Abstract
In automated manufacturing systems, resource failures are often inevitable. They reduce the number of available resources and may cause some processing routes of parts to halt and sometimes the whole system to shutdown. This article focuses on the robust deadlock control problem in automated manufacturing systems with multiple resource failures. To obtain such a robust controller, we first put forward a new concept of blocked states of automated manufacturing systems. From such a state, the production of some part types through one of their routes is blocked as caused by resource failures, and only after some failed resources are repaired, these parts can resume their normal processing. Then, these blocked states are characterized in terms of emptied siphons caused by resource failures. In order to prevent the system from deadlocks and blocked states, a robust controller is proposed by the following two steps. First, for siphons without unreliable resources, optimal deadlock control places are added. Then for siphons which contain unreliable resources, new control places are devised to ensure that they could be marked even when resource failures happen. It is proved that the proposed controller can guarantee that all types of parts can be processed repeatedly as long as one unit of unreliable resources can still work. This means that the proposed controller is of greatest robustness, that is, it can tolerate a maximum number of resource failures. Some examples are provided to illustrate the proposed method and show the advantage over the previous ones.