再制造系统车间调度研究
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摘要
随着资源危机和环境污染问题的日益严重,制造业在保持竞争力的同时,又要实现发展的可持续性,这一客观要求使得竞争性可持续制造(CSM)成为未来制造业发展的必然选择。再制造是CSM的重要组成部分,是实现可持续发展的重要途径。本文对其核心技术“再制造系统车间调度”进行了研究,主要工作和创新点如下:
     根据制造业的发展历程,指出CSM是未来制造业的发展方向,论述了再制造在CSM中的重要地位及其研究意义,对再制造系统车间调度相关内容的研究现状及其存在的主要问题进行了归纳和总结;并从再制造系统的系统组成、工作流程和实施再制造系统的主要模式等3个方面,阐述了再制造系统车间调度的运行环境。然后,研究了再制造系统车间调度的关键技术,提出了再制造系统车间调度的体系结构。
     对独立再制造系统大批量生产线的车间调度问题进行了研究。根据再制造修复时间的不确定性和再制造系统机加工和表面热处理共同存在的特殊生产状况,建立了考虑再制造系统特殊工序间存储策略的大批量生产线模糊调度数学模型,并设计了相应的OGA算法,针对OGA算法收敛速度慢和易于陷入局部收敛的问题,提出了基于精英交叉(EGA)和小生境域密度选择策略的ENGA算法。通过对某独立再制造企业废旧发动机缸体大批量再制造生产实例的研究,证明了本文建立的调度模型和提出的ENGA算法的正确性和有效性。最后,针对再制造系统存在诸多不确定性的特点,建立了最好解的鲁棒性评价模型,并通过模型选择出鲁棒性最优的解。
     对制造/再制造混合系统的车间调度问题进行了研究。针对废旧零部件再制造修复时间服从一定概率分布的特性,建立了制造/再制造混合系统随机期望值调度模型,模型根据制造/再制造混合系统的订单交货期要求,以新品制造费用、废旧品再制造费用和延迟惩罚费用等最小为目标,解决制造/再制造混合系统的任务分配和再制造系统的生产排序问题。针对包含随机再制造修复时间的期望值模型,提出了基于随机模拟、神经网络和遗传算法的HIA算法,为了提高算法的运行速度,针对制造/再制造混合系统的调度问题要求,提出了EDD-LPT启发式算法,并给出了EDD-LPT启发式算法的最坏误差界。最后,通过实例仿真证明了模型和算法的正确性。
     对再制造系统集成调度问题进行了研究。无论独立再制造系统还是制造/再制造混合系统都面临着系统平衡性和协调性的难题。针对该问题,选择再制造系统的可再制造性评价、再制造工艺规划与再制造修复的集成(IOARPPR)以及再制造拆卸与再制造装配的集成(IODA)为研究对象,对再制造系统的集成调度进行研究。对于IOARPPR问题,建立了废旧零部件的可再制造性评价模型,通过对废旧零部件的可再制造性评价,确定出可再制造件的工艺路线及其对应的可再制造度,然后,建立了再制造系统修复车间的集成调度模型,并通过双层遗传算法求解出最优工艺路线组合及其对应的最优调度结果;对于IODA问题,以零部件在拆卸与装配过程中的供给与需求的比例关系为纽带,建立了再制造系统拆卸与装配的集成调度模型,并提出了两阶段遗传算法和启发式自适应遗传算法分别对其进行求解,得到废旧品拆卸的最佳数量和最优拆卸序列。最后,分别对IOARPPR和IODA的集成调度问题进行了实例研究。
     提出了再制造系统的信息集成框架模型;从再制造车间调度系统的运行环境、Delphi与Matlab的集成、系统功能模块设计和车间调度软件的使用方法等4个方面对再制造车间调度系统的总体设计进行了研究;开发出再制造车间调度原型系统,证明了本文研究的再制造系统车间调度理论的可行性。
As the resourse crisis and environmental pollution are becoming more and more serious,the manufacturing industry needs to keep competion, and to achieve sustainable development.Thus, the competitive and sustainable manufacturing (CSM) is inevitable for manufacturingindustry developing. While,remanufacturing is an important component of CSM, and animportant way for achieving sustainable development. This dillertation emphasised on“scheduling of remanufacturing system”, the main contain and innovation is following:
     According to the development of manufacturing, this dissertation proposed that CSM isdeveloping direction of manufacturing in future, discussed the important position and researchsignificance of remanufacturing to CSM, and summarized research status of scheduling forremanufacturing and existing main problems. In addition, operating environment ofscheduling in remanufacturing system was discussed with consideration of systemcomposition, work flow and main modes. Finally, the key technologies of scheduling forremanufacturing system was researched, and the architecture of scheduling forremanufacturing system was proposed.
