Reference architecture for holonic manufacturing systems: PROSA

doi:10.1016/S0166-3615(98)00102-X

Computers in Industry

Volume 37, Issue 3, November 1998, Pages 255-274

https://doi.org/10.1016/S0166-3615(98)00102-X Get rights and content

Abstract

Future manufacturing systems need to cope with frequent changes and disturbances. As such, their control requires constant adaptation and high flexibility. Holonic manufacturing is a highly distributed control paradigm that promises to handle these problems successfully. It is based on the concept of autonomous co-operating agents, called `holons'. This paper gives an overview of the holonic reference architecture for manufacturing systems as developed at PMA-KULeuven. This architecture, called PROSA, consists of three types of basic holons: order holons, product holons, and resource holons. They are structured using the object-oriented concepts of aggregation and specialisation. Staff holons can be added to assist the basic holons with expert knowledge. The resulting architecture has a high degree of self-similarity, which reduces the complexity to integrate new components and enables easy reconfiguration of the system. PROSA shows to cover aspects of both hierarchical as well as heterarchical control approaches. As such, it can be regarded as a generalisation of the two former approaches. More importantly, PROSA introduces significant innovations: the system structure is decoupled from the control algorithm, logistical aspects can be decoupled from technical ones, and PROSA opens opportunities to achieve more advanced hybrid control algorithms.

Introduction

Market demand and environmental/societal pressures require effective manufacturing systems to adapt themselves at an ever-increasing pace. This creates the need for novel manufacturing control systems that are able to manage production change and disturbances both effectively and efficiently. To meet these new requirements, several new manufacturing paradigms are being investigated: bionic manufacturing [1], genetic manufacturing [2], the fractal factory [3], random manufacturing [4], virtual manufacturing [5], and holonic manufacturing [6].

The holonic manufacturing paradigm was developed in the framework of the Intelligent Manufacturing Systems (IMS) programme. In a feasibility study [7], conducted in 1994, six test cases were considered, one of which was `Holonic Manufacturing Systems: system components of autonomous modules and their distributed control,' or HMS. The HMS project aimed at a better understanding of the requirements for future-generation manufacturing systems and at ways to build systems satisfying these requirements. A holonic manufacturing architecture shall enable easy (self-)configuration, easy extension and modification of the system, and allow more flexibility and a larger decision space for higher control levels.

Presently, PMA-KULeuven continues its research on holonic manufacturing systems by carrying out a nationally funded research project called GOA/HMS—Concerted Research Action on Holonic Manufacturing Systems. In this project, PMA combines its knowledge in flexible shop floor control [8], non-linear process planning [9], reactive scheduling [10], and machine controllers to develop a holonic architecture for production systems and to implement two prototypes or testbeds. The first testbed is a five-axis milling workstation which will be used to demonstrate the NC-workstation holon [11]. The PMA-flexible assembly system [12]serves as testbed for implementing the holonic shop floor control architecture.

This paper describes the holonic reference architecture for manufacturing systems developed in GOA/HMS. A reference architecture is defined as a set of coherent engineering and design principles used in a specific domain. It aims at structuring the design of a specific system architecture by defining a unified terminology, the structure of the system, responsibilities of system components, by providing standard (template) components, by giving examples, etc. [13].

After a brief introduction into the holonic manufacturing concept, the paper discusses the structure of the architecture: the components, their responsibilities, and their interactions. Section 4motivates this design by comparing it to existing architectures. In the next two sections, more detailed aspects of the architecture are discussed: Section 5lists the data, functions, and interaction behaviour of the system components. Section 6describes the importance of the self-similarity encountered in this architecture. Finally, the section on different manufacturing viewpoints alerts the reader to the fact that depending upon his/her personal manufacturing background, the fundamentals of the described architecture may be perceived differently.

Section snippets

Holonic manufacturing concept

Over 30 years ago, Arthur Koestler proposed the word `holon' [14]. It is a combination of the Greek holos=whole, with the suffix -on which, as in proton or neutron, suggests a particle or part.

Two observations impelled Koestler to propose the concept of holon. (a) Complex systems will evolve from simple systems much more rapidly if there are stable intermediate forms than if there are not; the resulting complex systems in the former case will be hierarchic. (b) Although it is easy to identify

Structure of the HMS reference architecture

The structure of the HMS reference architecture is built around three types of basic holons: order holons, product holons, and resource holons. Each of them is responsible for one aspect of manufacturing control, be it logistics, technological planning, or resource capabilities respectively. These basic holons are structured using object-oriented concepts like aggregation and specialisation. Staff holons can be added to assist the basic holons with expert knowledge. These allow the use of

Comparison with other architectures

This section compares the structural characteristics of PROSA with the characteristics of the main competing reference architectures. This comparison serves as a motivation why PROSA is designed to consist out of three types of basic holons extended with the concept of staff holons.

