变结构工序状态网的模型与算法研究
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摘要
传统上将工艺规划和生产调度作为两个独立过程，往往造成工艺规划结果实际调度中不可用的问题，工艺规划和调度集成(IPPS)模型的提出试图解决此问题，全面反映生产系统的物流信息、状态信息和控制信息的柔性工艺路线模型是解决IPPS问题的关键技术之一。柔性工艺路线的建模面临两个方面的挑战：工序间逻辑关系的动态性和产品的中间状态组合爆炸性。针对中间状态组合爆炸问题提出了工序状态网(process state net, PSN)模型，以该模型为基础，考虑工序关系的动态性，进一步提出了变结构工序状态网模型(process state net with changeablestructure, PSN-CS)模型。
本文围绕变结构工序状态网展开工作，研究工序关系动态变化和产品中间状态组合爆炸条件下的柔性工艺路线的建模和优化；建立了基于PSN-CS的IPPS问题求解模型，探讨该模型下工序可并行情形的集成调度，主要工作集中于以下几点：
1. PSN模型
针对产品中间状态组合性增长问题提出了柔性工艺路线的PSN模型，该模型通过工序状态的概念，将产品中间状态表示为多个工序状态的组合，避免了每一个中间状态都需要模型中一个结点来表示，有效减少模型结点个数，简化了柔性工艺路线的模型表示。
2. PSN-CS模型
从工序输入角度探讨了导致工序逻辑动态变化的本质因素，提出了组合工件输入弧和组合工件使能弧的概念，进而给出了柔性工艺路线的PSN-CS模型，该模型有效表达了工序关系的动态变化而不增加模型结点数量，为柔性工艺路线模型自动生成打下了基础。
3. PSN-CS模型的构建和优化
将工件区分为基本工件和专用工件，并给出了基本工件提取算法，指出PSN-CS模型只需对基本工件建模，从结构上简化了PSN-CS模型，进而给出了工序逻辑关系映射为PSN-CS模型的算法。从经验规则、结构优化和层次优化三方面给出了PSN-CS模型的优化技术，有效降低了IPPS问题的求解空间。
4. PSN-CS模型的应用
建立了基于PSN-CS的IPPS问题模型，对生产任务的具体工艺路线生成和调整进行探讨，给出了工艺路线的生成和调整算法，研究了工序可并行条件下的IPPS问题遗传算法求解模型，提出了工序可并行情况下遗传算法调度的解码方法，最后以线束生产为例建立了线束IPPS原型系统。
The process planning and production scheduling are traditionally regarded as two independentprocedures, which often result in that the process planning is not usable in practical scheduling. TheIPPS (integrated process planning and scheduling) model is proposed for trying to solve the problem,where the flexible process route model which can completely reflect the logistics, state and controlinformation is one of the key technologies of IPPS. There are two challenges to build the flexibleprocess route model, i.e., the dynamics of logical relations between processes, and the combinationexplosion of intermediate states of products. Aiming at the combination explosion, the PSN (ProcessState Net) model is presented. Furthermore, considering the dynamics of process relations, thePSN-CS (Process State Net with Changeable Structure) model is proposed.
In the present dissertation, systematic researches are carried through revolving around thePSN-CS. Building and optimizing the flexible process route model under the conditions of dynamicchanges of process relations and combination explosion of intermediate states of products, areinvestigated, and then the solution model of IPPS based on PSN-CS is built, and lastly the integratedscheduling based on this model when the processes are parallelizable is discussed. The main worksof the present dissertation are as follows:
1. PSN model
Aiming at the sharp growth of intermediate states of products, the PSN model of flexibleprocess route is put forward. The model uses the combination of some process states to represent theintermediate states of products by introducing the concept of process state, which avoids that eachintermediate state is represented by a node in the model. So the model effectively reduces thenumber of nodes and simplifies the model representation of flexible process route.
2. PSN-CS Model
The essence factors which result in the dynamic change of process logic relations are discussed,and the concepts of combination input arc of workpiece and combination enabling arc of workpieceare put forward, and then based on the two concepts, the PSN-CS model for flexible process route isproposed. The PSN-CS model effectively expresses the dynamic change of process relations withoutincreasing the number of nodes, thus lays the foundation for automatic generation of the flexibleprocess route model.
3. Building and optimizing for PSN-CS model
The workpieces are divided into the basic and special ones, and the extraction algorithm forbasic workpieces is given; it is pointed out that PSN-CS model should build just for basic workpieces,which simplifies the PSN-CS model from its structure. Then the algorithm is given for mapping process logic relationship to PSN-CS model. The optimization techniques for PSN-CS model areprovided from three aspects, i.e., experience rules, structure optimization and level optimization,which effectively reduce the solution space of IPPS problems.
