized one is the
Microcomputer solution to this requirement, how to choose the appropriate
control architecture still remains as a question.
Real Time Network Distributed I/O
Decentralized controls have three typical architectures,
which are hierarchical decomposition, oligarchical and
Control Controller Controller Controller heterarchical approaches [4]. Generally, the hierarchical
Program Node 1 Node 2 Node 3 decomposition to large-scale control systems involves
decomposing the overall system into small sub-systems
that have weaker interactions with each other and also
lower degree of cooperative autonomy. On the other hand,
the heterarchical approach supports higher degree of
autonomy but it may take much more time during
decision-making, especially when a large number of agents
(holons) are encountered.
Fig.3 Holonic distributed control Control architectures for real-time and distributed
manufacturing systems often need to meet a number of
An industrial process/machine control system is the requirements, such as autonomy, reliability, fault-tolerant,
“sense and brain for the muscle” behind any automated interoperability, re-configurability, and other real-time
manufacturing equipment. Its functions are that of functionality. For example, for a stage of batch production
periodically comparing sensory process/discrete input on a shop floor, one set of machines is needed, but for the
variables with setpoints/logic states, computing the outputs next batch there may be a need to drop some machines and
according to a predefined control algorithm/logic and add others. The functional group of machines and other
communicating the output signals to the final control manufacturing resources will become a ‘virtual cluster’
element for actuation. Realization of these functions poses only for the period necessary. Large clusters will hence
significant problems due to the conflicting requirements of become a ‘virtual factory’. There may be several virtual
control functions at various levels in hierarchy. The higher factories within a given physical factory at any one time
level functions require complex information processing on and these will be re-configured on the fly as needed. These
a relatively small volume of filtered data. On the other changing requirements lead to the concept of a partial
hand, the lower level control functions require processing dynamic control hierarchy. The partial dynamic control
of large amounts of raw data under real-time constraints. hierarchy hybridizing both hierarchical and heterarchical
In the real world, autonomous and cooperative control architectures has been here adopted for the system
systems often operate under real-time constraints and are implementation. The use of partial dynamic hierarchies
inherently distributed and dynamic. Traditional static and assists reconfigurability and can provide a better system
hierarchical control system structures do not suffice for performance than either single control approaches [4].

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3.2 Function Block Architecture function block to the next. As shown in Fig.5, a function
Currently, there are growing interests in new block consists of a set of event inputs and outputs, a set of
technologies and architectures for creating the next data inputs and outputs, a set of internal variables and state
generation of distributed control systems for industrial information, an execution control function, and a set of
automation. These technologies will reduce the time to algorithms. The execution control function, the
bring new systems on stream, and leverage the integration algorithms, and the internal variables and state
of business and industrial systems [6]. Also, a control information which persist between invocations of
system needs to use a specification model that is the algorithms, are invisible outside of the function block.
standard across various manufacturing applications. The
Event inputs Event outputs
fusion of the partial dynamic control hierarchy with IEC-
1499 function block architecture meets such a requirement Instance identifier
Event flow Event flow
and will facilitate distributed control systems being created Execution
Control
by the interconnection of software components. (hidden)

The IEC-1499 function block architecture [5] is an Type identifier


emerging standard for distributed industrial process Data flow
Algorithms
(hidden) Data flow
measurement and control systems. It uses an explicit event Internal data
driven model and also provides for data flow and finite (hidden)

state automata based controls. As shown in Fig.4, an


industrial process measurement and control system Data inputs Data outputs
(IPMCS) is modeled in this IEC-1499 standard as a Resource capabilities
collection of controller devices interconnected and (Scheduling, communication mapping, process mapping)

