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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

A Cooperative Problem Solving Framework for Computer-Aided Process


Planning

Utpal Bose
College of Business, Texas A&M University-Corpus Christi, 6300 Ocean Drive, Corpus Christi,
TX 78412
ubose@falcon.tamucc.edu

Abstract

Computer-aided process planning is the link between design and manufacturing in a computer-integrated
manufacturing (CIM) environment. The process planning problem comes out as a rigid hierarchical structure of
tasks where the lowest levels are well defined tasks, such as determination of machine and cutting parameters, while
the top levels control, coordinate, and manage the entire system. Such a top-down manner of coordination makes it
a tightly coupled distributed decision-making situation. The complexity of CIM systems with hierarchical structures
grows rapidly with the size of the system making them very expensive. Also, assimilating a large array of knowledge
sources to plan the activities is a major hurdle.
Cooperative distributed problem-solving (CDPS) is concerned with the cooperative solution of problems by a
decentralized group of cooperating intelligent agents. CDPS techniques have good adaptive capability, make the
system modular, are faster due to parallel operation of subsystems, possess greater reliability through redundancy,
can over-ride limited resources, and can collect knowledge. This paper describes a conceptual framework of
applying CDPS to CAPP for general-purpose process modeling. The problem in process planning has been mapped
onto a CDPS architecture based on multistage negotiation. The needed agents are defined, and their roles in the
architecture and the knowledge that each agent would need are described at the conceptual level. Potential benefits
of the framework in solving process planning problems in an intelligent and distributed manner have been
discussed.

1. Introduction used to add intelligence to the CAPP systems is


cooperative distributed problem solving (CDPS).
Computer-aided process planning (CAPP) forms an Cooperative distributed problem solving (CDPS)
imperative connection between design and manufacturing considers how a problem can be solved by decomposing it
operations in the computer-integrated manufacturing into subproblems and distributing those among a network
(CIM) environment. A CAPP system aims to automate the of problem solvers. The problem solvers are modules,
generation of process plans so that functions, such as often called nodes or agents, that cooperate at the level of
process selection, tool selection, feature sequencing, and dividing and sharing knowledge about the problem and its
machine tool selection can be performed without human solution [26], [17], [29]. The agents might be capable of
intervention. While the CAPP systems built using sophisticated problem solving and can work
different approaches have been tackling process-planning independently, but the problems to be solved are such that
problems, they have achieved limited success towards no single agent has the necessary expertise, resources, or
performing as an intelligent process planning system. information to solve the problem by itself [10]. In CDPS,
They can plan parts with limited amount of geometric the agents cooperatively solve a problem by sharing their
variations, and many planning functions, such as expertise, resources, and information to solve the
fixturing, tool selection, set-up planning, etc. are not subproblems, and then integrate the subproblems to
integrated. The systems do not possess intelligent generate the complete solution to the original problem.
capabilities, such as the ability to automatically adapt Solving inherently distributed problems is analogous to
plans according to the availability of resources, or share decision-making at an organizational level, where the
knowledge among the various planning related functional decision is made by multiple decision-makers, and then it
modules. An artificially intelligent (AI) tool that can be affects several organization units or issues. Computer-

