Automatic Creation of Sequential Control Schemes in Polynomial Time

Of all hard- and software developed for industrial control purposes, the majority is devoted to sequential, or binary valued, control and only a minor part to classical linear control. The sequential parts of the controller are typically invoked during startup or shut-down phases to bring the system either into its normal operating region or into some safe standby region. Despite its importance, fairly little theoretical research has been devoted to this area, and sequential control programs are still created manually without much support for a systematic approach. We propose a method to create sequential control programs automatically and online upon request, for example when a plant fault has occurred. The main idea is to spend some effort off-line on modeling the process, and from this model generate the control strategy, i.e. the plan. Here we present a planning tool implemented in a real-time expert system called G2. The planning system contains algorithms for creating plans in form of minimal GRAFCET charts that show maximal parallelism. The algorithms can handle a restricted class of problems and for this class the complexity only increases polynomially with the number of state variables