基于虚拟现实的齿轮加工设备布局与仿真技术研究
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摘要
随着齿轮工业的飞速的发展,在现有齿轮加工车间设备布局下的生产模式已经不能够适应其变化速度,造成了齿轮加工物流不畅、齿轮制造周期不能满足交货期的要求,生产调度失灵等问题,给车间生产管理带来许多难题。为此重新设计齿轮加工车间的设备布置和改造原有车间设备布置即有其现实意义,又可为后续发展提供动力。本篇文章通过分析齿轮加工工艺研究了齿轮加工车间设备布局的方法,建立齿轮加工车间布置模型,在Flexsim中模拟了齿轮加工车间设备布置方案,进行齿轮生产系统仿真寻找生产瓶颈,从而提出潜在的可行改进方案。本文主要从以下几个方面着手研究：
(1)在分析了各种齿轮生产工艺的基础上,阐述了齿轮加工车间设备布置理论。并在此基础上建立齿轮加工车间设备布置抽象模型。通过改进的蚁群算法求解车间布置模型。针对齿轮加工车间混合布置模型提出了一种设计方法。
(2)运用基于Flexsim的虚拟现实系统仿真软件建立齿轮加工车间设备布置模型,并对齿轮加工设备布置模型进行修改。通过齿轮生产系统仿真对设备布置方案进行评价。
(3)将Flexsim中建立齿轮生产系统仿真模型的仿真过程分为三步：
第一步,对齿轮生产过程的数据(如、齿轮加工时间、故障停机时间等)进行收集、拟合、估计；
第二步,对齿轮生产系统仿真模型检验,确定与现实齿轮加工车间生产系统的符合度；
第三步,运行仿真试验、分析仿真模型输出数据,寻找系统瓶颈并提出可行的改进方案。
(4)以某企业厂锥齿轮生产线为例建立系统仿真模型,提出改进方案。运行结果显示生产线满足生产需求,设备利用率达到预期期望。
With the development of market economy, the gear industry in China has developed quickly, while the workshop manufacturing pattern is developing too slowly to catch up with it, which led to many problems to gear industry, just like logistics influence, the manufacturing cycle fails to full fill the sales requirement, as well as production schedule failures. All these matters make troubles to the manufacturing management. To solve these problems, redesigning and reforming the equipment arrangement of the gear job shop seems necessary and meaningfull, and also can offer power to the following development. This paper researched the method of gear job shop equipment arrangement through analyzing gear manufacturing process, set up the job shop arrangement model, imitated gear job shop equipment arrangement programs with virtual reality of which based on Web, finally found the bottleneck in the gear manufacturing system emulation in Flexsim from which proposed the potential feasible improvement program. In this paper, the main contents can be summarized as follows:
Based on the analysis of various gear manufacturing processes, stated gear job shop equipment arrangement theory, on which basis established gear job shop equipment arrangement abstract model and solve facility layout model through the improved ACO. Finally offered one design measure in view of gear work shop mixed arrangement.
Established Gear layout model with virtual reality technology based on Flexsim. realized arrangement model changes through human-computer interaction. Carried on appraisal through gear production system simulation to the work shop arrangement plan.
Built a gear manufacturing system simulation model in Flexsim, and divided the simulation into three steps:
First, collecting, fitting and estimating the gear production process data (eg, the manufacturing time, downtime, etc.);
Second, inspecting the gear production system simulation model.
Third, run the simulation test and analyze simulation model output data, to look for the system bottlenecks and propose possible improved program.
Finally, built a system simulation model in the example of one factory bevel gear production line, offered an improved program. The results showed that the improved production line meets the production requirements, and equipment utilization achieves the desired expectations.
