网络联盟制造环境下生产过程快速响应技术研究
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摘要
制造业面临的市场变化日益频繁且无法预知,客户需求的个性化和多样化,导致产品生命周期缩短、更新速度不断加快。为了在激烈的市场竞争中取胜,企业应能适时动态地调整其制造模式和控制策略,以支持对市场的快速反应。网络联盟制造是适合中小型制造企业的一种生产模式,它通过网络实现制造资源、制造信息的集成与共享,通过联盟企业的协作提高制造系统的敏捷性、柔性和市场应变能力。本文针对装备制造业的生产特点,研究网络联盟制造环境下生产过程快速响应策略及其关键技术,以期满足多变的客户化生产需求。
1.研究了制造企业生产过程的快速响应机制,建立了基于网络联盟及资源共享的快速响应系统的结构模型,期望从企业联盟构建层、客户需求分析层、生产任务规划层、生产资源重构层、生产调度实施层五个层次提升制造系统的快速响应性能,并对系统的结构与功能模型进行分析和描述,从而形成生产过程快速响应体系结构。
2.提出一种基于服务资源匹配的制造企业联盟构建方法。以资源描述框架的数据模型为基础,建立了制造服务资源描述模型和服务资源匹配策略；给出了服务资源的定性属性匹配和定量属性匹配算法；建立了服务资源的匹配搜索流程,从而实现利用网络制造服务资源共享平台,形成更广范围的企业联盟,以便更加及时地得到联盟企业的生产技术支持。
3.依据Agent的基础结构,建立了基于多Agent的生产过程快速响应系统的结构模型,重点研究了客户需求向生产需求转变过程的Agent辅助；在深入研究该辅助模式下生产任务规划策略的基础上,提出了基于退火进化算法的生产任务分配优化方法,实现以招投标结果为基础的综合评标,从而获得生产任务的全局最优分配方案；借助可靠性理论,提出一种提高多Agent系统可靠性的并联结构,构造出可靠性最大化问题的求解算法。
4.提出了基于多色集合理论的系统资源重构建模方法和方案评价指标体系,利用元素、个人颜色、统一颜色等概念,建立制造资源与系统功能的映射关系,通过搜索围道布尔矩阵来获得系统资源重构的方案。在此基础上,探讨了重构方案评价指标的选取、处理和评价方法。其中,提出功能冗余度作为重构方案的重要评价指标,并给出该指标的有效计算方法。从而实现不同生产需求的生产资源快速组织。
5.研究了多订单生产环境下的计划与调度集成优化问题,在充分考虑产品的结构约束、资源能力约束、提前-延期惩罚、设备间的运输时间以及多工艺路线问题等的基础上建立了单件生产和小批量生产模式下的问题规划模型。设计了带精英策略的蚁群求解算法,实现了直接面向多个订单的工序级任务调度,将计划层与调度层统一起来,避免计划与调度衔接过程中约束关系的丢失,便于获得全局最优解。实例运行验证了蚁群算法求解该问题的可行性及算法性能的优越性。
在上述研究的基础上,建立了一个生产过程快速响应原型系统,完成了基于JSP的生产过程快速响应系统软件的开发,通过在企业的部分应用进一步验证了本文所提理论和方法的正确性和可行性。
Market changes that manufacturings face are frequent and unpredictable, and customers' requirements are individualized and diversified, which lead to the shortening of product cycle and the speeding up of product updating. Thus, enterprises should dynamically adjust their manufacturing mode and controlling strategy to make quick response to the changing market so as to succeed in the intense market competition. Network alliance manufacturing is a kind of production mode which is suitable for the medium and small-sized enterprises. It fulfills the manufacturing information integration and resources sharing by means of network; enhaces manufacturing system's agility, flexibility, and ability of meeting market by means of alliance cooperation. Aiming at the production feature of equipment manufacturing, this dissertation studies the rapid response strategies and key technologies of the production process under the network alliance manufacturing environment so as to satisfy customized requirements.
1. Rapid response mechanism of the production process is studied, and structure mode of the response system based on network alliance and resources'sharing is established in this research. The improvement of manufacturing system's response property is expected to be achieved from such five levels as enterprise alliance constructing, customer requirements analyzing, production task palnning, production resources reconfigurating, and production schedule executing. And the response system's structure and function model are analyzed and described so as to formulate rapid response architecture of the production process.
