摩擦输送汽车混流装配线中短期决策平衡调度问题研究与应用
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摘要
面向汽车装配的摩擦驱动物料输送成套装备以其高效、柔性、节能环保等特性，在国内外众多汽车制造企业得到广泛应用。针对采用摩擦驱动物料输送装备的汽车装配线，开展汽车装配中短期决策平衡调度问题研究，有助于进一步发挥新技术的优势，对促进我国汽车产业的发展有着重要的意义。
本文的总体研究思路是：以采用摩擦驱动技术和分布式自治控制技术的汽车混流装配线生产系统为研究对象，针对中短期决策的平衡调度问题，寻找两者之间联系，结合新型物料输送装备的特性，重点关注平衡调度两方面对混流装配线的共同影响，从不同的角度对问题展开深入的理论研究及技术开发。首先，结合摩擦输送技术的特点，针对不同类型的装配线，探寻平衡调度问题中各种因素对其生产效率的影响，选择合适的优化目标，提出优化问题的数学模型；然后，针对不同的优化模型，设计了相应的进化算法及关键操作，以改善算法性能，提高求解特定问题的效率。并通过大量对比实验，证实算法的正确性，还通过对算法加以改进，以获得更好的实验结果；为了更好地验证算法的有效性，通过设计合适的控件属性和控制方法，采用eM-Plant仿真软件对算法进行了仿真；最后，以本文取得的理论成果和提出的优化算法为基础，完成了面向实际应用的平衡调度优化系统设计开发，并进行了初步的实际应用，提升了研究成果的实用性。主要内容如下：
第一，采用摩擦输送技术的汽车总装线具有节拍高，兼容车型多等特点，这些特点为中短期决策的平衡调度问题带来巨大的挑战。本文以免疫克隆选择算法为基础，提出了一种新的疫苗共生的克隆选择优化算法，设计了疫苗种群的编码，解码，评价等进化操作，并将这种新算法应用于单目标的平衡优化问题及多目标的调度优化问题。
第二，柔性摆式摩擦驱动技术和位移自补偿摩擦驱动技术是摩擦驱动技术中的两个核心技术。这些不但给装配线带来了高度的柔性,同时，给汽车装配线形成紧凑的U型布局和空间交叉布局提供了极大的便利。本文深入分析了混流生产方式对这种U型装配线工作站作业时间的影响，指出了从平衡与调度两个方面同时对装配线进行优化的必要性。以负荷均衡化，最小化零部件消耗平准率，最小化生产准备成本作为优化目标，针对平衡与调度两方面既有联系又有区别的特点，提出了一种协同进化免疫克隆选择算法，同时从平衡与调度两个方面对装配线进行优化。并以eM-Plant仿真平台为基础，设计了一种虚拟生产模型的仿真方法，解决了没有基本控件可以模拟U型装配线的问题。
第三，针对混流直线型装配线，本文提出了采用临时工工作时间作为作业负荷均衡的衡量准则，进一步建立了从平衡与调度两个方面对工作站负荷强度进行优化的混流直线型装配线平衡调度综合问题数学模型，设计了一种克隆选择算法与局域搜索算法相结合的混合算法。摩擦驱动汽车装配线采用分布式自治控制技术可方便地实现变生产节拍生产。本文利用这一特点，进一步降低混流直线型装配线的作业负荷不平衡。建立了变生产节拍下的混流直线型装配线平衡调度问题模型，依据模型中变量关系的紧密程度，设计了一种同步与异步进化相结合的混合协同进化算法，有效提高了算法性能，降低了算法运行时间。在eM-Plant仿真平台中，设计了一种基于Line控件和Method触发控制的仿真方法，准确地对目标函数值进行了仿真。
第四，针对混流装配线重平衡相关理论研究的不足之处，本文提出了订单改变下的重平衡调度问题；利用单推送台对两线之间的生产序列进行调整，设计了适合单推送台约束条件的编码解码方式，并采用多目标免疫克隆选择算法对此类重平衡问题进行求解。
本文在理论研究基础之上，结合企业实际应用的需求，设计开发了面向汽车装配线的平衡调度优化系统。系统共分为六个主要功能模块：生产数据管理，算法配置，平衡优化模块，平衡调度优化功能模块，调度优化功能模块，重调度优化功能模块。该系统可以针对不同规划设计阶段的优化目标，进行系统调度优化，为生产实际提供技术支持。经过试运行，取得了良好的应用效果，也充分证明了本文提出的优化技术、方法的正确性和有效性。
本文最后对取得的创新成果进行了总结，并对进一步的研究内容进行了展望。
The friction drive material delivery facilities developed for auto assembly have been widelyapplied in the automotive industry as the characteristic of high efficiency, flexibility and low depletionof energy. Researching on the mid-to-short decision making problems of balancing and sequencingbased on this new friction drive mixed-model assembly line is helpful for the using of theseadvantages further and will be very meaningful for the developing of Chinese auto industry.