(1)在分析了各种齿轮生产工艺的基础上,阐述了齿轮加工车间设备布置理论。并在此基础上建立齿轮加工车间设备布置抽象模型。通过改进的蚁群算法求解车间布置模型。针对齿轮加工车间混合布置模型提出了一种设计方法。
(2)运用基于Flexsim的虚拟现实系统仿真软件建立齿轮加工车间设备布置模型,并对齿轮加工设备布置模型进行修改。通过齿轮生产系统仿真对设备布置方案进行评价。
(3)将Flexsim中建立齿轮生产系统仿真模型的仿真过程分为三步：
第一步,对齿轮生产过程的数据(如、齿轮加工时间、故障停机时间等)进行收集、拟合、估计；
第二步,对齿轮生产系统仿真模型检验,确定与现实齿轮加工车间生产系统的符合度；
第三步,运行仿真试验、分析仿真模型输出数据,寻找系统瓶颈并提出可行的改进方案。
(4)以某企业厂锥齿轮生产线为例建立系统仿真模型,提出改进方案。运行结果显示生产线满足生产需求,设备利用率达到预期期望。
With the development of market economy, the gear industry in China has developed quickly, while the workshop manufacturing pattern is developing too slowly to catch up with it, which led to many problems to gear industry, just like logistics influence, the manufacturing cycle fails to full fill the sales requirement, as well as production schedule failures. All these matters make troubles to the manufacturing management. To solve these problems, redesigning and reforming the equipment arrangement of the gear job shop seems necessary and meaningfull, and also can offer power to the following development. This paper researched the method of gear job shop equipment arrangement through analyzing gear manufacturing process, set up the job shop arrangement model, imitated gear job shop equipment arrangement programs with virtual reality of which based on Web, finally found the bottleneck in the gear manufacturing system emulation in Flexsim from which proposed the potential feasible improvement program. In this paper, the main contents can be summarized as follows:
Based on the analysis of various gear manufacturing processes, stated gear job shop equipment arrangement theory, on which basis established gear job shop equipment arrangement abstract model and solve facility layout model through the improved ACO. Finally offered one design measure in view of gear work shop mixed arrangement.
Established Gear layout model with virtual reality technology based on Flexsim. realized arrangement model changes through human-computer interaction. Carried on appraisal through gear production system simulation to the work shop arrangement plan.
Built a gear manufacturing system simulation model in Flexsim, and divided the simulation into three steps:
First, collecting, fitting and estimating the gear production process data (eg, the manufacturing time, downtime, etc.);
Second, inspecting the gear production system simulation model.
Third, run the simulation test and analyze simulation model output data, to look for the system bottlenecks and propose possible improved program.
Finally, built a system simulation model in the example of one factory bevel gear production line, offered an improved program. The results showed that the improved production line meets the production requirements, and equipment utilization achieves the desired expectations.
引文
[1]胡广华.制造车间布局优化方法研究与系统实现[D].华中科技大学博士学位论文.2007.1-3
[2]http://baike.baidu.com/view/25045.htm.百度百科.2010
[3]贝炳林.车间布局综合评价[D].上海交通大学硕士学位论文.2006：3-4
[4]谷雪峰.F集团A生产车间设施布局改善研究及应用[D].重庆大学.2009：6
[5]刘弟新.机械加工设备布局方法及其仿真技术研究[D].大连理工大学.2006：2-6：
[6]Kouvelis. Practical Plant Layout. McGraw-Hill, MI, NY,1995.
[7]成孟金,赵飞.简化线性规划模型的方法研究及实现[J].计算机与信息技术,2009,(03).36-37
[8]张景.基于AHP及混合整数规划法的配送中心选址[J].浙江交通职业技术学院学报,2009,(02)：102-103
[9]丰建荣,刘志河,刘正和.混合整数规划问题遗传算法的研究及仿真实现[J].系统仿真学报,2004,(04)：87-89
[10]张亚南,阚树林,王越.用蚁群算法解决动态设施布置问题[J].工业工程,2007,(02)：22-23
[11]奚文,李靖.面向机械制造系统设施布置的优化模型[J].机电一体化,2008,(01).
[12]楼洪梁,杨将新,林亚福,胡建坤,吴昭同,盛伯浩.基于图论的可重构制造系统重构策略[J].机械工程学报,2006,(03).
[13]窦建平,戴先中,孟正大.基于图论的可重构制造系统重构方案选择[J].计算机集成制造系统,2007,(07).