2. Constructing method of manufacturing enterprise alliance based on service resources matching is put forword. Taking the data model of resource description framework as the basis, manufacturing service resource description model and matching strategy are established, service resources'qualitative property matching and quantitative property matching algorithm are presented, and service resources'searching flow is set up so that a more extensive enterprise alliance, which could promptly achieve other alliance enterprises'support, is formed by using the network manufacturing service sharing plateform.
3. On the basis of agent basic structure, multi-agent based structural model of the rapid response system in production process is set up, agent assistance in the transferring from customers'requrements to production requirements is studied; and on the basis of production task planning strategy under the circumstance of indepth study of this assistance mode, annealing evolution algorithm deduced optimal assigning method of production tasks is proposed, and synthetical biding evaluation which takes the tendering result as basis is realizes so that an overall optimal assigning scheme of production tasks is obtained. With the help of reliablity theory, a kind of parallel structure to improve the reliability of muti-agent system is propsed, and the algorithm that can solve the maximized problem of reliability is constructed.
4. Resource reconfiguration modeling method and its scheme evaluation indicator system based on polychromatic sets theory are proposed. Mapping relationship between manufacturing resources and system functions are established by the use of element, individual color sets as well as unified color sets. Resource reconfiguration schemes are achieved through searching the contour Boolean matrix. Selecting, processing and evaluating method of the reconfiguration scheme's evaluation indicator are discussed. In which, function redundancy proposed in this dissertation is an important evaluation indicator of the reconfiguration scheme, and its effective calculation method is given in this dissertation. Thereby, production resources rapid organizing of the different production requirements is achieved.
5. Production planning and scheduling integrated optimization problem is studied under the multi-order environment. Integer programming models of the individual production and small-lot production are established based on the consideration of product assembly structure constraint, resource capacity constraint, earliness-tardiness penalty, transporting time, and multi-process route problems. The ant colony algorithm with elitist strategy is designed to achieve multiorder-oriented task scheduling, thus planning layer and scheduling layer are unified which can avoid constraints losing in combining process of planning and scheduling. The feasibility of ant colony algorithm to solve the problem and the superiority of arithmetic performance are verified by means of running some practical instances.
On the basis of the aforementioned study, a rapid response prototype system of production process is established, and the rapid response system software based on java server pages is developed. The correctness and feasibility of this dissertation proposed theory and method are further verified through partial applications in enterprises.
1.研究了制造企业生产过程的快速响应机制,建立了基于网络联盟及资源共享的快速响应系统的结构模型,期望从企业联盟构建层、客户需求分析层、生产任务规划层、生产资源重构层、生产调度实施层五个层次提升制造系统的快速响应性能,并对系统的结构与功能模型进行分析和描述,从而形成生产过程快速响应体系结构。
2.提出一种基于服务资源匹配的制造企业联盟构建方法。以资源描述框架的数据模型为基础,建立了制造服务资源描述模型和服务资源匹配策略；给出了服务资源的定性属性匹配和定量属性匹配算法；建立了服务资源的匹配搜索流程,从而实现利用网络制造服务资源共享平台,形成更广范围的企业联盟,以便更加及时地得到联盟企业的生产技术支持。
3.依据Agent的基础结构,建立了基于多Agent的生产过程快速响应系统的结构模型,重点研究了客户需求向生产需求转变过程的Agent辅助；在深入研究该辅助模式下生产任务规划策略的基础上,提出了基于退火进化算法的生产任务分配优化方法,实现以招投标结果为基础的综合评标,从而获得生产任务的全局最优分配方案；借助可靠性理论,提出一种提高多Agent系统可靠性的并联结构,构造出可靠性最大化问题的求解算法。
4.提出了基于多色集合理论的系统资源重构建模方法和方案评价指标体系,利用元素、个人颜色、统一颜色等概念,建立制造资源与系统功能的映射关系,通过搜索围道布尔矩阵来获得系统资源重构的方案。在此基础上,探讨了重构方案评价指标的选取、处理和评价方法。其中,提出功能冗余度作为重构方案的重要评价指标,并给出该指标的有效计算方法。从而实现不同生产需求的生产资源快速组织。
5.研究了多订单生产环境下的计划与调度集成优化问题,在充分考虑产品的结构约束、资源能力约束、提前-延期惩罚、设备间的运输时间以及多工艺路线问题等的基础上建立了单件生产和小批量生产模式下的问题规划模型。设计了带精英策略的蚁群求解算法,实现了直接面向多个订单的工序级任务调度,将计划层与调度层统一起来,避免计划与调度衔接过程中约束关系的丢失,便于获得全局最优解。实例运行验证了蚁群算法求解该问题的可行性及算法性能的优越性。
在上述研究的基础上,建立了一个生产过程快速响应原型系统,完成了基于JSP的生产过程快速响应系统软件的开发,通过在企业的部分应用进一步验证了本文所提理论和方法的正确性和可行性。