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

based and communication-technology-based support material of the component, specifications of the machine
systems, called organizational decision support systems tools, cutting tools and work holding devices, operation
(ODSS), have been conceived to support such decision- sequencing, and production costs are synthesized to create
making processes. In one perspective of the ODSS, a a process plan [34]. Some of the generative type CAPP
distributed DSS (DDSS) supports distributed decision- systems are PMPS [19], GAPP [14], GARI [7], TOM
making, where a set of related decisions is distributed [21], PROPLAN [25], SIPP [23], and XPLANE [32]. The
among a set of decision-makers so that not all decisions limitations of these CAPPs include (i) selective geometry
can be made by a single decision-maker [31]. The of the part, and (ii) lack of important functional modules
assumption that the decisions in the set are related to each of planning systems, such as tool and fixture selection
other makes cooperation among the decision-makers a [12]. A methodology to support planning and machining
motivating factor [31]. Therefore the techniques in CDPS capability of feature-based design and automatic tool
can be applied effectively to construct an ODSS. selection was proposed [15], but no record could be found
Computer-integrated manufacturing (CIM) is an area of its implementation.
where DDSS can be used effectively. This paper discusses Some CAPPs can generate a list of all possible
within a conceptual overview how the CDPS techniques operations associated with the family in which the part
could assist in providing some of the solutions to the falls, such as the one proposed by McMahon et al. [22]
problem of integration in CIM. In CIM, the domain of where a recursive algorithm produces candidate operation
computer-aided process planning (CAPP) is chosen to sequences that are then ranked by applying manufacturing
which the CDPS techniques are applied. In section 2, the heuristics. No evidence, however, could be found that the
current state of art in CAPP systems is discussed; section available CAPPs could easily adapt the sequence of
3 discusses the appropriateness of applying CDPS operations for varying technological resources, such as
techniques to achieve an intelligent CAPP system; an available machines or fixtures. Mathematical approaches
architecture of an intelligent CAPP system using CDPS like integer programming have been suggested for
techniques is proposed in section 4; and section 5 sequencing and grouping operations [13], though the
concludes the paper. The proposed architecture of the proposed approach does not count for technological
CDPS technique will be implemented to develop a constraints.
prototype CAPP system and the expected benefits The process planning problem is traditionally
evaluated when the resources and facilities become formulated in the concepts of hierarchic structures [11],
available. where the lowest levels are dedicated to a well defined set
of tasks such as determining specific machine and cutting
2. Research in Computer-Aided Process parameters, feeds, speeds, etc., while the top levels of
Planning control coordinate and manage the entire system. Such a
top-down manner of coordination makes it a tightly
In CIM, computer-aided process planning (CAPP) is coupled distributed decision-making situation. While on
the function within a manufacturing facility that one hand, the rigid structure of hierarchical systems and
establishes the processes and process parameters to be the master/slave coupling between their levels provide fast
used along with the machines performing those processes, response times, on the other hand, the structure of these
to convert a piece of material from its initial form to a systems becomes fixed early in their development,
final form which is predetermined on a detailed making subsequent changes difficult for systems beyond a
engineering drawing [2], [3]. Two forms of automated certain complexity. The complexity of CIM systems with
process planning are in use – retrieval or variant type, and hierarchical architectures grows rapidly with the size of
generative type. the system, resulting in higher costs in development,
In retrieval type CAPP, parts are classified into family implementation, operation, maintenance, and modification
groups, such that each group has a standard process plan. [8].
Some retrieval type process planning systems are CAPP Another hurdle to be overcome in integrating planning
[20], CAPSY [30], AUTOCAP [35], and TOJICAP [36]. activities is assimilating different knowledge sources.
Limitations in these systems include (i) a new part can be Direct integration of various knowledge sources is not an
processed only if it relates to an original family group; (ii) easy task due to their different representations,
a certain degree of modifications are usually necessary foundations, and levels of abstraction [6]. In the ODSS
when a new part is to be processed using the plan [4]; and context, this is a semistructured distributed decision-
(iii) though these systems assisted human process making problem, as there may be conflicting
planners, these did not integrate design and manufacturing representation of knowledge from the various sources,
operations [12]. thus showing inconsistency relative to the overall problem
In generative type CAPP, various process information [31].
such as knowledge of geometry of the component,