The main thinking of this dissertation is listed below: In the background of the mixed-modelassembly lines （MMAL） in which the adaptive vector-friction drive and the distributed self-controltechnologies are applied, the mid-to-short term decision-making problems have been discussed.Connection between the balancing and sequencing of the MMAL integrated with the characteristicsbrought by the new conveyor has been explored and the combined affect on the MMAL has been paidclose attention to. The whole research has been analyzed from different points of view: First, theimpact of various factors on production efficiency for different kinds of MMAL brought by newtechnologies has been studied. Mathematical models of the balancing and sequencing （B&S）problem with appropriate objective functions have been proposed; Second, correspondingevolutionary algorithms for different optimization models have been designed. The structures of thealgorithms have been designed and some key operators have been improved in order to enhance theperformance of these algorithms. Considerable contrastive experiments have been carried out and theresult data shows the improvement brought by some innovative operators and the superiority of thealgorithm. In order to certify the effectiveness of the algorithms further more, some results of thealgorithms have been modeled. During the process of simulating, appropriate control properties andmethods have been set up in the simulation models of eM-Plant software. At last, for the applicationof the theory, the optimization software of balancing and sequencing which integrates all the theoriesand algorithms of this dissertation has been developed. Then the preliminary application increases thepracticality of this research. The main subjects are as follows:
First, the friction drive assembly line has a low cycle time and many different kinds of models.These characteristics have become new challenges in balancing and sequencing problems. Clonalselection algorithm, the basic algorithm of this research, has been first introduced. Then a novelvaccine co-evolutionary clonal selection algorithm has been proposed. The coding and evaluationoperators of vaccine populations have been designed. This new algorithm has been applied for bothsingle-objective balancing problem and multi-objective sequencing problem. Meanwhile, a newcoding strategy has been devised for the balancing problem and a new evaluation method has beenraised to make up for the deficiency that different coding often has the same fitness in the sequencingproblem.
Second, the flexible-swayed friction drive and the displacement self-compensate friction driveare core technologies of friction drive technologies. These provide the assembly lines with highflexibility and convenience for the layout of compact U-shaped lines and space-crossed lines. Theimpact on the work-time of workstations caused by the mixed-model production mode has beendisplayed, which highlights the necessity of optimization from both balancing and sequencing. Multiple objections of balancing workload, minimizing the part usage variation and minimizing thesetup cost have been optimized by an immune co-evolutionary algorithm which is designedconsidering both the connection and distinguish between the balancing and sequencing problem. Avirtual union-model method is developed for the short of basic controls so that the simulation byeM-Plant can be executed on U-shaped assembly lines.
Third, minimizing the utility work time has been adopted as the objective function of the B&Sproblem of straight shaped assembly line. The mathematical model of optimizing workload from bothbalancing and sequencing has been established. A novel hybrid strategy based on immune clonalselection algorithm and local search algorithm has been brought up for this complex problem.According to the characteristic of the assembly line come up with the distributed self-controltechnology, variable cycle time has been adopted to further reduce the unbalance of the workstations.Considering the relationship between those variables, a hybrid co-evolutionary algorithm whichcombines both synchronous evolution and asynchronous evolution has been raised so that theperformance and efficiency of the algorithm can be improved. A simulation method using “Line”control and “method” control has been designed and applied in order to simulate the objectivefunction exactly.
Fourth, considering the lack of related researches for rebalancing problem, the rebalancing andsequencing problem caused by changing orders has been given. The strategy of adjusting sequencesusing single pull-off table between different lines has been proposed. Proper coding and decodingoperators of multiple–objective clonal selection algorithm have been designed for this resequencingproblem.
Based on the theory of this dissertation, the software of balancing and sequencing system hasbeen developed. This system has been divided to six functional modules: the production datamanagement module, the algorithm configuration module, the balancing module, the balancing andsequencing module, the sequencing module and the rebalancing module. This system can providetechnical support for the optimization of production considering different objectives of differentphases. The operating effects of this system has been elaborated and compared in detail in order toprove the correctness of the theory and the effectiveness of the system of this research.
