基于Plant Simulation模具生产车间调度策略仿真研究

发布时间：2018-11-25 15:58

【摘要】：模具生产属于典型的小批量、多品种、订单式的生产模式,其生产过程存在较大的不确定性,例如：任务工时、机器故障发生的时间和修复时间、订单到达时间等等,而模具企业的供货周期、服务水平是模具企业的核心竞争力之一,因此模具生产调度问题既是一个难题又是模具生产管理技术中的重点。本文所研究的模具柔性流水车间调度问题属于最困难的约束组合优化问题和典型的NP难题,其特点是没有一个有效的算法能在多项式时间内求出其最优解。通过建立数学模型的分析方法往往具有一定局限性,一方面,其模型高度复杂而难以求得最优解,另一方面数学模型很难全面地反映模具制造系统中的许多实际生产特征,因此采用计算机仿真模拟技术来研究模具生产调度问题是一种较好的方法。通过实际调研,某轮胎模具企业钢花纹柔性流水车间环境下存在着工时不确定、机器故障以及急单到达等不确定因素,将导致加工任务的延期,而这些延期累积一定程度后将会对生产调度任务产生显著的影响,为此,本文提出了一种基于累积延期的反应式调度策略,然后采用Plant Simulation软件建立仿真模型,在该仿真模型上运行了所提出的策略,并通过实验验证和评价了该策略。本文的主要研究内容：一、建立了轮胎模具钢花纹柔性流水车间模型,明确了仿真的系统边界以及相关假设,并且通过对企业历史生产数据的定量分析建立了工件工时的离散概率模型,该结果是本文建立Plant Simulation仿真平台的数据基础。二、提出一种基于累积延期的反应式驱动方式,给出了工件累积延期的计算公式和反应式调度的驱动机制。三、通过对模具车间精车、CNC线切割、电火花加工三道序的实地调研,基于某企业的生产组织结构用Plant Simulation建立三阶段多台机模具柔性流水车间仿真模型,从生产流程、生产资源、工件模型等几个方面分析并建立Plant Simulation模型,然后通过Plant Simulation软件的功能模块以及Simtalk语言实现了本文所提出的基于累积延期的混合驱动反应式调度策略。四、设计仿真实验,通过改变关键参数产生多个情景研究所提出的策略的特性。然后,对比其他典型策略验证了本文所提出的基于累积延期的反应式策略的有效性。结论显示,本文所提出的策略能较好兼顾生产的稳定性和生产效率。本论文得到国家自然科学基金项目(编号50875051)资助。
[Abstract]:Die production is a typical small batch, multi-variety, order-type production mode, its production process has greater uncertainty, such as: task hours, machine failure and repair time, order arrival time, etc. The supply cycle and service level of mould enterprises are one of the core competitiveness of die and mould enterprises, so the scheduling problem of mould production is not only a difficult problem but also a key point in die production management technology. The flexible flow shop scheduling problem in this paper belongs to the most difficult constrained combinatorial optimization problem and the typical NP problem. Its characteristic is that there is no effective algorithm to find its optimal solution in polynomial time. The analytical method of establishing mathematical model often has some limitations. On the one hand, the model is highly complex and difficult to obtain the optimal solution, on the other hand, it is difficult to fully reflect many actual production characteristics in the mould manufacturing system. Therefore, it is a better method to use computer simulation technology to study die production scheduling problem. Through actual investigation, there are uncertain factors such as uncertain working hours, machine failure and urgent arrival in the steel pattern flexible flow workshop of a tire mould enterprise, which will lead to the delay of the processing task. However, these delays will have a significant impact on production scheduling tasks. Therefore, a reactive scheduling strategy based on cumulative delay is proposed, and then the simulation model is established by using Plant Simulation software. The proposed strategy is run on the simulation model, and the strategy is verified and evaluated by experiments. The main research contents of this paper are as follows: first, the model of tire mould steel pattern flexible flow shop is established, and the system boundary and related assumptions are defined. The discrete probability model of workpiece man-hour is established by quantitative analysis of enterprise historical production data, which is the data base of Plant Simulation simulation platform in this paper. Secondly, a reactive driving method based on cumulative delay is proposed, and the formula for calculating the cumulative delay of workpiece and the driving mechanism for reactive scheduling are given. Third, based on the field investigation of the three sequence of precision car, CNC wire cutting and EDM in the mould workshop, based on the production organization structure of a certain enterprise, the simulation model of flexible flow shop of three stage multi-machine mould is established with Plant Simulation, and from the production process, The Plant Simulation model is analyzed and established in several aspects such as production resources and workpiece model. Then the hybrid driven reactive scheduling strategy based on cumulative delay is implemented through the function modules of Plant Simulation software and Simtalk language. Fourthly, the simulation experiment is designed to produce the characteristics of several scenarios by changing the key parameters. Then, compared with other typical strategies, the effectiveness of the cumulative delay based response strategy proposed in this paper is verified. The conclusion shows that the strategy proposed in this paper can give good consideration to the stability and efficiency of production. This paper is supported by the National Natural Science Foundation of China (No. 50875051).
【学位授予单位】：广东工业大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH186

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