communicating with each other by means of one or more


communication networks that may be organized in a Fig.5 Function block model
hierarchical manner. The control functions performed by
an IPMCS are modeled as applications. An application A distributable control application usually consists of a
may reside completely in a single controller device or may network, in which nodes are function blocks and branches
be distributed among several devices. are data and event connections. Figure 6 illustrates an
application defined by function block diagrams with event
Communication network(s) and data flows among function block instances. The event
flow determines the scheduling and execution of the
operations specified in function block’s algorithms. Events
and data are always shown flowing into the left side of
each function block; outputs and generated events are
Device 1 Device 2 Device 3 Device 4
depicted on the right of the function block.
Application A
In the near future, since industrial controllers and
Application B instruments will either provide function blocks as part of
Appl. C the device firmware or provide function block libraries
from which function blocks can be selected and/or
downloaded [6], system design based on IEC-1499 will
Controlled process become the accepted process of function block selection,
configuration and interconnection.
Fig.4 Specification model of IPMCS
Event flow
In industrial control systems, the function block is a
well-established concept for defining robust, reusable
software components. A function block can provide a
software solution to a small problem, such as the control of
a valve, or to control a major unit of factory, such as a ∗ ∗ ∗
complete production line. As an atomic distributable
control function unit, a function block instance is a
Data flow
functional unit of software comprising an individual,
named copy of the data structure specified by a function
block type, which persists from one invocation of the Fig.6 Control application model

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4. SYSTEM IMPLEMENTATION This reference functional architecture has multiple
An agent-based intelligent control system is being functional levels. Each level in turn consists of multiple
implemented for PC or other platforms. The system is layers. A DIC interacts with the low-level machine/process
designed to be able to provide flexible and generic environment and with other DIC’s through external
interconnection between agents to facilitate distribution, physical I/O interface devices such as sensors, actuators
coordination, and cooperation. It is also required to be able and communication media.
to cope with the reconfiguration of its manufacturing The hardware layer is comprised of modular hardware
environments and to generate updated control programs in entities that serve as the physical platform for agents. The
real-time whenever the control relationships are changed. distributed operating system layer agents provide a number
of services to the agents of higher layers to interact with
4.1 Functional Requirements
the lower hardware elements and the external world. They
An intelligent control system is a real-time control
provide services to assist higher layers to create, maintain,
system executing both intelligent and distributed control
and destroy agents. They also help in separating hardware
tasks. It should be intelligent enough to automatically
dependencies and provide location transparency. The
adapt to the ever-changing requirements of the controlled
library layer agents are comprised of reusable software in
system. The functional requirements of a distributed
the form of standard control function blocks and provide
intelligent controller (DIC) and its reference architecture
services to agents of higher layers.
are summarized and shown in Fig.7.
The program layer agents consist of user-defined
High Level control agents that are local components of distributed
APPLICATION

V
PCEH * Planning S O
L
C
O control applications. The program layer agents also
U M
Execution S/H
T
M
E
A
G
P provide services for higher level agents facilitating
Logical L
E
Control Program H/S
I
M O N
E
X
information gathering and reconfiguration of operational
E F C
Holons Y
I
T strategies. The execution layer agents are involved in
D Y
Library H A control tasks such as executing intelligent control
SYSTEM

Physical OS H
A
strategies, fault diagnostics, fault recovery, data
Controller
Legend
acquisition, scheduling, and decision making. The optional
Holons Hardware
Hardware
planning layer (if presents) would consist of agents that
Dependency
will be involved in strategic long term planning.
WORLD