     Mass production line scheduling problem for independent remanufacturing system wasstudied. Considering the uncertainty of remanufacturing repair time and special productionconditions, those conditions under which machining and surface heat treatment co-exist inremanufacturing system, the mass production line fuzzy mathematical model for schedulingwas built up with considering storage strategy between special processes in remanufacturingsystem, and OGA algorithm was also designed. The shortcoming of ordinary geneticalgorithm is reflected in slow convergence and easy to fall into local optimum, soelitist-crossover niching genetic algorithm was proposed based on elitist-crossover and nichedomain density selection strategy. Then, the example of mass production for engine cylinderremanufacturing from an independent remanufacturer was simulated through the algorithmmodel, which results show that scheduling model and the proposed ENGA algorithm arefeasible. Finally, according to many characteristics of uncertainty in the remanufacturingsystems, a robust evaluation model was built up for optimal solution of scheduling problem,and choose the solution with best robustness through example calculation
     The scheduling problem of manufacturing/remanufacturing system was studied in thisdillertation. Because of the characteristic of the time which was cost in the process of wasteparts remanufacturing obey probability distribution function, a random expectationsnumerical scheduling model of manufacturing/remanufacturing system was set up. In here,take the time of manufacturing/remanufacturing system order delivery as the requirementsconditions, and take the least cost of new product manufacturing, the least cost of wasteproduct remanufacturing and least delay penalty fees as the solving target. Above all in orderto solve the problem of task assignment for manufacturing/remanufacturing system andremanufacturing production order. According to the expected value model with randomremanufacturing time, HIA algorithm was suggested base on random simulation, neuralnetwork and genetic algorithm in this dillertation. In order to improve the speed of algorithm,EDD-LPT heuristic algorithm was also suggested on the basis of the requirements of theproblem of scheduling, and its worst error bounds of this algorithm was provided. Finally,through the simulation proved the correctness of the proposed algorithm and the model.
     In this dillertation, meanwhile, the integrated scheduling problem of remanufacturingsystem scheduling was studied. The balance and coordination of system are very difficultproblems no matter independent remanufacturing system or manufacturing/remanufacturingsystem. Aiming at this issue, take the integrated optimization for assessment ofremanufacturability, process planning and scheduling of repair shop, the integratedoptimization of remanufacturing disassemble and remanufacturing assembly as the researchobject, the integrated scheduling problem of remanufacturing system was studied; ForIOARPPR problem, the assessment model of remanufacturability of the waste parts was setup, through which, the process route and corresponding remanufacture degrees weredetermined. Then, the scheduling model for repair workshop of remanufacturing system wasset up, and the optimal combination process route and the corresponding optimal schedulingresults were solved through the double genetic algorithm; For IODA problem, the assemblyscheduling model of remanufacturing system was established. On the base of parts deliverytime and the optimal scheduling assembly time of remanufacturing, quantity and completiontime of remanufacturable parts were obtained through the rumsfeld decomposition, therebyintegrated optimization between manufacturing assembly shop and repair shop was correspondly realized. And then the two-stage genetic algorithm and heuristic adaptivegenetic algorithm were put forward for solving IODA problem. Finally, examples ofintegrated scheduling for IOARPPR and IODA were studied.
     The information integration framework model of the remanufacturing system wasproposed. And then the overall design of the production scheduling system for theremanufacturing system was elaborated from four aspects as operating environment of theproduction scheduling system、Delphi and Matlab integration、the features modular design ofthe remanufacturing system and how to use the production scheduling software. Finally, therunning instance of production scheduling system for remanufacturing system was given,which proved the feasibility of the theory studied in this dillertation.
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