4. The application of PSN-CS Model
The IPPS problem model is established based on PSN-CS. Generating and adjusting the specificprocess route of production tasks are discussed, and then the generation and adjustment algorithm ofprocess route is given. The GA (Genetic Algorithm) solution model for IPPS problems under thecondition of which process can be parallelizable, is researched, and the decoding procedure for GAis researched. At last, taking the wire harness production as an example, the harness IPPS prototypesystem has been developed.
本文围绕变结构工序状态网展开工作，研究工序关系动态变化和产品中间状态组合爆炸条件下的柔性工艺路线的建模和优化；建立了基于PSN-CS的IPPS问题求解模型，探讨该模型下工序可并行情形的集成调度，主要工作集中于以下几点：
1. PSN模型
针对产品中间状态组合性增长问题提出了柔性工艺路线的PSN模型，该模型通过工序状态的概念，将产品中间状态表示为多个工序状态的组合，避免了每一个中间状态都需要模型中一个结点来表示，有效减少模型结点个数，简化了柔性工艺路线的模型表示。
2. PSN-CS模型
从工序输入角度探讨了导致工序逻辑动态变化的本质因素，提出了组合工件输入弧和组合工件使能弧的概念，进而给出了柔性工艺路线的PSN-CS模型，该模型有效表达了工序关系的动态变化而不增加模型结点数量，为柔性工艺路线模型自动生成打下了基础。
3. PSN-CS模型的构建和优化
将工件区分为基本工件和专用工件，并给出了基本工件提取算法，指出PSN-CS模型只需对基本工件建模，从结构上简化了PSN-CS模型，进而给出了工序逻辑关系映射为PSN-CS模型的算法。从经验规则、结构优化和层次优化三方面给出了PSN-CS模型的优化技术，有效降低了IPPS问题的求解空间。
4. PSN-CS模型的应用
建立了基于PSN-CS的IPPS问题模型，对生产任务的具体工艺路线生成和调整进行探讨，给出了工艺路线的生成和调整算法，研究了工序可并行条件下的IPPS问题遗传算法求解模型，提出了工序可并行情况下遗传算法调度的解码方法，最后以线束生产为例建立了线束IPPS原型系统。
The process planning and production scheduling are traditionally regarded as two independentprocedures, which often result in that the process planning is not usable in practical scheduling. TheIPPS (integrated process planning and scheduling) model is proposed for trying to solve the problem,where the flexible process route model which can completely reflect the logistics, state and controlinformation is one of the key technologies of IPPS. There are two challenges to build the flexibleprocess route model, i.e., the dynamics of logical relations between processes, and the combinationexplosion of intermediate states of products. Aiming at the combination explosion, the PSN (ProcessState Net) model is presented. Furthermore, considering the dynamics of process relations, thePSN-CS (Process State Net with Changeable Structure) model is proposed.
In the present dissertation, systematic researches are carried through revolving around thePSN-CS. Building and optimizing the flexible process route model under the conditions of dynamicchanges of process relations and combination explosion of intermediate states of products, areinvestigated, and then the solution model of IPPS based on PSN-CS is built, and lastly the integratedscheduling based on this model when the processes are parallelizable is discussed. The main worksof the present dissertation are as follows:
1. PSN model
Aiming at the sharp growth of intermediate states of products, the PSN model of flexibleprocess route is put forward. The model uses the combination of some process states to represent theintermediate states of products by introducing the concept of process state, which avoids that eachintermediate state is represented by a node in the model. So the model effectively reduces thenumber of nodes and simplifies the model representation of flexible process route.
2. PSN-CS Model
The essence factors which result in the dynamic change of process logic relations are discussed,and the concepts of combination input arc of workpiece and combination enabling arc of workpieceare put forward, and then based on the two concepts, the PSN-CS model for flexible process route isproposed. The PSN-CS model effectively expresses the dynamic change of process relations withoutincreasing the number of nodes, thus lays the foundation for automatic generation of the flexibleprocess route model.
3. Building and optimizing for PSN-CS model
The workpieces are divided into the basic and special ones, and the extraction algorithm forbasic workpieces is given; it is pointed out that PSN-CS model should build just for basic workpieces,which simplifies the PSN-CS model from its structure. Then the algorithm is given for mapping process logic relationship to PSN-CS model. The optimization techniques for PSN-CS model areprovided from three aspects, i.e., experience rules, structure optimization and level optimization,which effectively reduce the solution space of IPPS problems.
4. The application of PSN-CS Model
The IPPS problem model is established based on PSN-CS. Generating and adjusting the specificprocess route of production tasks are discussed, and then the generation and adjustment algorithm ofprocess route is given. The GA (Genetic Algorithm) solution model for IPPS problems under thecondition of which process can be parallelizable, is researched, and the decoding procedure for GAis researched. At last, taking the wire harness production as an example, the harness IPPS prototypesystem has been developed.
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