面向绿色制造的机械加工系统任务优化调度方法研究
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摘要
绿色制造是一种以减少资源消耗、降低环境影响为主要目标的现代制造模式,是人类社会可持续发展战略在现代制造业中的体现,也是当前世界工业发达国家广泛关注的重要技术领域和产业发展方向。制造过程是直接产生资源消耗,排放环境污染物以及造成职业健康与安全问题的主要环节之一。如何减少制造过程中的资源消耗和环境影响,是开展绿色制造研究的主要目标之一。
机械加工过程是一种典型的制造过程。机械加工系统通过机械加工过程,将原材料或半成品转化为形状、尺寸、精度合格的成品或零部件的同时,消耗了大量的能量、物料资源,并产生了大量的废料、噪声等环境排放。目前,国内外对机械加工系统的资源消耗和环境影响问题开展了不少的研究,从产品设计、工艺方法等方面,提供了较好的解决方法和途径;而从生产优化运作的角度,综合考虑机械加工过程中资源消耗和环境影响问题的研究相对较少。本论文结合国家自然科学基金项目“面向绿色制造的机械加工任务优化调度方法研究(项目编号50475062)”以及国家科技支撑计划课题“制造企业生产过程绿色规划与优化运行技术(项目编号2006BAF02A03)”,对面向绿色制造的机械加工系统任务优化调度问题的提出、总体模型以及若干应用模型等内容进行了研究。
在论述了绿色制造的内涵、机械加工系统的绿色制造研究、以及生产过程的优化调度问题等相关内容的基础上,通过试验分析发现,生产优化调度中的调度方案不同,会对机械加工系统生产过程中的资源消耗和环境排放产生影响。基于此,提出了一种集成考虑资源消耗和环境影响因素的面向绿色制造的机械加工系统任务优化调度问题,对该问题进行了系统的描述,并从研究目的、对象、方法以及结果等方面,与传统的调度问题进行了对比分析。
在分析机械加工系统的资源环境属性的基础上,建立了面向绿色制造的机械加工系统任务优化调度的总体模型。首先建立了该总体模型的基本框架,该框架主要由资源环境属性分析以及面向绿色制造的调度模型等两个部分组成。通过资源环境属性分析,建立调度方法中的资源环境属性优化目标集;并通过构建一个由理想模型和应用模型组成的分层结构的多模型框架,对面向绿色制造的调度模型的建模进行了分析;引入资源环境系数矩阵,则可将各种资源环境优化目标集成到调度模型中,从而建立相应的应用模型。
在上述总体模型分析的基础上,开展面向绿色制造的机械加工系统任务优化调度的应用模型的研究。结合多模型框架中的节能型调度模型、节能&降噪型调度模型、以及面向资源&环境综合因素的调度模型等三种应用模型,以并行机问题为对象,对三种应用模型的建立,资源环境系数矩阵的建立,以及求解过程进行了研究和实例分析。
结合所建立的总体模型和应用模型,开发了一种面向绿色制造的机械加工系统任务优化调度应用支持原型系统,用于辅助车间生产调度人员在安排调度方案时,对加工过程中产生的资源消耗、环境影响等相关因素进行综合的决策分析。构建了该系统的体系结构,并对其基本的运行流程、功能模块设计以及数据库设计等进行了分析,最后结合某机床厂的齿轮加工车间对该系统的应用情况进行了介绍。
Green manufacturing is a modern manufacturing mode with goals of reducing resource consumption and environmental impacts, which is the embodiment of sustainable development in manufacturing industry, and is also the important technical area and industry development trends concerned extensively by the developed countries. Manufacturing processes is one of the primary activities which directly consume resources, and discharge environmental emission. Therefore, it is the main goal of green manufacturing to reduce the resource consumption and environmental impacts caused by manufacturing processes.