I/O Sensors, Actuators & Com. Media Soft Real


External S Time
World
Environmen Machine/Process H Hard Real The lower layers, namely, OS, Library and Program
Time
* High Level Planning, Coordination, and Execution Holons
layers are predominantly hard real time since they have to
respond immediately to internal/external events. On the
Fig.7 Reference functional architecture other hand, the Execution and the Planning layers are
predominantly soft real time involving high variance
This architecture can be divided as shown into four execution periods. As one traverses down the multiple
different groups of entities: a) External world, b) Physical layers, the following can be noted. The available time to
controller holons, c) Logical control holons, and d) High respond, the complexity of operations and hence the
level planning, coordination and execution holons (PCEH). processing time increase with higher layers, while the
What is the advantage of separating the logical control volume of raw data to be processed decreases. The notion
layer from the physical controller layer? This is of vital of agency, i.e. the amount of intelligent responsibility
importance in distributed control function design because delegated by the agents, increases progressively.
logical control holons do not need to be mapped to
physical controller holons to achieve a one-to-one 4.2 System Architecture
correspondence. For instance, one logical control holon The structure of this control system at the higher level
can be mapped across to two or more physical controller is based on partial dynamic hierarchies, which can
holons, and two or more logical control holons can also be dynamically organize multi-agent decision-making using
mapped to one single physical controller holon, etc. If task decomposition. Heterogeneous intelligent agents, used
there is the capability of mirroring or shadowing the in the system development, are dynamically grouped into
physical controller holon’s states, it is possible to have virtual clusters that can be created and destroyed as needed
other physical controller holons pick up the responsibility within the dynamic hierarchy. Overall coordination of the
and carry out the work of physical controller holons that system is accomplished by high-level mediator agents,
fail, for the purpose of fault recovery. On the other hand, at which ensure that partial local solutions to decision
the logical control level, the design emphasis in control problems are integrated into the overall global decision
function can be put on intelligent capabilities. problems. Current research is being conducted into also

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implementing partial dynamic hierarchies at the lower 4.3 High Level Interactions with DCOS
process/machine control level where real-time control Based on the reference functional architecture shown
constraints must be met. in Fig.7, high-level control applications need to interact
Figure 8 shows the reference architecture for the real- with low-level intelligent sensors/actuators via the DCOS.
time control system, which is comprised of four major They also require the DCOS-based infrastructure on each
physical components: microcomputers, primary factory intelligent controller to provide services for the transfer of
control networks, distributed intelligent controllers and data and events between distributed function blocks.
secondary control networks. However, since the DCOS is a protected operating
system for security reasons, it imposes a strict system-
Microcomputer Microcomputer application barrier. The user tasks cannot access system
Factory Control
agents or objects directly. To circumvent this situation,
Network dummy objects are used. As shown in Fig.9, these dummy
objects correspond to system agents on the application side.
The result is returned to the dummy objects after
execution, and passed to the user task for continuation.
Intelligent Intelligent Intelligent Intelligent
Controller Controller Controller Controller
System O b jects

System A g ents
Distributed System
Fieldbus : Intelligent I/O Intelligent Fieldbus : Intelligent I/O
to Sensors and Actuators Controller to Sensors and Actuators A p p lication
D u m m y O bjects

Fig.8 Reference system architecture


A p p lication Task
All the four components are soft-wired and can be
dynamically reconfigured on the fly. The microcomputers
Fig.9 System-application interaction
serve the purposes of system engineering interface (SEI)
functions, such as programming, system configuration, In addition to dummy objects, the DCOS also provides
monitoring, data acquisition, and supervisory planning and a system engineering interface (SEI) agent to shake hands
control. The primary communication network serves to with higher-level control and supervisory applications. The
control and coordinate all the distributed intelligent SEI agent, as shown in Fig.10, acts as a remote liaison for
controllers within the factory control system. It also serves its name sake. It is a task (or tasks if multi-threaded) with
as the communication link between the controllers and the super-user privilege that helps the remote commands from
microcomputers. Each distributed intelligent controller any SEI in a distributed control system be turned into local
serves the purpose of controlling an autonomous process/ actions. It provides services to configure the local
machine resource. The secondary communication network components of DCOS from a remote node. It implements
serves not only as the interface between one distributed simple file transfer protocol to download distributable
intelligent controller and its distributed intelligent sensors program units (function blocks) and other data files into
and actuators, but also as a communication link among the local physical controller holons dynamically.
constituent intelligent controllers. Such a controller is, by
nature, a real-time system and it involves prioritized
U ser
execution of both hard and soft real-time control tasks
System System
concurrently.
Engineering Commands Engineering
The above metamorphic control architecture is open, Interface Interface
software centric, and useful for real-time distributed event-
driven control of dynamic re-configurable systems. Using a
behavior based heterogeneous multi-agent system to OS Agents SEI Agent
provide uniform functions for a distributed controller OS
(DCOS), the proposed architecture is being implemented User Tasks
in an Intelligent Control System under development at N ode X
University of Calgary. The key lower layers of it have
already been tested and shown to operate as designed [7]. Fig.10 SEI agent-user interaction

