可重构板式家具生产系统的建模与优化研究
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摘要
可重构制造系统作为一种新型的制造模式,能够适应多品种、变批量、快速多变的用户和市场需求,快速调整企业的生产过程和生产能力,因此成为最具潜力和竞争力的生产模式。由于可重构制造系统具有模块化、集成化、快速重组性等特点,将其与板式家具生产系统结合在一起,通过对可重构板式家具生产系统的建模、调度和控制,能够为家具生产企业实现生产线的重构和优化提供理论支持,缩短企业的生产周期,降低企业的生产成本,极大地增强企业的市场竞争能力。本文的研究成果能够为板式家具生产企业的技术升级与改造奠定理论基础,具有重要的理论研究和实际指导意义。本文以国家林业局948项目“实木优选在线检测与控制关键技术(040-41311401)”为背景,开展可重构板式家具生产系统的建模与优化研究。
本文在构建可重构板式家具生产系统的基础上,以面向对象的赋时着色Petri网为模型,对板式家具生产线的设备布局优化与车间生产调度优化进行了研究,主要研究工作和取得的成果如下：
(1)提出了可重构板式家具生产的概念,构建了可重构板式家具生产系统的理论框架,给出了可重构板式家具生产系统的定义、组成和特点,建立了系统的重构评价体系,确定了可重构板式家具生产系统的关键技术。
(2)建立了基于面向对象的赋时着色Petri网(TCPN)模型。针对板式家具生产系统的功能模块化和动态重构等特点,将生产过程进行分解,建立各个生产活动的功能模型,按照功能模型到动态模型的映射关系,获得各生产活动的TCPN模型,由过渡变迁将各TCPN模型连接起来,形成整个系统的OOTCPN模型。同时对系统的稳定概率、生产率和设备利用率等性能指标进行了分析,结果表明可重构板式家具生产系统的OOTCPN模型既可以描述系统的静态特性,又可以描述系统的动态特性；既能够进行定性分析,又能够进行定量分析,模型具有较强的可操作性。
(3)根据现有设备的功能和特点,将车间内的设备分为不同的设备组,在考虑产品加工路径和系统重构的基础上,基于改进的自适应遗传算法对设备布局进行研究,建立了点阵式设备布局形式,并与常见的线型布局和U型布局进行比较,结果表明点阵式布局形式有效地降低了物流费用,同时提高了车间的面积利用率,具有较强的可行性。
(4)针对生产订单的快速变化,提出了基于面向对象的赋时着色Petri网和GASA混合遗传算法的车间调度优化算法,以OOTCPN模型的变迁激发序列作为染色体编码,进行选择、交叉和变异操作,以最短生产周期和重构费用作为优化目标,对系统资源进行快速重组,仿真结果表明该算法具有较好的稳定性。
As an advanced manufacturing mode, reconfigurable manufacturing system could adopt the demand of the users and the market, which had the characters such as multi-item, scalable batch, rapid changes and so on, and adjust the manufacturing processs and ability of the enterprises. Therefore, the reconfigurable manufacturing mode has become one of the most potential and competitive technology. The panel furniture manufacturing system and the reconfigurable manufacturing hang together, because the reconfigurable manufacturing system had the characters of modularization, Integration, reconfiguration. The study on the modeling. Scheduling and controlling could provide theoretical support for the reconfiguring and optimizing of the furniture enterprises, and enhance the market competeve ability of the erterprise. The reseach of the paper laid the theoretical foundation for the technical upgrading and transformation of the panel furniture manufacturing enterprises, which has important theoretical research and pratical significance. This paper carried out the research on the modeling and optimating of the reconfigurable panel furniture manufacturing system with the background of State Forestry Administration948Project:the key technology of wood detecting and controlling online.
This paper concentrated on optimating of the devices layout and schedule of the reconfigureable panel furniture manufactureing system based on the object-oriented timed-colored Petri net model. Generally, the main achievements in this paper are as follows:
(1)Propose the concept of the reconfigurable panel furniture manufactureing system (RPFMS). The theoretical framework of RPFMS is built. The definition, composition, characteristics and performance indicators of the RPFMS were defined. The design pricinples, the evaluation system and the key enabling technologies of the RPFMS were built.
(2) The object-oriented timed-colored Petri net (OOTCPN) model of the system was built by using IDEFO function module.The production process is broken down, the functional model of every processs is built, then the the TCPN model of every processs is built. Then, the OOTCPN model of the whole system is obtained through connecting the transitions. The performance indicators such as stable propbility, production cycle, and reconfigurabling time and equipment utilization and so on are analisised. The results showed that the OOTCPN model could describe not only the static characteristics, but also the dynamic characteristics.
(3) The equipments of the worshop were devided into deffirent groups, according to the existing equipments. The layout based on the improved adaptive genetic algorithm (AGA) was studied, considering the processing path and the system configuration. The dot-matrix layout was built. The result of the simulation showed that the the dot-matris layout reduced the logistics costs efeectively, improved the area utilizeation of the workshop comparing with the linear layout and U-shaped layout, which has strong feasibility.