At the end of this dissertation, the summary of the innovations in this research has been givenand the further research has been forecasted.
本文的总体研究思路是：以采用摩擦驱动技术和分布式自治控制技术的汽车混流装配线生产系统为研究对象，针对中短期决策的平衡调度问题，寻找两者之间联系，结合新型物料输送装备的特性，重点关注平衡调度两方面对混流装配线的共同影响，从不同的角度对问题展开深入的理论研究及技术开发。首先，结合摩擦输送技术的特点，针对不同类型的装配线，探寻平衡调度问题中各种因素对其生产效率的影响，选择合适的优化目标，提出优化问题的数学模型；然后，针对不同的优化模型，设计了相应的进化算法及关键操作，以改善算法性能，提高求解特定问题的效率。并通过大量对比实验，证实算法的正确性，还通过对算法加以改进，以获得更好的实验结果；为了更好地验证算法的有效性，通过设计合适的控件属性和控制方法，采用eM-Plant仿真软件对算法进行了仿真；最后，以本文取得的理论成果和提出的优化算法为基础，完成了面向实际应用的平衡调度优化系统设计开发，并进行了初步的实际应用，提升了研究成果的实用性。主要内容如下：
第一，采用摩擦输送技术的汽车总装线具有节拍高，兼容车型多等特点，这些特点为中短期决策的平衡调度问题带来巨大的挑战。本文以免疫克隆选择算法为基础，提出了一种新的疫苗共生的克隆选择优化算法，设计了疫苗种群的编码，解码，评价等进化操作，并将这种新算法应用于单目标的平衡优化问题及多目标的调度优化问题。
第二，柔性摆式摩擦驱动技术和位移自补偿摩擦驱动技术是摩擦驱动技术中的两个核心技术。这些不但给装配线带来了高度的柔性,同时，给汽车装配线形成紧凑的U型布局和空间交叉布局提供了极大的便利。本文深入分析了混流生产方式对这种U型装配线工作站作业时间的影响，指出了从平衡与调度两个方面同时对装配线进行优化的必要性。以负荷均衡化，最小化零部件消耗平准率，最小化生产准备成本作为优化目标，针对平衡与调度两方面既有联系又有区别的特点，提出了一种协同进化免疫克隆选择算法，同时从平衡与调度两个方面对装配线进行优化。并以eM-Plant仿真平台为基础，设计了一种虚拟生产模型的仿真方法，解决了没有基本控件可以模拟U型装配线的问题。
第三，针对混流直线型装配线，本文提出了采用临时工工作时间作为作业负荷均衡的衡量准则，进一步建立了从平衡与调度两个方面对工作站负荷强度进行优化的混流直线型装配线平衡调度综合问题数学模型，设计了一种克隆选择算法与局域搜索算法相结合的混合算法。摩擦驱动汽车装配线采用分布式自治控制技术可方便地实现变生产节拍生产。本文利用这一特点，进一步降低混流直线型装配线的作业负荷不平衡。建立了变生产节拍下的混流直线型装配线平衡调度问题模型，依据模型中变量关系的紧密程度，设计了一种同步与异步进化相结合的混合协同进化算法，有效提高了算法性能，降低了算法运行时间。在eM-Plant仿真平台中，设计了一种基于Line控件和Method触发控制的仿真方法，准确地对目标函数值进行了仿真。
第四，针对混流装配线重平衡相关理论研究的不足之处，本文提出了订单改变下的重平衡调度问题；利用单推送台对两线之间的生产序列进行调整，设计了适合单推送台约束条件的编码解码方式，并采用多目标免疫克隆选择算法对此类重平衡问题进行求解。
本文在理论研究基础之上，结合企业实际应用的需求，设计开发了面向汽车装配线的平衡调度优化系统。系统共分为六个主要功能模块：生产数据管理，算法配置，平衡优化模块，平衡调度优化功能模块，调度优化功能模块，重调度优化功能模块。该系统可以针对不同规划设计阶段的优化目标，进行系统调度优化，为生产实际提供技术支持。经过试运行，取得了良好的应用效果，也充分证明了本文提出的优化技术、方法的正确性和有效性。
本文最后对取得的创新成果进行了总结，并对进一步的研究内容进行了展望。
The friction drive material delivery facilities developed for auto assembly have been widelyapplied in the automotive industry as the characteristic of high efficiency, flexibility and low depletionof energy. Researching on the mid-to-short decision making problems of balancing and sequencingbased on this new friction drive mixed-model assembly line is helpful for the using of theseadvantages further and will be very meaningful for the developing of Chinese auto industry.