From the comparison below, it is concluded that PROSA is covering all aspects of hierarchical and heterarchical control architectures. It covers all relevant functions and it can incorporate a wide range of control

Detailed model of the basic holons

From the examples given in the previous sections, the reader may already have derived data, functions, and interaction behaviour of the holons. This section more explicitly describes the data held by the holons, the functions which each holon needs to fulfil, and interactions between the holons. The data and functions give a more detailed insight in the responsibilities of the three basic holons. The interaction behaviour gives simple examples of the process knowledge, production knowledge, and

Self-similarity in holonic systems

Self-similarity in PROSA is an important characteristic which partly determines the reconfigurability of the control system. Homogeneous system components reduce the complexity of the overall system, which simplify the development and integration of new holons into the system. The HMS architecture contains self-similar components, meaning that holons of the same type have similar interfaces and similar behaviour. This allows holons to be internally different, while not imposing additional

Different viewpoints on the basic holons

From previous presentations and discussions about PROSA with other researchers, we learned that, depending upon their personal manufacturing background, the fundamentals of the described architecture may be perceived differently. Depending on the reader`s viewpoint, the basic holons have a different ontology. From some viewpoint, a specific holon seems to be a passive information server. Another viewpoint focuses on the way this holon generates and maintains the information, so the same holon

Conclusions

The HMS architecture PROSA consists of three types of basic holons: resource holons, product holons and order holons. Every basic holon type focuses on different responsibilities of the manufacturing system. The holons exchange process knowledge, production knowledge, and process execution knowledge respectively. Aggregation is used to focus on different levels of holons. Specialisation is used to focus on different functionalities of holons. Staff holons are optional elements which may assist

Acknowledgements

This paper presents research results obtained through work sponsored by the Concerted Research Action (GOA) on holonic manufacturing, supported by the Office of the Prime Minister, Science Policy Programming, through the K.U.Leuven Research Council.

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Prof. Dr. Ir. Hendrik Van Brussel, born at Ieper, Belgium on 24 October 1944, obtained the degree of Technical Engineer in mechanical engineering from the Hoger Technisch Instituut in Ostend, Belgium in 1965 and an engineering degree in electrical engineering at MS level from Katholieke Universiteit Leuven, Belgium. In 1971 he got his PhD Degree in mechanical engineering, also from K.U.Leuven. From 1971 until 1973 he was establishing a Metal Industries Development Centre in Bandung, Indonesia and he was an associate professor at Institut Teknologi Bandung, Indonesia. Consequently, he returned to K.U.Leuven where he is presently full professor in mechatronics and automation and chairman of the Department of Mechanical Engineering. He was a pioneer in robotics research in Europe and an active promotor of the mechatronics idea as a new paradigm in machine design. He has published more than 200 papers on different aspects of robotics, mechatronics and flexible automation. His present research interest are shifting towards holonic manufacturing systems and precision engineering, including microrobotics. He is Fellow of SME and IEEE and in 1994 he received a honorary doctor degree form the `Politehnica' University in Bucarest, Romania and from RWTH, Aachen, Germany. He is also a Member of the Royal Academy of Sciences, Literature and Fine Arts of Belgium and Active Member of CIRP (International Institution for Production Engineering Research).

Ir. Jo Wyns received the mechanical engineering degree in 1993 from the Katholieke Universiteit Leuven, Belgium. He is a candidate for the PhD degree in mechanical engineering from the K.U.Leuven. Since 1993, he is with the Mechanical Engineering Department, division PMA, of the K.U.Leuven. His main research interests are in holonic manufacturing systems architecture, and dynamic resource allocation.

Dr. Ir. Paul Valckenaers received the applied mathematics engineering degree in 1983, the computer science engineering degree in 1985, and the mechanical engineering PhD degree in 1993, all from the Katholieke Universiteit Leuven, Belgium. Since 1986, he is with the mechanical engineering department, division PMA, of the Katholieke Universiteit Leuven. His main research interests are in programming, scheduling and control of flexible production systems and design theory for the development of complex adaptive production systems. His current research activities focus on Holonic Manufacturing Systems (HMS).

Ir. Luc Bongaerts received the mechanical engineering degree in 1992 from the Katholieke Universiteit Leuven, Belgium. He is a candidate for the PhD degree in mechanical engineering from the K.U.Leuven. Since 1992, he is with the Mechanical Engineering Department, division PMA, of the K.U.Leuven, first as an IWONL bursary, from 1994 as an IWT bursary, and from 1996 as a K.U.Leuven bursary on the Concerted Research Action on Holonic Manufacturing Systems. From 1998, he is project engineer in the HMS/HANDS project. He is also involved in the MASCADA project and in the Esprit Working Groups IiMB and IMS-WG. His main research interests are scheduling and control of flexible and holonic manufacturing systems.

Ir. Patrick Peeters received the mechanical engineering degree in 1996 from the Katholieke Universiteit Leuven, Belgium. He is a candidate for the PhD degree in mechanical engineering from the K.U.Leuven. Since 1996, he is with the Mechanical Engineering Department, division PMA, of the K.U.Leuven. His main research interests are multi-agent systems for manufacturing control, flexible flow lines, and plant modelling and simulation.