[14]孙焰,郑文家.基于重心模型和层次分析法的配送中心选址研究[J].物流科技,2009,(03).
[15]于哲舟,吕聪颖,周春光.二次分配问题的粒子群算法求解[J].计算机工程与应用,2005.
[16]Drezner Z. Anewgenetic algorithmfor the quadratic assign-ment problem.Informs Journal on Computing,2003,15 (3):320-330.
[17]Marcello Braglia, Simone Zanon, Lucio Zavanella. Layout design in dynamic environments: strategies and quantitative indices[J].TNT.J.PROD.RES,2003,41(5):995-1016.
[18]Leonardo Chwif, Marcos R. Pereira Barretto, Lucas Antonio Moscato. A solution to the facility layout problem using simulated annealing.Computers in Industry,1998,36(1-2): 125-132
[19]S. Kirkpatrick, C.D.Gelatt, M.P. Vechhi. Optimization by Simulated Annealing.Science, 1983,220:671-680.
[20]Alfonsas Misevicius. A Tabu Search Algorithm for the Quadratic Assignment Problem[J]. Computational Optimization and Applications,2005,30(1).
[21].Talbi E G, Roux O, Fonlupt C, et al. Parallel ant colonies for the quadratic assignment problem.Future Generation Computer Systems,2001,17 (4):441-449.
[22]Kennedy J, Eberhart.R. Particle swarm optimization.Proceedings of IEEE International Conference on Neural Networks.IEEE.1995,:1942～1948.
[23]SUN Cui-cui LIN Du. Research on packing problem based on sequence pair and simulated annealing algorithm[C]. Microcomputer Information,2010.4
[24]苏小进.机械加工车间设备布局建模与算法研究[D].上海交通大学硕士学位论文.2009
[25]曹战.基于遗传算法的车间设备布局问题研究[D].大连交通大学硕士学位论文.2007
[26]姚伟.数字化生产车间的布局及优化研究[D].西安电子科技大学.2009
[27]昊良杰,魏东,刘刚.基于禁忌搜索和蚁群算法的广义分配问题研究[J].计算机工程与设计2009,30(15)3591
[28]路可臻,王祖朝,康辉英.一种针对QAP问题的改进蚁群算法研究[J].电脑知识与技术2007,19(2)：240
[29]Legato Pasquale, Mazza Rina M. Berth planning and resources optimization at a container terminal via discrete event simula-tion[J].Europe Journal of Research.2001,133:537-547
[30]金凤花.典型制造企业生产物流系统仿真[D].吉林大学,2007.
[31]施围.基于EXTEND的生产物流系统仿真研究[D].武汉理工大学,2006.
[32]Diego A Tacconi, Frank L Lewis. A New Matrix Model for Discrete Event Systems: Application to Simulation.IEEE Control Systems,1997,:62-71.
[33]赵骥, 肖田元, 赵银燕, 董建华, 王云莉.基于Internet的虚拟资源动态集成技术研究[J].计算机集成制造系统-CIMS,2002, (10)
[34]侯文皓.多单元柔性制造系统的人机比仿真建模与分析研究[D].上海交通大学,2006.
[35]刘昶,史海波,袁杰.基于广义随机Petri网的制造过程建模与分析方法[J].计算机集成制造系统,2008,09(6)：1704-1710.
[36]余流,姚锡凡,张征,于广.基于Flexsim的加工车间的仿真[J].微计算机信息.2009
[37]龚波.基于WITNESS的生产物流系统仿真研究[D].武汉理工大学,2008.
[38]边境.虚拟柔性制造仿真系统的研究与开发[D].天津大学.2008
[39]李昂,王继宁.齿轮加工工艺、质量检测与通用标准规范全书[M].
[40]李经民.机械加工车间设备布局模型及其评价算法的研究[D].大连交通大学硕士学位论文.2005
[41]陈彦飞.可重构制造系统设备布局规划技术研究[D].北京交通大学.2009
[42]郭彩芬.离散制造系统在制品库存控制[J].航空制造技术,2008,(09).
