Implementação de controle supervisório em CLP de um sistema flexível de manufatura com aplicação em planta física e virtual

Abstract

With the technological advancement of recent decades and the development of numerous discrete event-driven systems, such as flexible manufacturing systems, service queues, communication systems, urban traffic systems, robotics, among others, formal control techniques for this class of systems have emerged, based on logical, event-driven rules that determine their evolution. Supervisory Control Theory is a formal control method for DES that synthesizes a non-blocking and minimally restrictive supervisor, which disables the occurrence of events, modeling the system's behavior to comply with certain specifications. Programmable logic controllers remain, even today, the main technological solution adopted in the control of automated systems. Various techniques for implementing supervisors, obtained through SCT, in PLC, have been developed and presented over the past decades, dealing with cyclical limitations of electronic circuits. Furthermore, with the emergence of technologies such as virtual commissioning, cyber-physical systems, and digital twins, new solutions that allow the development of virtual models capable of simulating the dynamic behavior of industrial plants have become increasingly prevalent in this context. This work conducts the study, modeling, and implementation of supervisory control in PLC, using a flexible manufacturing system as a case study. Different methodologies are investigated, and typical implementation problems are presented, with possible solutions discussed. Three implementations with distinct structures are developed, applied to: a virtual model developed in 3D simulation software; an educational prototype of the system; and a composite model with synchronization between physical and virtual plants. An alternative solution regarding the policy of generating controllable events by the control structure is also presented. The obtained results demonstrate the success of each proposal, as well as the challenges and limitations encountered.