Machining is a typical kind of manufacturing process. Machining systems transform raw material or semi products into qualified final products or semi-final products by machining. Unfortunately, an amount of energy and material is consumed while a lot of waste and noise are discharged during the machining processes. At present, many researches have been carried on aiming at this issue, and some good solutions have been provided from the aspects of design and process planning. However, the research on the issue of reducing recourse consumption and environmental impacts at the operational of scheduling lever is rarely studied. With the foundation of the National Natural Science Foundation and National Key Project of Scientific and Technical Supporting Programs, this paper studies on the optimal scheduling method of machining tasks for green manufacturing, the details of which are presented below.
As the basis of the research, the introduction of green manufacturing, the issues of green manufacturing in machining systems, and the scheduling problems have been presented. Experiments have shown that the different scheduling schema influent the resource consumption and environmental impacts during the machining processes even if the same batch of tasks are been machined by the same machine system. Based on it, the scheduling problem for machining systems integrating with resource and environmental factors has been proposed, the schematic description of this problem has been presented, and the comparison between the traditional scheduling problem and the proposed one has been analyzed from the purpose, the objectives, the approaches, and the results.
The holistic model of the scheduling problem for green manufacturing has been established on the basis of the analysis of resource and environmental characteristics of machining systems. Firstly, the schematic framework of the holistic model has been built up, which consist of two primary parts of the analysis of resource and environmental characteristics and the scheduling model for green manufacturing. The analysis of resource and environmental characteristics is used for the scheduling objective sets of resource and environmental considerations, and the scheduling model for green manufacturing is a model framework with hierarchical configuration which is composed of the ideal model and the various practical models. The coefficient matrix about resource and environment is adopted to integrate the various objectives of resource and environmental factors into the scheduling models.
With regards to the hierarchical model framework, the practical models have been studied including the saving-energy scheduling model, the saving-energy & reducing-noise scheduling model, and the resource & environmental scheduling model. Considering the parallel machines scheduling problem, the establishment of the three practical models and related coefficient matrix, the procedures of solving the models are introduced, and some examples are presented as well.
Based on the research on the holistic model and practical models, the scheduling supporting system of machining tasks for green manufacturing has been developed, the function of which is benefit for the scheduling decision-making with consideration of resource consumption and environmental impacts. The architecture of the system is established, and the workflow, the design of function structure and database of the system are also given. The case in a certain gear machining shop floor is shown to demonstrate the system.
机械加工过程是一种典型的制造过程。机械加工系统通过机械加工过程,将原材料或半成品转化为形状、尺寸、精度合格的成品或零部件的同时,消耗了大量的能量、物料资源,并产生了大量的废料、噪声等环境排放。目前,国内外对机械加工系统的资源消耗和环境影响问题开展了不少的研究,从产品设计、工艺方法等方面,提供了较好的解决方法和途径;而从生产优化运作的角度,综合考虑机械加工过程中资源消耗和环境影响问题的研究相对较少。本论文结合国家自然科学基金项目“面向绿色制造的机械加工任务优化调度方法研究(项目编号50475062)”以及国家科技支撑计划课题“制造企业生产过程绿色规划与优化运行技术(项目编号2006BAF02A03)”,对面向绿色制造的机械加工系统任务优化调度问题的提出、总体模型以及若干应用模型等内容进行了研究。
在论述了绿色制造的内涵、机械加工系统的绿色制造研究、以及生产过程的优化调度问题等相关内容的基础上,通过试验分析发现,生产优化调度中的调度方案不同,会对机械加工系统生产过程中的资源消耗和环境排放产生影响。基于此,提出了一种集成考虑资源消耗和环境影响因素的面向绿色制造的机械加工系统任务优化调度问题,对该问题进行了系统的描述,并从研究目的、对象、方法以及结果等方面,与传统的调度问题进行了对比分析。
在分析机械加工系统的资源环境属性的基础上,建立了面向绿色制造的机械加工系统任务优化调度的总体模型。首先建立了该总体模型的基本框架,该框架主要由资源环境属性分析以及面向绿色制造的调度模型等两个部分组成。通过资源环境属性分析,建立调度方法中的资源环境属性优化目标集;并通过构建一个由理想模型和应用模型组成的分层结构的多模型框架,对面向绿色制造的调度模型的建模进行了分析;引入资源环境系数矩阵,则可将各种资源环境优化目标集成到调度模型中,从而建立相应的应用模型。
在上述总体模型分析的基础上,开展面向绿色制造的机械加工系统任务优化调度的应用模型的研究。结合多模型框架中的节能型调度模型、节能&降噪型调度模型、以及面向资源&环境综合因素的调度模型等三种应用模型,以并行机问题为对象,对三种应用模型的建立,资源环境系数矩阵的建立,以及求解过程进行了研究和实例分析。