The main thinking of this dissertation is listed below: In the background of the mixed-modelassembly lines （MMAL） in which the adaptive vector-friction drive and the distributed self-controltechnologies are applied, the mid-to-short term decision-making problems have been discussed.Connection between the balancing and sequencing of the MMAL integrated with the characteristicsbrought by the new conveyor has been explored and the combined affect on the MMAL has been paidclose attention to. The whole research has been analyzed from different points of view: First, theimpact of various factors on production efficiency for different kinds of MMAL brought by newtechnologies has been studied. Mathematical models of the balancing and sequencing （B&S）problem with appropriate objective functions have been proposed; Second, correspondingevolutionary algorithms for different optimization models have been designed. The structures of thealgorithms have been designed and some key operators have been improved in order to enhance theperformance of these algorithms. Considerable contrastive experiments have been carried out and theresult data shows the improvement brought by some innovative operators and the superiority of thealgorithm. In order to certify the effectiveness of the algorithms further more, some results of thealgorithms have been modeled. During the process of simulating, appropriate control properties andmethods have been set up in the simulation models of eM-Plant software. At last, for the applicationof the theory, the optimization software of balancing and sequencing which integrates all the theoriesand algorithms of this dissertation has been developed. Then the preliminary application increases thepracticality of this research. The main subjects are as follows:
First, the friction drive assembly line has a low cycle time and many different kinds of models.These characteristics have become new challenges in balancing and sequencing problems. Clonalselection algorithm, the basic algorithm of this research, has been first introduced. Then a novelvaccine co-evolutionary clonal selection algorithm has been proposed. The coding and evaluationoperators of vaccine populations have been designed. This new algorithm has been applied for bothsingle-objective balancing problem and multi-objective sequencing problem. Meanwhile, a newcoding strategy has been devised for the balancing problem and a new evaluation method has beenraised to make up for the deficiency that different coding often has the same fitness in the sequencingproblem.
Second, the flexible-swayed friction drive and the displacement self-compensate friction driveare core technologies of friction drive technologies. These provide the assembly lines with highflexibility and convenience for the layout of compact U-shaped lines and space-crossed lines. Theimpact on the work-time of workstations caused by the mixed-model production mode has beendisplayed, which highlights the necessity of optimization from both balancing and sequencing. Multiple objections of balancing workload, minimizing the part usage variation and minimizing thesetup cost have been optimized by an immune co-evolutionary algorithm which is designedconsidering both the connection and distinguish between the balancing and sequencing problem. Avirtual union-model method is developed for the short of basic controls so that the simulation byeM-Plant can be executed on U-shaped assembly lines.
Third, minimizing the utility work time has been adopted as the objective function of the B&Sproblem of straight shaped assembly line. The mathematical model of optimizing workload from bothbalancing and sequencing has been established. A novel hybrid strategy based on immune clonalselection algorithm and local search algorithm has been brought up for this complex problem.According to the characteristic of the assembly line come up with the distributed self-controltechnology, variable cycle time has been adopted to further reduce the unbalance of the workstations.Considering the relationship between those variables, a hybrid co-evolutionary algorithm whichcombines both synchronous evolution and asynchronous evolution has been raised so that theperformance and efficiency of the algorithm can be improved. A simulation method using “Line”control and “method” control has been designed and applied in order to simulate the objectivefunction exactly.
Fourth, considering the lack of related researches for rebalancing problem, the rebalancing andsequencing problem caused by changing orders has been given. The strategy of adjusting sequencesusing single pull-off table between different lines has been proposed. Proper coding and decodingoperators of multiple–objective clonal selection algorithm have been designed for this resequencingproblem.
Based on the theory of this dissertation, the software of balancing and sequencing system hasbeen developed. This system has been divided to six functional modules: the production datamanagement module, the algorithm configuration module, the balancing module, the balancing andsequencing module, the sequencing module and the rebalancing module. This system can providetechnical support for the optimization of production considering different objectives of differentphases. The operating effects of this system has been elaborated and compared in detail in order toprove the correctness of the theory and the effectiveness of the system of this research.
At the end of this dissertation, the summary of the innovations in this research has been givenand the further research has been forecasted.
引文
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