(4) The hybrid flow shop scheduling was optimized based on OOTCPN and GASA (genetic algorithm-simulated annealing) because of the rapid changes of the processing orders. The scheduleing scheme achieved rapid reconfiguration as the optimization objectives in the shortest production cycle and the reconfiguration cost. The result of the simulation showed that the method has the better stability.
本文在构建可重构板式家具生产系统的基础上,以面向对象的赋时着色Petri网为模型,对板式家具生产线的设备布局优化与车间生产调度优化进行了研究,主要研究工作和取得的成果如下：
(1)提出了可重构板式家具生产的概念,构建了可重构板式家具生产系统的理论框架,给出了可重构板式家具生产系统的定义、组成和特点,建立了系统的重构评价体系,确定了可重构板式家具生产系统的关键技术。
(2)建立了基于面向对象的赋时着色Petri网(TCPN)模型。针对板式家具生产系统的功能模块化和动态重构等特点,将生产过程进行分解,建立各个生产活动的功能模型,按照功能模型到动态模型的映射关系,获得各生产活动的TCPN模型,由过渡变迁将各TCPN模型连接起来,形成整个系统的OOTCPN模型。同时对系统的稳定概率、生产率和设备利用率等性能指标进行了分析,结果表明可重构板式家具生产系统的OOTCPN模型既可以描述系统的静态特性,又可以描述系统的动态特性；既能够进行定性分析,又能够进行定量分析,模型具有较强的可操作性。
(3)根据现有设备的功能和特点,将车间内的设备分为不同的设备组,在考虑产品加工路径和系统重构的基础上,基于改进的自适应遗传算法对设备布局进行研究,建立了点阵式设备布局形式,并与常见的线型布局和U型布局进行比较,结果表明点阵式布局形式有效地降低了物流费用,同时提高了车间的面积利用率,具有较强的可行性。
(4)针对生产订单的快速变化,提出了基于面向对象的赋时着色Petri网和GASA混合遗传算法的车间调度优化算法,以OOTCPN模型的变迁激发序列作为染色体编码,进行选择、交叉和变异操作,以最短生产周期和重构费用作为优化目标,对系统资源进行快速重组,仿真结果表明该算法具有较好的稳定性。
As an advanced manufacturing mode, reconfigurable manufacturing system could adopt the demand of the users and the market, which had the characters such as multi-item, scalable batch, rapid changes and so on, and adjust the manufacturing processs and ability of the enterprises. Therefore, the reconfigurable manufacturing mode has become one of the most potential and competitive technology. The panel furniture manufacturing system and the reconfigurable manufacturing hang together, because the reconfigurable manufacturing system had the characters of modularization, Integration, reconfiguration. The study on the modeling. Scheduling and controlling could provide theoretical support for the reconfiguring and optimizing of the furniture enterprises, and enhance the market competeve ability of the erterprise. The reseach of the paper laid the theoretical foundation for the technical upgrading and transformation of the panel furniture manufacturing enterprises, which has important theoretical research and pratical significance. This paper carried out the research on the modeling and optimating of the reconfigurable panel furniture manufacturing system with the background of State Forestry Administration948Project:the key technology of wood detecting and controlling online.
This paper concentrated on optimating of the devices layout and schedule of the reconfigureable panel furniture manufactureing system based on the object-oriented timed-colored Petri net model. Generally, the main achievements in this paper are as follows:
(1)Propose the concept of the reconfigurable panel furniture manufactureing system (RPFMS). The theoretical framework of RPFMS is built. The definition, composition, characteristics and performance indicators of the RPFMS were defined. The design pricinples, the evaluation system and the key enabling technologies of the RPFMS were built.
(2) The object-oriented timed-colored Petri net (OOTCPN) model of the system was built by using IDEFO function module.The production process is broken down, the functional model of every processs is built, then the the TCPN model of every processs is built. Then, the OOTCPN model of the whole system is obtained through connecting the transitions. The performance indicators such as stable propbility, production cycle, and reconfigurabling time and equipment utilization and so on are analisised. The results showed that the OOTCPN model could describe not only the static characteristics, but also the dynamic characteristics.
(3) The equipments of the worshop were devided into deffirent groups, according to the existing equipments. The layout based on the improved adaptive genetic algorithm (AGA) was studied, considering the processing path and the system configuration. The dot-matrix layout was built. The result of the simulation showed that the the dot-matris layout reduced the logistics costs efeectively, improved the area utilizeation of the workshop comparing with the linear layout and U-shaped layout, which has strong feasibility.
(4) The hybrid flow shop scheduling was optimized based on OOTCPN and GASA (genetic algorithm-simulated annealing) because of the rapid changes of the processing orders. The scheduleing scheme achieved rapid reconfiguration as the optimization objectives in the shortest production cycle and the reconfiguration cost. The result of the simulation showed that the method has the better stability.
引文
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