Theoretical Foundations and Hierarchical Supervisory Control of Automated Manufacturing Systems Using Transition-Bounded Unbounded Petri Nets

This paper introduces a unified supervisory control framework for automated manufacturing systems (AMSs) based on Transition-Bounded Unbounded Petri Nets (tUPNs). The approach integrates hierarchical Generalized Mutual Exclusion Constraints (GMECs) with decentralized predicate-based supervision to address scalability, fault tolerance, and real-time adaptability in distributed manufacturing. By enforcing boundedness at critical transitions, tUPNs enable accurate modeling of high-throughput systems while preserving liveness and safety through P-semiflow invariants. The hybrid architecture combines centralized supervisors with local feedback controllers to ensure deadlock-free operation. Simulation-based validation demonstrates robust performance: 97.2% recovery success, zero deadlocks, and stable throughput (1.66 ± 0.01 parts/s) under dynamic faults. The framework achieves polynomial-time complexity O(|T|) and provides a direct mapping to IEC 61131-3 constructs, supporting future industrial deployment.