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

Increased automation of planning activities requires action in specialized, bounded contexts, for purposes of
greater autonomy of systems and subsystems. control, extensibility, and comprehensibility [1].
Autonomous systems need capabilities of self-diagnoses, The current state of application of AI techniques in
self-debugging, planning and re-planning, etc., which can automated process planning occurs in two separate
be realized through AI procedures, such as CDPS portions [27]. In the first portion, the features and
techniques. description of the part are interpreted from the CAD
database to perform geometric reasoning about the shape,
3. Integrating CDPS into CAPP features, and relationships between features. The second
portion consists of the expert system for process planning.
In contrast to the traditional centralized approach of An automatic process planning system has to perform
constructing intelligent systems, CDPS is concerned with several functions, such as [2], (a) interface with the design
the cooperative solution of problems by a decentralized stage for better part understanding, (b) generate processes

group of cooperating intelligent agents. As shown in the for each manufacturing feature, (c) select fixturing
schematic diagram in Figure 1, each agent consists of a elements, and (d) select machining parameters, among
local knowledge base, and inference engine and a local others. Problems are thus functionally distributed among
planner giving it deductive capability, and a domains of knowledge, such as machining parameter
communication mechanism that enables it to interact with selection knowledge, and surface feature extraction
relevant experts in the community [24]. The planning knowledge. Performance of the desired task involves
capability is provided to coordinate the activities of the developing and coordinating the actions of distributed
local agents. A global query presented to a group of agents representing each knowledge domain. This is
agents is decomposed into various subqueries, which are achievable by the distributed interpretation capability of a
distributed to the relevant agents. The partial solutions CDPS network [16]. Such a capability can coordinate the
created by the local agents are reconstituted and selective exchange of partial interpretations, so that the
rationalized to produce a total solution to the original nodes representing knowledge domains can help each
query. CDPS techniques (a) have good adaptive other resolve ambiguities and can integrate local results
capability; (b) make the system modular; (c) are faster due into complete solutions.
to parallel operation of subsystems; (d) possess greater A desirable feature of a CAPP is its capability to
reliability through redundancy; (e) can over-ride limited generate alternative process plans. This is achievable
resources through exchange of predictive information, through the negotiation approach of CDPS, where each
tasks, goals, constraints, partial solutions, and knowledge node capable of solving a subproblem turns in one or
between the agents [10]; and (f) can collect knowledge or more bids to the coordinating node, thus providing a basis
for alternative solutions [5], [28].

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

The CAPP system requires several knowledge domains, each of which possesses a large number of rules.

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

Since the computation time grows exponentially with the 4.1. Overview of Design
number of rules, it is necessary to reduce the
computational effort. The parallelism provided by the The proposed automated process planning system
CDPS network provides an environment for faster consists of three types of agents: the job process planning
problem-solving. manager (PPM), the work center manager (WCM), and
Furthermore, CDPS resolves any possible conflict that the work center knowledge experts (CKE) (see Figure 2).
may arise between rules, a situation not unexpected due to The system
the presence of several knowledge domains. The a) prepares a process plan of a work-order,
coordination mechanisms in CDPS control problem b) estimates completion time and cost of the work-order
solving so that cooperating nodes work together as a without considering scheduling parameters, and
