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轧辊热处理过程中若干调度问题的启发式算法研究
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摘要
轧辊行业属于钢铁制造行业的上层企业。轧辊生产工艺流程由造型、冶炼、浇铸、热处理、机加工等诸多工艺组成。其中,由于热处理工艺加工周期长、生产成本高,使其在轧辊生产工艺流程中处于突出重要的地位。近年来,随着钢铁行业的迅速发展,轧辊产品的需求量不断提高,轧辊企业的生产订单不断增加,造成热处理工艺中的加热炉数量相对减少,进而使得热处理过程成为整个生产工艺流程的瓶颈。因此,在现有资源条件下,如何提高热处理过程中加热炉的利用率,提高轧辊企业的生产管理水平,降低生产成本,提升企业竞争力具有十分重要的意义。
     本文以国内某机械轧辊企业生产与信息管理开发项目为依托,通过对企业的实地调研,并应用生产管理及系统工程的相关理论,在建立轧辊生产计划与调度体系构架的基础上,针对轧辊生产热处理过程中若干优化调度问题进行了研究。该研究是国家“973”项目(2009CB320601)和国家杰出青年基金项目(70625001)的重要组成部分。论文的主要研究工作包括以下五个方面:
     (1)对轧辊生产计划与调度过程进行了研究。通过分析轧辊生产工艺流程的特点以及实际生产中生产管理方法存在的问题,应用生产管理的相关理论知识,建立了轧辊生产计划与调度体系构架,并在该体系构架的基础上,建立了轧辊生产计划与调度系统功能结构图,为后续热处理过程中若干优化调度问题的研究奠定了基础;
     (2)针对面向热处理过程的辊坯组批和批次调度的单阶段优化调度问题进行了研究,该问题被归结为具有组批的并行机调度问题。建立了问题的数学模型,提出了三种辊坯组批启发式和三种批次调度启发式,并将其有效地结合对模型进行求解,通过对实验结果比较与分析,验证了算法的有效性,并针对该问题给出了相应的最佳求解方法;
     (3)针对面向热处理过程的批次指派和批次调度的单阶段优化调度问题进行了研究,该问题属于具有指派的并行机调度问题。针对问题中高温炉容积不同这一特点,分别对确定性指派和非确定性指派并行机调度问题提出了相应的指派启发式算法,并结合研究内容(2)中的批次调度启发式对建立的数学模型进行求解,在分析实验结果的基础上,我们得知应用调整最短加工时间辊坯批次的非确定性指派启发式算法得到的调度结果最优;
     (4)针对面向热处理过程的辊坯组批、批次指派及批次调度的单阶段集成决策问题进行了研究。建立了问题的数学模型,针对轧辊热处理实际生产中两种不同容积的高温炉数量相等的特点,提出了一种交替组批启发式算法,在批次调度阶段提出了一种采用顺序编码方式的遗传算法。通过实验结果的比较分析,验证了算法的可行性和有效性,为企业决策者合理安排生产提供依据;
     (5)针对面向热处理过程的加热炉容积相同情况下的多阶段优化调度问题进行了研究,该问题被归结为无等待混合流水车间调度问题。建立了问题的数学模型,针对辊坯批次在任意两个阶段间不允许等待这一特点,提出了一种分阶段无等待算法,并将该算法与离散粒子群优化算法相结合对模型求解,为了保证算法中的粒子始终保持顺序编码方式,提出了一种可行解调整策略。最后通过实验结果的比较分析,验证了算法的有效性,并给出了具有实际参考价值的设备改进策略,对生产决策者合理安排生产具有一定指导意义。
The mill roll industry is an upper-layer enterprise of the iron and steel manufacturing industry. The mill roll process flow is composed of the smelting, the molding, the casting, the heat treatment and the machining crafts and so on, in which the heat treatment plays a special important role because of the long processing cycle and high production costs in the mill roll process flow. In recent years, along with the rapid development of the iron and steel industry, the demand quantity of mill roll products and the production order quantity of the mill roll enterprise are increased continuously, which will lead to a reduction relatively for the heating quantity of the heat treatment. And then the heat treatment process becomes a bottleneck of the whole mill roll production flow. Therefore, under the condition of the existing resources, how to improve the utilization ratio of heating furnace in the heat treatment process, improve the production management level, and reduce production costs is very important to increase competitiveness of enterprises.
     In this dissertation, based on a production and information management development project of the machinery and mill roll enterprise in mainland China, and through investigating the actual situation of this enterprise and applying the relevant theories of the production management and the systems engineering, and then on the basis of establishing the system architecture of the mill roll production planning and scheduling, we establish the system function diagram of the mill roll production planning and scheduling. It lays a foundation for the following study on some optimization and scheduling problems of the mill roll heat treatment process. At the same time, it is a constituent part of the national '985'project (2009CB320601) and the'National Natural Science Funds for Distinguished Young Scholar project'(70625001).
     To sum up, this dissertation focuses on the five key problems:
     (1) We discuss the process of the mill roll production planning and scheduling. On the basis of analyzing the characteristics of the mill roll production flow and some production management problems in the actual production, and applying the relevant theory of the production management, the system architecture of the mill roll production planning and scheduling is built. This system architecture includes five function modules:data management, production contract making, master production planning making, monthly production planning and job scheduling making.
     (2) We study a single-stage optimization scheduling problem with the rough mill roll batching and the batch scheduling for the heat treatment process. This problem can be seen as a parallel machines scheduling problem with batch loading. On this basis, we tried to combine three rough mill roll batching heuristics with three batch scheduling heuristics to solve the built mathematical model. In the simulation experiment, the effectiveness of the algorithm is demonstrated by the comparisons and analyses of results. At last, the optimization solving method is given for this problem.
     (3) We discuss a single-stage optimization scheduling problem with the batch assignment and the batch scheduling for the heat treatment process. This problem belongs to a parallel machines scheduling problem with assignment. With regard to the high temperature furnaces with different volumes, we present different assignment heuristics for both the parallel machines scheduling with specified assignment and the parallel machines scheduling with unspecified assignment respectively. We tried to combine all assignment heuristics with batch scheduling heuristics of (2) to solve the built mathematical model. The last simulation experiments show that the optimization scheduling results of the adjusting roller batches of shortest processing time with unspecified assignment heuristics are superior to those of other assignment heuristics.
     (4) We discuss a single-stage integrated decision-making problem with the rough mill roll batching, the batch assignment and the batch scheduling for the heat treatment process. In this problem, because the number of high temperature furnaces is equal to that of low temperature furnaces, we present the alternative batching assignment heuristics during the batch assignment. Furthermore, we develop a genetic algorithm with the sequence encoding during the batch scheduling. At last, the effectiveness of the algorithm is demonstrated by the comparisons and analyses of results, and some methods are given for the policy-maker to arrange production reasonably.
     (5) We discuss a multi-stage optimization scheduling problem with the same volume of heating furnaces for the heat treatment process. This problem can be seen as a no-wait hybrid flow shop scheduling problem. According to the no-wait characteristic between two sequential operations of the batch, the no-wait algorithm in stages is designed. Combined with the no-wait algorithm in stages, a discrete particle swarm optimization algorithm is developed to solve the integer-programming model. In order to assure the particle encoding still keep the sequential encoding we present a feasible solution adjustment method. At last, the effectiveness of the algorithm is demonstrated by the comparisons and analyses of results, and the equipment reformation strategies of actual reference value are given as well which is beneficial for the policy-maker to arrange production reasonably.
引文
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