[43]晏干平.A公司冲压车间设备布局研究[D].重庆大学工程硕士学位论文.2008
[44]http://www.pmec.net/bencandy-22-46347-1.htm.中国设备管理网.2010
[45]齐二石.生产与运作管理教程[M].清华大学出版社.2006
[46]宋昌慧.改进遗传算法在设备布局问题中应用[D].南京理工大学硕士学位论文.2009
[47]张翠军,邹慧,张有华.基于二次分配问题的混合蚁群算法[J].计算机工程与应用,2008,(10)
[48]于瑞峰,王永县.手工装配作业单元的布局优化设计研究[J].工业工程管理.2004.2：36-39
[49]李士勇等.蚁群算法及其应用[M].哈尔滨工业大学出版社.2004
[50]Xia, Y., Yuan, Y. Anew linearization method for quadratic assignment problems. Optimization Methods and Software,2006,21 (5):803～816.
[51]Jerry Banks.肖田元,范文慧译.离散系统仿真(原书第四版).机械工业出版社.2007
[52]何智春.基于Flexsim的机加工车间设施布置目建模与仿真[D].武汉理工大学硕士学位论文.2009
[53]秦天保,王岩峰.面向应用的仿真建模与分析——使用ExtendSim[M].清华大学出版社.2009
[54]许香穗、蔡建国.成组技术(第2版)[M].机械工业出版社.2008
[2]http://baike.baidu.com/view/25045.htm.百度百科.2010
[3]贝炳林.车间布局综合评价[D].上海交通大学硕士学位论文.2006：3-4
[4]谷雪峰.F集团A生产车间设施布局改善研究及应用[D].重庆大学.2009：6
[5]刘弟新.机械加工设备布局方法及其仿真技术研究[D].大连理工大学.2006：2-6：
[6]Kouvelis. Practical Plant Layout. McGraw-Hill, MI, NY,1995.
[7]成孟金,赵飞.简化线性规划模型的方法研究及实现[J].计算机与信息技术,2009,(03).36-37
[8]张景.基于AHP及混合整数规划法的配送中心选址[J].浙江交通职业技术学院学报,2009,(02)：102-103
[9]丰建荣,刘志河,刘正和.混合整数规划问题遗传算法的研究及仿真实现[J].系统仿真学报,2004,(04)：87-89
[10]张亚南,阚树林,王越.用蚁群算法解决动态设施布置问题[J].工业工程,2007,(02)：22-23
[11]奚文,李靖.面向机械制造系统设施布置的优化模型[J].机电一体化,2008,(01).
[12]楼洪梁,杨将新,林亚福,胡建坤,吴昭同,盛伯浩.基于图论的可重构制造系统重构策略[J].机械工程学报,2006,(03).
[13]窦建平,戴先中,孟正大.基于图论的可重构制造系统重构方案选择[J].计算机集成制造系统,2007,(07).
[14]孙焰,郑文家.基于重心模型和层次分析法的配送中心选址研究[J].物流科技,2009,(03).
[15]于哲舟,吕聪颖,周春光.二次分配问题的粒子群算法求解[J].计算机工程与应用,2005.
[16]Drezner Z. Anewgenetic algorithmfor the quadratic assign-ment problem.Informs Journal on Computing,2003,15 (3):320-330.
[17]Marcello Braglia, Simone Zanon, Lucio Zavanella. Layout design in dynamic environments: strategies and quantitative indices[J].TNT.J.PROD.RES,2003,41(5):995-1016.
[18]Leonardo Chwif, Marcos R. Pereira Barretto, Lucas Antonio Moscato. A solution to the facility layout problem using simulated annealing.Computers in Industry,1998,36(1-2): 125-132
[19]S. Kirkpatrick, C.D.Gelatt, M.P. Vechhi. Optimization by Simulated Annealing.Science, 1983,220:671-680.
[20]Alfonsas Misevicius. A Tabu Search Algorithm for the Quadratic Assignment Problem[J]. Computational Optimization and Applications,2005,30(1).
[21].Talbi E G, Roux O, Fonlupt C, et al. Parallel ant colonies for the quadratic assignment problem.Future Generation Computer Systems,2001,17 (4):441-449.