coherent team [10], [18]. Keeping in perspective the c) prepares a design reassessment report in the eventuality
capabilities that CDPS can provide to CAPP, an of either being unable to meet design specifications, or de-
architecture for CAPP based on the CDPS approach is tecting abnormally high completion time or cost.
proposed in the following section. When a new job arrives in the system, the PPM is
responsible for coordinating the complete process
4. CDPS Based CAPP System planning of the job, and for estimating the completion
time and cost. The WCM is responsible for coordinating
The planning of manufacturing processes involves the process planning activities at its work center and send
three phases: (a) planning summary, which involves all required information to the PPM. The CKEs manage
selecting machine tools and machining operations, and the various knowledge bases at the work centers, and
creating a routing sheet; (b) dimension analysis, which work together to provide all the information to the WCM.
involves calculating the tolerance build-up on each The agents are assigned the following functions:
surface to be machined and ensuring that the specified PPM: to prepare a process plan for a given work order,
requirements are met, if necessary through alternative that meets the requirement of either a minimum
machining operations, resequenced operations, or as a last completion time or cost, according to what is desired by
measure resort to reevaluation of the design values of the the user;
geometry and tolerances; and (c) detailed planning, where WCM: to assess which processes its work center can
the details of machine operation, tools, and work holding accomplish and at what cost/time, and to choose that
devices are determined. The complexity of a job's process alternative of a particular process that takes the minimum
planning and the vast amount of information that a system cost/time;
would need to process to make planning decisions makes CKE: to find if the specific requirement of the process
process planning an appropriate candidate for being de- related to the CKE's knowledge base can be met by the
signed as a multiagent planning system. work-center's capability. If the specific requirement can
Problem decomposition is an effective method for be met then the CKE is to provide the cost and time
coping with complexity and information overload. The information.
nature of planning decisions and the structure of
manufacturing knowledge base suggest a natural 4.2. Scheme of Operation
decomposition of the problem around work-orders and
work-centers. This decomposition results in subproblems Swanson [31] suggests that an ODSS can assist in
that individually require much smaller amounts of distributed decision-making through negotiated choice.
information to solve. The information requirements for The scheme of the proposed CAPP adopts a multistage
solving each subproblem overlap only slightly with other negotiation approach, [5] that is an extension of the
subproblems, so that the task of decoupling subproblems Contract-Net protocol [29]. The protocol considers a
is easier. A distributed system can be designed where each class of task allocation problems called distributed
agent/problem-solver addresses a subproblem and constraint satisfaction problems, in which a coordinated
interacts with others to construct a complete plan. In set of actions is required to achieve the goals of the
knowledge-based systems, computation time tends to network, but each agent has only limited resources
increase rapidly with the size of the knowledge base [9]. available for completing all of its assigned actions.
A distributed system that is made up of many loosely Multistage negotiation extends the basic Contract-Net
coupled systems with small knowledge bases is expected protocol to allow iterative negotiation during the bidding
to be faster than a centralized system consisting of a and awarding of tasks. At each iteration, each agent
central knowledge base. Interaction between sub-systems, detects whether a choice it has made violates the expecta-
however, may increase the communication load. tions of another agent concerning the use of resources.
Through multistage negotiation, agents exchange only
enough information to converge on compatible choices