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4.4 Control Function Design The architecture can be divided into three functional
As mentioned in section 4.1, one of the advantages of components: Library, Editor and UI (user interface)
separating the logical control layer from the physical Control. Each houses some specific functionality. The
controller layer is that the higher application level control library component consists of five types of library (i.e. data
function design can focuses on intelligent capabilities. This type, function, basic function block, composite function
task is performed via an intelligent programming interface block, and application) and a shared library of DCOS. The
based on agent technology and function block concepts. editor component consists of five types of editors
The visual programming interface can facilitate not only associated with appropriate library types. At highest level,
the rapid development of distributable control applications the UI control component provides the functionality such
but also the automatic run-time control code generation. as library management, editor control, control code
generation, and cross compilation.
An agent is defined as an autonomous software entity
that inter-operates asynchronously with other agents It should be noticed that function blocks are different
through a well-defined message passing mechanism. It is a from functions in basic concept. A function is used to
distributed computing entity and possesses autonomous define the algorithm of a given basic function block and is
execution control. (A holon, in contrast, need not only be designed based on IEC-1131-3 standards [8] by using its
software but can also include hardware.) graphical function block diagram (FBD) language. It is a
subroutine that creates one output from one or more inputs.
Since the IEC-1499 function block architecture will
A function cannot maintain state information between
become the industrial standard for distributed control
calls, i.e. it should produce identical output for the same
systems in next generation manufacturing environments,
input(s) on every call. However, function blocks, especially
this visual programming interface adopts it for generating
basic function blocks, are atomic units of distribution.
distributed control functions utilizing both basic function
They may have multiple outputs and can maintain internal
blocks (BFBs) and composite function blocks (CFBs). The
state information. Therefore, a function block can generate
BFBs are predefined executable and distributable control
different output(s) even if the same inputs are applied. The
units, which use appropriate execution control charts
BFBs are implemented as agents involving atomic unit of
(ECCs) to control their algorithms. On the other hand, the
concurrency (i.e. having single independent thread of
CFBs are the combinations of the BFBs and/or other
execution control). The CFBs are also atomic units of
CFBs. They do not need ECCs for execution control and
distribution, but their complexity of event flows requires
have no algorithms for themselves. Since a CFB provides
multi-threaded concurrent execution models. Figure 12
the mechanisms for specifying complex control behaviors,
shows simple examples of the BFB and the CFB.
it can be extended and designed as a distributable control
application holon. Such a control application holon (agent) EI variables EO variables Event inputs Event outputs
is comprised of one or more CFB(s), each of which in turn
consists of one or more BFB(s).
Execution
Figure 11 illustrates the architecture of this intelligent Control
Chart
programming interface. It utilizes a graphical behavior
Type identifier Type identifier
specification method for better comprehension, facilitates
software reuse, and automatically generates the run-time
Algorithms
control code for cross compilation.

Internal
Agent-based Intelligent Visual Programming Interface variables
UI Control

Library Editor Control Code Cross


Management Control Generation Compilation Input variables Output variables Input variables Output variables

(a) BFB (b) CFB


Editor

DType Func BFB CFB App


Editor Editor Editor Editor Editor
Fig.12 Definitions of function blocks
Library

DType Func BFB CFB App DCOS


Based on the architecture shown in Fig.11, the visual
Lib Lib Lib Lib Lib Lib programming interface is being implemented as an iconic
GUI system. The state machine of a basic function block is
specified through event inputs, event outputs, state blocks,
Fig.11 Architecture of programming interface interconnections and transition conditions. Combining

1998 University of Calgary – Reprint of original paper - 158 -


BFBs properly, a user can design a composite function REFERENCES
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