Market changes that manufacturings face are frequent and unpredictable, and customers' requirements are individualized and diversified, which lead to the shortening of product cycle and the speeding up of product updating. Thus, enterprises should dynamically adjust their manufacturing mode and controlling strategy to make quick response to the changing market so as to succeed in the intense market competition. Network alliance manufacturing is a kind of production mode which is suitable for the medium and small-sized enterprises. It fulfills the manufacturing information integration and resources sharing by means of network; enhaces manufacturing system's agility, flexibility, and ability of meeting market by means of alliance cooperation. Aiming at the production feature of equipment manufacturing, this dissertation studies the rapid response strategies and key technologies of the production process under the network alliance manufacturing environment so as to satisfy customized requirements.
1. Rapid response mechanism of the production process is studied, and structure mode of the response system based on network alliance and resources'sharing is established in this research. The improvement of manufacturing system's response property is expected to be achieved from such five levels as enterprise alliance constructing, customer requirements analyzing, production task palnning, production resources reconfigurating, and production schedule executing. And the response system's structure and function model are analyzed and described so as to formulate rapid response architecture of the production process.
2. Constructing method of manufacturing enterprise alliance based on service resources matching is put forword. Taking the data model of resource description framework as the basis, manufacturing service resource description model and matching strategy are established, service resources'qualitative property matching and quantitative property matching algorithm are presented, and service resources'searching flow is set up so that a more extensive enterprise alliance, which could promptly achieve other alliance enterprises'support, is formed by using the network manufacturing service sharing plateform.
3. On the basis of agent basic structure, multi-agent based structural model of the rapid response system in production process is set up, agent assistance in the transferring from customers'requrements to production requirements is studied; and on the basis of production task planning strategy under the circumstance of indepth study of this assistance mode, annealing evolution algorithm deduced optimal assigning method of production tasks is proposed, and synthetical biding evaluation which takes the tendering result as basis is realizes so that an overall optimal assigning scheme of production tasks is obtained. With the help of reliablity theory, a kind of parallel structure to improve the reliability of muti-agent system is propsed, and the algorithm that can solve the maximized problem of reliability is constructed.
4. Resource reconfiguration modeling method and its scheme evaluation indicator system based on polychromatic sets theory are proposed. Mapping relationship between manufacturing resources and system functions are established by the use of element, individual color sets as well as unified color sets. Resource reconfiguration schemes are achieved through searching the contour Boolean matrix. Selecting, processing and evaluating method of the reconfiguration scheme's evaluation indicator are discussed. In which, function redundancy proposed in this dissertation is an important evaluation indicator of the reconfiguration scheme, and its effective calculation method is given in this dissertation. Thereby, production resources rapid organizing of the different production requirements is achieved.
5. Production planning and scheduling integrated optimization problem is studied under the multi-order environment. Integer programming models of the individual production and small-lot production are established based on the consideration of product assembly structure constraint, resource capacity constraint, earliness-tardiness penalty, transporting time, and multi-process route problems. The ant colony algorithm with elitist strategy is designed to achieve multiorder-oriented task scheduling, thus planning layer and scheduling layer are unified which can avoid constraints losing in combining process of planning and scheduling. The feasibility of ant colony algorithm to solve the problem and the superiority of arithmetic performance are verified by means of running some practical instances.
On the basis of the aforementioned study, a rapid response prototype system of production process is established, and the rapid response system software based on java server pages is developed. The correctness and feasibility of this dissertation proposed theory and method are further verified through partial applications in enterprises.
引文
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