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

that satisfy their constraints, rather than insisting that each contract and it responds to the request by specifying a
agent have a global view of all agents' choices and their candidate process operation for a given time period and
resource utilization requirements. cost. One request may generate more than one bid, each
With the arrival of a new work-order in the system, the bid specifying an operation different from the other in
PPM sends out requests for bids to perform operations some respect. The more bids a PPM receives for a
listed in the operations routing chart, which is generated request, the greater the flexibility the PPM has in building
with the help of a part representation and reasoning an economical process plan. The last stage of contracting
algorithm, such as the one proposed by McMahon et al. is award, which is a bid that has been accepted and
[22]. The flow of information among agents is shown in represents the final contract. The terms of the contract
Figure 2. The requests are sent out in a sequence that contain the completion time and cost of the operation, and
meets the precedence constraints as they appear in the the corresponding machine function parameters.
operations routing. The requests are directed only to those The agents are discussed in more detail in the next
WCMs that have the capability to carry out the operation, section.
thus reducing the communication load involved in sending
out the requests to WCMs. For example, for a drilling 4.3. The Process Planning Manager (PPM) Agent
operation the PPM does not send out a request to the
WCM of a milling machine. Furthermore, the request The PPM receives as input the design data of an work-
may specify that the WCM may bid only if it is able to order, interacts with contracting agents (WCM) to dis-
satisfy specified cut-off limits for specific parameters, or tribute subtasks of the problem, and outputs the most
alternatively ask the WCM to respond with only a limited economical process plan for the given work-order.
number of best bids. Such a requirement will minimize Process planning knowledge formalism schemes have
the number of undesirable bids thus further reducing the been categorized into two groups for most effective
communication load on the system. On receipt of the purposes [33]. They are facts or declarative knowledge,
request, the WCM determines whether its work center and rules or procedural knowledge. The PPM agent has
possesses all the capabilities to carry out the operation. It access to this knowledge from the following knowledge
sends out the process details to all the CKEs possessing bases, which form a component of the agent itself.
related knowledge bases, which search through their a) Workpiece (surface feature) knowledge: It consists of
knowledge bases and communicate with peer CKEs to geometric knowledge, like the general shape, length,
share constraints imposed by them, as well as resolve diameter, number of surfaces to be machined, etc. of the
conflicts of sharing resources of the work center. The workpiece. The work-order related facts can be extracted
CKEs send the process parameters, processing time, and from CAD data received as input or entered by the user.
cost to the WCM. b) Operation sequence knowledge: It consists of
The WCM compiles the parameters, determines the extracting and formalizing rules for operation sequencing,
optimum parameters if alternatives are provided to it, and so that the PPM can set up the operation sequence by
evaluates the cost and time of all the possible processes itself. The PPM will determine the operations and
that meet the requirements of the request sent out by the sequence them on a macro basis. That is, every operation
PPM. The WCM sends all the possible alternative shall be determined by identifying a group of subopera-
processes as bids to the PPM. If the work center cannot tions constituting that operation, which can be carried out
perform the operation due to its limited capacity, it at one machine.
communicates its inability to bid to the PPM. c) Product qualification (surface finish and tolerances)
The PPM reviews all the bids received from the knowledge: Knowledge about the product quality in terms
WCMs, and selects the one that meets the user's criteria of of surface finish, maximum allowable size tolerances, and
minimum cost/time. It then sends an award of contract to geometric dimensioning and tolerancing data is stored in
the chosen WCM, which acknowledges acceptance. The this knowledge base. If the work-order related data cannot
purpose of the award is to store the data about the be extracted from the input, these have to be entered by
operation of a job that is now linked to a work-center, the user.
which can be used for scheduling activities. d) Machine operation knowledge: Knowledge about a
The contracting that takes place between the PPM, certain type of surface being produced at a certain
WCM, and CKE occurs in three stages. In the first stage, performance level (quality) for a specific machining
the PPM agent announces a task (called a request) - in this process is stored.
case the process operation - to be carried out, along with e) Machine tool knowledge: This knowledge consists of a
the relevant information to the contractor agents, WCMs. machine's characteristics, such as size, horsepower,
The request also seeks values of measurement parameters rigidity, structure, and available tools, all of which decide
like operation completion times or costs from the what type of surfaces a machine can produce.
contracting agents. A bid is the second stage of the

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999
Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