结合所建立的总体模型和应用模型,开发了一种面向绿色制造的机械加工系统任务优化调度应用支持原型系统,用于辅助车间生产调度人员在安排调度方案时,对加工过程中产生的资源消耗、环境影响等相关因素进行综合的决策分析。构建了该系统的体系结构,并对其基本的运行流程、功能模块设计以及数据库设计等进行了分析,最后结合某机床厂的齿轮加工车间对该系统的应用情况进行了介绍。
Green manufacturing is a modern manufacturing mode with goals of reducing resource consumption and environmental impacts, which is the embodiment of sustainable development in manufacturing industry, and is also the important technical area and industry development trends concerned extensively by the developed countries. Manufacturing processes is one of the primary activities which directly consume resources, and discharge environmental emission. Therefore, it is the main goal of green manufacturing to reduce the resource consumption and environmental impacts caused by manufacturing processes.
Machining is a typical kind of manufacturing process. Machining systems transform raw material or semi products into qualified final products or semi-final products by machining. Unfortunately, an amount of energy and material is consumed while a lot of waste and noise are discharged during the machining processes. At present, many researches have been carried on aiming at this issue, and some good solutions have been provided from the aspects of design and process planning. However, the research on the issue of reducing recourse consumption and environmental impacts at the operational of scheduling lever is rarely studied. With the foundation of the National Natural Science Foundation and National Key Project of Scientific and Technical Supporting Programs, this paper studies on the optimal scheduling method of machining tasks for green manufacturing, the details of which are presented below.
As the basis of the research, the introduction of green manufacturing, the issues of green manufacturing in machining systems, and the scheduling problems have been presented. Experiments have shown that the different scheduling schema influent the resource consumption and environmental impacts during the machining processes even if the same batch of tasks are been machined by the same machine system. Based on it, the scheduling problem for machining systems integrating with resource and environmental factors has been proposed, the schematic description of this problem has been presented, and the comparison between the traditional scheduling problem and the proposed one has been analyzed from the purpose, the objectives, the approaches, and the results.
The holistic model of the scheduling problem for green manufacturing has been established on the basis of the analysis of resource and environmental characteristics of machining systems. Firstly, the schematic framework of the holistic model has been built up, which consist of two primary parts of the analysis of resource and environmental characteristics and the scheduling model for green manufacturing. The analysis of resource and environmental characteristics is used for the scheduling objective sets of resource and environmental considerations, and the scheduling model for green manufacturing is a model framework with hierarchical configuration which is composed of the ideal model and the various practical models. The coefficient matrix about resource and environment is adopted to integrate the various objectives of resource and environmental factors into the scheduling models.
With regards to the hierarchical model framework, the practical models have been studied including the saving-energy scheduling model, the saving-energy & reducing-noise scheduling model, and the resource & environmental scheduling model. Considering the parallel machines scheduling problem, the establishment of the three practical models and related coefficient matrix, the procedures of solving the models are introduced, and some examples are presented as well.
Based on the research on the holistic model and practical models, the scheduling supporting system of machining tasks for green manufacturing has been developed, the function of which is benefit for the scheduling decision-making with consideration of resource consumption and environmental impacts. The architecture of the system is established, and the workflow, the design of function structure and database of the system are also given. The case in a certain gear machining shop floor is shown to demonstrate the system.
引文
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