[22]Kennedy J, Eberhart.R. Particle swarm optimization.Proceedings of IEEE International Conference on Neural Networks.IEEE.1995,:1942～1948.
[23]SUN Cui-cui LIN Du. Research on packing problem based on sequence pair and simulated annealing algorithm[C]. Microcomputer Information,2010.4
[24]苏小进.机械加工车间设备布局建模与算法研究[D].上海交通大学硕士学位论文.2009
[25]曹战.基于遗传算法的车间设备布局问题研究[D].大连交通大学硕士学位论文.2007
[26]姚伟.数字化生产车间的布局及优化研究[D].西安电子科技大学.2009
[27]昊良杰,魏东,刘刚.基于禁忌搜索和蚁群算法的广义分配问题研究[J].计算机工程与设计2009,30(15)3591
[28]路可臻,王祖朝,康辉英.一种针对QAP问题的改进蚁群算法研究[J].电脑知识与技术2007,19(2)：240
[29]Legato Pasquale, Mazza Rina M. Berth planning and resources optimization at a container terminal via discrete event simula-tion[J].Europe Journal of Research.2001,133:537-547
[30]金凤花.典型制造企业生产物流系统仿真[D].吉林大学,2007.
[31]施围.基于EXTEND的生产物流系统仿真研究[D].武汉理工大学,2006.
[32]Diego A Tacconi, Frank L Lewis. A New Matrix Model for Discrete Event Systems: Application to Simulation.IEEE Control Systems,1997,:62-71.
[33]赵骥, 肖田元, 赵银燕, 董建华, 王云莉.基于Internet的虚拟资源动态集成技术研究[J].计算机集成制造系统-CIMS,2002, (10)
[34]侯文皓.多单元柔性制造系统的人机比仿真建模与分析研究[D].上海交通大学,2006.
[35]刘昶,史海波,袁杰.基于广义随机Petri网的制造过程建模与分析方法[J].计算机集成制造系统,2008,09(6)：1704-1710.
[36]余流,姚锡凡,张征,于广.基于Flexsim的加工车间的仿真[J].微计算机信息.2009
[37]龚波.基于WITNESS的生产物流系统仿真研究[D].武汉理工大学,2008.
[38]边境.虚拟柔性制造仿真系统的研究与开发[D].天津大学.2008
[39]李昂,王继宁.齿轮加工工艺、质量检测与通用标准规范全书[M].
[40]李经民.机械加工车间设备布局模型及其评价算法的研究[D].大连交通大学硕士学位论文.2005
[41]陈彦飞.可重构制造系统设备布局规划技术研究[D].北京交通大学.2009
[42]郭彩芬.离散制造系统在制品库存控制[J].航空制造技术,2008,(09).
[43]晏干平.A公司冲压车间设备布局研究[D].重庆大学工程硕士学位论文.2008
[44]http://www.pmec.net/bencandy-22-46347-1.htm.中国设备管理网.2010
[45]齐二石.生产与运作管理教程[M].清华大学出版社.2006
[46]宋昌慧.改进遗传算法在设备布局问题中应用[D].南京理工大学硕士学位论文.2009
[47]张翠军,邹慧,张有华.基于二次分配问题的混合蚁群算法[J].计算机工程与应用,2008,(10)
[48]于瑞峰,王永县.手工装配作业单元的布局优化设计研究[J].工业工程管理.2004.2：36-39
[49]李士勇等.蚁群算法及其应用[M].哈尔滨工业大学出版社.2004
[50]Xia, Y., Yuan, Y. Anew linearization method for quadratic assignment problems. Optimization Methods and Software,2006,21 (5):803～816.
[51]Jerry Banks.肖田元,范文慧译.离散系统仿真(原书第四版).机械工业出版社.2007
[52]何智春.基于Flexsim的机加工车间设施布置目建模与仿真[D].武汉理工大学硕士学位论文.2009
[53]秦天保,王岩峰.面向应用的仿真建模与分析——使用ExtendSim[M].清华大学出版社.2009
[54]许香穗、蔡建国.成组技术(第2版)[M].机械工业出版社.2008