On the basis of the knowledge about work-center The WCM accesses the work-center-specific operation
capabilities, workpiece geometry, and required operation, sequence knowledge bases and determines the sequence
the PPM sends requests to only those WCMs capable of of the suboperations needed for the required process
performing the operation. However, based on the detailed operation to be accomplished. The WCM may come up
local knowledge the WCM has, it may not be able to send with alternative sequences of suboperations, which will be
a bid to the PPM due to constraints in the work-center treated as alternative bids. It provides the parameters of
capabilities. If the PPM does not receive any bid for an the suboperations to all the CKEs, which respond with the
operation, the PPM communicates the status to the user parameters of the machine functions, time required to
indicating the reasons, which might be tight tolerances, complete each component of the suboperations, and the
out-of-limit dimensions, or other insufficient resources. corresponding costs. The CKEs also provide any possible
The user may then choose to modify the parameters of the alternative parameters for a suboperation. The WCM puts
operation and return it to the system. For complete plan together the information given by the CKEs and prepares
output by the PPM, if the user finds that the completion the bids including alternatives.
time or cost is too high, he may review the complete plan
to determine the operation components that contribute 4.5. The Center Knowledge Expert (CKE) Agent
towards the high cost or time. The user may then modify
the operation parameters and return the work-order to the The CKEs receive the parameters of the suboperations
system to have a new process plan worked out. All the from the WCM and determine the machine function
bids that are returned by WCMs represent alternative parameters that will be applicable from its specific
ways for carrying out the process. The PPM can prepare knowledge base. For example, the tooling-selection CKE
separate plans, one which has the minimum cost, and will determine which tool will perform the specific
another plan that gives the least processing time. suboperation, while the machine-parameter-selection CKE
will set the tool rotation speed and feed rates. The CKEs
4.4. The Work Center Manager (WCM) Agent need to communicate with each other to ensure that what
one CKE selects as a feasible function parameter value
A WCM represents a work-center that can perform does not conflict with the knowledge possessed by
machining operations. When a WCM receives a request another CKE and relevant to its selection of the parameter
from the PPM, it also receives the workpiece facts and the value. For example, when the tooling-selection CKE
finished requirements of the operation. The WCM has the selects the tool, it needs to communicate the selection to
following knowledge bases available for access. the machining-parameter-selection CKE so that the
a) Operation constraint knowledge: There exists a appropriate machining speeds and feed rates are selected.
particular process sequence for an operation. For example, Communication among the CKEs is also required to
rough boring comes before semifinish boring, and resolve any conflict arising from sharing of resources.
semifinish boring comes before finish boring. When a For example, besides the data on the workpiece geometry,
WCM is requested to bid for a boring operation, it uses the type of tool as well as the chosen reference surface
the knowledge base to determine the suboperations and may affect the choice of the job holding device which has
the sequence of those. to be decided by the jig-and-fixture-selection CKE. There
b) Geometry Rules: There are optimum process sequences is a possibility of a conflict arising in the choice of the job
in certain operations because of geometric features holding device due to the simultaneous presence of
involved in the operation. For example, in drilling two different determining factors. Then the corresponding
concentric holes of different diameters and depths, the CKEs, that is the tooling-selection CKE, the jig-and-
hole with the larger diameter and smaller depth has to be fixture-selection CKE, and the reference-surface-selection
drilled first. The reverse sequence will give the same CKE need to cooperate to resolve the conflict and choose
result, but the time consumed will be more. a job holding device that meets the requirements of all
c) Tool sequence knowledge: The sequence of processes concerned knowledge bases. If the conflict cannot be
for an operation on a machine might be influenced by the resolved within the requirements provided by the WCM,
types of tools available on that machine. Furthermore, the CKEs will inform the WCM about the conflict and
grouping surfaces based on tool types might save seek a relaxation in the requirements.
significant tool change time. For the function parameters that the CKE sets, it also
d) Geometric tolerancing knowledge: This knowledge determines the time required and the cost of carrying out
base consists of a set of rules that describes the constraints that function.
for the selection and sequencing of processes based on the Each CKE at a work-center possesses a specific
tolerances corresponding to the geometric dimensioning expertise, and bears the name of that knowledge base as
of the work-piece. follows.

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Proceedings of the 32nd Hawaii International Conference on System Sciences - 1999

a) Tooling-selection CKE: The CKE uses tool selection f) negotiations and interactions amongst human experts
rules to identify the type of surface to be machined and with different expertise can be simulated; and
then to locate a tool capable of producing that surface. g) a higher degree of system reliability is provided since
b) Jig-and-fixture-selection CKE: On the basis of the distributed systems possess more robustness and ensure
shape, basic dimensions, technological requirements of a graceful degradation of performance if one or more of the
workpiece, and machine dynamics, the CKE selects jigs agents fail.
and fixtures to hold the workpiece. A limitation of the proposed system, is that it focuses
c) Machine-parameter-selection CKE: The CKE selects on the manufacturing process and does not completely
the machine operation parameters, such as the tool speed, integrate between design and manufacturing operations.
feed, workpiece feed, cutting fluid selection and feed. The system can be extended to interface with cell
d) Reference-surface-selection CKE: The CKE selects the controllers which generate code to be fed into numerically
reference surfaces for each operation. The reference controlled machines (represented by WCMs). Though the
surfaces are primarily used as the measuring or inspection system does not consider the scheduling activities that
planes during machining. The quality of reference surface constitute an important aspect of the manufacturing
selection has tremendous impact on the product quality process, it can be conveniently augmented to include a
and production costs. cooperative scheduling system, as it already has the
structure for cooperative decision making and possesses
5. Conclusion the knowledge bases of the work-centers.

In cooperative distributed artificial intelligence we 6. References


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