A Distributed Coordination Approach to Reconfigurable Process Control

A Distributed Coordination Approach to Reconfigurable Process Control
Nirav N. Chokshi • Duncan C. McFarlane
Contents
Part I P r o b l e m D e v e l o p m e n t
1 I n t r o d u c t i o n 3
1.1 Introduction 3
1.2 Need for Reconfigurable Process Control 4
1.3 Motivation for Research 7
1.4 Outline of the D R P C Approach 8
1.5 Structure of the Monograph 13
2 Reconfigurable P r o c e s s Control R e s e a r c h 15
2.1 Introduction 15
2.2 Classification of Manufacturing Systems 15
2.3 Industrial Process Control Systems 18
2.4 Distributed Approaches in Control 29
2.5 Reconfigurable Control Research in Other Domains 37
2.6 Summary 40
Part II A D i s t r i b u t e d Reconfigurable P r o c e s s Control A p p r o a c h
3 D R P C : D i s t r i b u t e d Reconfigurable P r o c e s s Control 43
3.1 Introduction 43
3.2 Addressing the Needs for Reconfigurable Process Control 43
3.3 Introducing the D R P C Approach 48
4 Reconfigurable P r o c e s s Control A r c h i t e c t u r e 51
4.1 Introduction 51
4.2 Specification of Process Elements in a R P C System 53
4.3 Migrating to Process Elements 60
4.4 An Illustrative Example 61
4.5 Comments on the D R P C Architecture 65
4.6 Summary 69x Contents
5 A n Interaction M o d e l for Reconfigurable P r o c e s s Control . 71
5.1 Introduction 71
5.2 Specification of the Interactions Between Process Elements . . . 73
5.3 An Illustrative Example 82
5.4 Comments on the D R P C Interaction Model 87
5.5 Summary 91
6 A D i s t r i b u t e d A l g o r i t h m for Reconfigurable P r o c e s s
Control 93
6.1 Introduction 93
6.2 Distributed Control Problem 95
6.3 Distributed Coordination Approach 100
6.4 Problem Decomposition 103
6.5 Solution of Two-Stage Problems 103
6.6 Solution of the Multi-Stage Problem 113
6.7 Implementation and Numerical Examples 119
6.8 Future Extensions 123
6.9 Summary 124
Part III A n A s s e s s m e n t of t h e D R P C A p p r o a c h
7 A p p l i c a t i o n of D i s t r i b u t e d C o o r d i n a t i o n A p p r o a c h —
A Case E x a m p l e 127
7.1 Introduction 127
7.2 Process Description 127
7.3 Problem Description 130
7.4 Application of the D R P C Approach 131
7.5 Summary 148
8 Conclusion s 149
8.1 Main Contributions 149
8.2 Limitations of the Research 151
8.3 Future Challenges 152
A p p e n d i x to C h a p t e r 6: B a c k g r o u n d C o n c e p t s 153
A.l Basic Sensitivity Theorem 153
A.2 The Concept of Primal Decomposition 154
A p p e n d i x t o C h a p t e r 6 — I m p l e m e n t a t i o n of D i s t r i b u t e d
C o o r d i n a t i o n A l g o r i t h m 163
B.l Data Structures 163
B.2 Unit Module 165
B.3 Overall Implementation 165Contents xi
Appendix to Chapters 6 and 7 — Problem Data for Numerical
Examples 169
References 177
Index 187
Index
agent-based control, 8, 34
aggregation hierarchy, 21
approximate cut update technique, 107,
154
architecture, 51
basic sensitivity theorem, 107, 153
bottom-up integration, 35, 149
campaign operations, 17
case example
list of cases, 133
problem description, 130-131
process description, 127
processing tasks, 128
scenarios, 130-131
collaboration, 71
communication, 71
communication networks, 38
computer integrated manufacturing, 21,
52
continuous process, 16
contracting, 9, 36, 40, 45, 72
resource-based view, 45
task-based view, 45
control architecture, 52
coordination, 8, 29, 71
cost of change curve, 26
decentralised control, 29, 31
decomposition, 29, 30, 162
define phase, 74
recipe mapping, 74, 76
product-centric approach, 76
unit-centric approach, 76
synthesis, 74, 78-81
demand-pull, 151
design method, 152
direct digital control, 18
discontinuous operations, 5, 16
discrete process, 15
distributed control systems, 19
distributed coordination, 8, 31, 44, 100
distribution, 29
DRPC approach, 43
analogy from virtual enterprise, 46
introducing, 48
research approach, 44
vs. contracting, 45
dynamic programming, 32
dynamic supply chains, 46
easy modifiability, 28
energy crisis, 5, 19
fault-tolerance, 28
feasibility cut, 160
feasibility restoration technique, 161
fixed connectivity layout, 133, 134
flexible connectivity layout, 133, 136
formation control, 37
full connectivity layout, 133, 135
functional hierarchy, 21
future challenges, 152
header element
control functions, 57
data model, 57188 Index
definition, 54
examples, 55
heterarchical architectures, 52
hierarchical architectures, 52
hierarchical control, 6, 21
hierarchical coordination, 30
holarchy, 52
holonic manufacturing, 8, 33
human interaction, 152
identify phase, 73
interaction, 71
interaction protocol, 79
material demand allocation, 81
service demand allocation, 82
ISA-S88 standard, 23
ISA-S95 standard, 23
junction block, 103
MIXER, 103
MULTIFEED, 103
MULTIPROD, 103
SPLITTER, 103
superset block, 110
lagrangian decomposition, 36, 45
limitations, 151
linear support, 156
local decisions, 29
low and late commitment, 34
manufacturing control, 21
manufacturing systems
classification, 15
discrete vs. continuous, 16
marginal cost, 30, 102, 154
market programming, 36, 45
migration approach, 60
multi-layer control, 31
multi-level coordination, 30
multiproduct process, 17
multipurpose process, 17
nested decomposition, 32, 100, 151
non-linear recipe, 82, 128
open technologies, 20
operate phase, 75
optimality cut, 102, 159
P-Graph, 96
PID control, 18
pipeless plants, 134
plug-and-produce, 10
power systems, 38
price-demand interactions, 101, 151
primal decomposition, 102, 154
process elements
aggregation, 58
association, 58
internal structure, 58-59
physical connections, 59-60
supplier-customer design, 79
supply chain analogy, 56
types, 53
process industries, 4
process scheme, 73
processing task, 73
product element
control functions, 57
data model, 57
definition, 54
product holon, 35, 45
product recipe, 23, 73
product-centric approach, 76, 84
product/process diversity, 6, 28
production capability information, 23
production definition information, 22
production information, 23
programmable logic controllers, 19
purdue reference model, 21
real-time control, 22
reconfigurability, 24
business needs, 24-25
engineering and design needs, 25-27
operational needs, 27-28
system requirements, 28
reconfigurable process control, 24
reconfiguration process, 73
reconfigure phase, 75
reference architecture, 35, 51
relaxation techniques, 32
resource holon, 35, 45
responsiveness, 6, 28, 131
semicontinuous process, 17
service, 54
service elementcontrol functions, 57
data model, 57
definition, 54
examples, 55
shadow price, 154
strategic learning, 7
superset block, 105
supply chain management, 39
system architecture, 51
tangential approximation, 155
terminate phase, 75
top-down decomposition, 35, 149
transaction, 78
Index 189
two-level coordination, 155
unit element
control functions, 57
data model, 57
definition, 54
examples, 55
unit module, 146, 151, 165
unit-centric approach, 76, 85
virtual enterprise, 9, 39
description, 46
life cycle model, 46
order fulfillment process, 47

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