CPS-Based Self-Adaptive Collaborative Control for Smart Production-Logistics Systems

Discrete manufacturing systems are characterized by dynamics and uncertainty of operations and behavior due to exceptions in production-logistics synchronization. To deal with this problem, a self-adaptive collaborative control (SCC) mode is proposed for smart production-logistics systems to enhance the capability of intelligence, flexibility, and resilience. By leveraging cyber-physical systems (CPSs) and industrial Internet of Things (IIoT), real-time status data are collected and processed to perform decision making and optimization. Hybrid automata is used to model the dynamic behavior of physical manufacturing resources, such as machines and vehicles in shop floors. Three levels of collaborative control granularity, including nodal SCC, local SCC, and global SCC, are introduced to address different degrees of exceptions. Collaborative optimization problems are solved using analytical target cascading (ATC). A proof of concept simulation based on a Chinese aero-engine manufacturer validates the applicability and efficiency of the proposed method, showing reductions in waiting time, makespan, and energy consumption with reasonable computational time. This article potentially enables manufacturers to implement CPS and IIoT in manufacturing environments and build up smart, flexible, and resilient production-logistics systems.