烟叶原料配方立体仓库优化运行与仿真研究
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摘要
传统的立体仓库(Automatic Storage&Retrieval System,简称AS/RS)存在货物进出库效率低,运行维护成本高,人工操作误差等不利因素,不利于提高烟草企业的工作效率与市场竞争力。烟叶原料配方自动化立体仓库(Tobacco RawMaterial Blending of Automatic Storage and Retrieval System,简称TRMB-AS/RS)是烟草行业现代物流的一个重要组成部分,是实施烟叶精确配方、批次管理、排序投料、均匀掺对、批内质量控制、霉变剔出、紧急补料的物流起源点,TRMB-AS/RS的高效合理的运行可以加快物资流动的速度,保障生产的顺利进行,并可以实现对资源有效控制和管理,对整个烟包生产起着至关重要的作用。本文根据烟叶企业的生产实际情况和国内外烟厂企业的发展趋势,结合济南将军卷烟厂烟叶原料配方立体仓库改进升级的实际需求,以“烟叶配方立体仓库优化运行及仿真研究”为题,提出了基于多Agent理论的烟厂按需生产控制方法,开展了堆垛机及AGV的作业优化研究,对于丰富烟厂企业AS/RS的作业优化具有重要的理论意义,提高烟草企业自动化立体仓库的工作效率,降低运行维护成本,增强企业的市场竞争力,和提高企业创新能力具有重大的实用价值。
研究了TRMB-AS/RS系统规划设计的指导思想、设计依据、设计原则、设计规范、设计内容和设计步骤,规划了TRMB-AS/RS的物料单元和相关参数,阐述了TRMB-AS/RS的功能区域划分,提出了TRMB-AS/RS入库和出库区域的工艺流程设计,规划并选择了TRMB-AS/RS的高层货架、堆垛机、往复式穿梭车(有轨固定路径AGV)和托盘输送机等设备及其参数。
分析了烟草行业生产运行中存在的问题和开发烟草行业生产管理系统的必要性,提出了基于多Agent理论的烟厂按需生产控制方法,建立了烟厂的按需生产运行系统整体框架,定义了各分Agent系统,建立了基于Agent的烟厂按需生产模糊神经网络模型,以便企业可通过对各种突发事件的应变措施的不断学习来提高该网络模型的可伸缩性与敏捷性,保障企业生产管理系统的稳定、高效运行。
为了提高烟叶原料立体仓库堆垛机的作业效率,解泱多台堆垛机作业不均衡问题,基于堆垛机出入库优先原则,采用了堆垛机在全速和减速运行状态下联合作业和单作业两种模式的作业时间计算方法,提出了以各堆垛机作业时间总和最小和作业时间均衡为目标的出入库作业优化模型,提高了出入库的作业效率。针对一个具体烟叶立体仓库实例,在相同参数下,进行了作业优化前后的比较,结果表明:通过采用优化作业方法,作业效率得到了提高,各堆垛机的作业不均衡性大为减小。
基于出入库优先原则,进行了TRMB-AS/RS的调度运行的作业描述,提出了AGV在出入库作业时遵循的原则和建模假设条件,分析了有轨固定路径AGV的时间处理模型,建立了基于作业时间最短,所有等待时间最小的AGV调度模型,提出了基于遗传算法的求解策略,阐述了算法实现的设计流程,遗传编码、遗传操作处理内容。针对多AGV的作业调度特点,分析了多AGV与单AGV作业调度及优化求解过程的不同点。为烟草企业进一步应用和改进自动化仓库提供了可靠的理论依据。
使用eM-Plant仿真软件,对烟叶配方自动化立体仓库进行虚拟仿真。基于烟叶原料出入库优化设计,自动化立体仓库堆垛机工作优化设计,以及自动化立体仓库AGV自动运输系统的工作优化设计,建立起完整的烟叶配方自动化立体仓库虚拟模型。对仓库中可能出现的各种状况和需要改进的部分,在虚拟的环境下做出详细的判断,在eM-Plant软件中不断改进仓库的设计与配置,实现烟叶配方自动化立体仓库的虚拟化设计。提出了TRMB-AS/RS的动态特性建模方法,给出了TRMB-AS/RS从虚拟物理建模到虚拟动态特性建模的设计步骤,确定了TRMB-AS/RS仿真运行策略、仿真钟的推进方法,并给出了基于eM-Plant的TRMB-AS/RS仿真模型实例。为烟草企业自动化立体仓库设计和建造提供可靠的理论依据。
The traditional tobacco raw material warehouse has some disadvantage factors, such as low efficiency of goods in and out warehouse, high cost of operation and service, errors caused by human operation, which would be negative for cigarette enterprise to improve efficiency and market competitiveness. The theme of the paper is the "Design and optimizing operation of Tobacco Raw Material Blending of Automatic Storage and Retrieval System", which is combined with the actual requirement of the automated warehouse of the cigarette enterprise. The results of this study would impulse the improvement of efficiency, cost-reducing of operating and servicing, and development of the market competitiveness of the enterprise.
Base on the modern advantage design technique, this paper consider the warehouse function with the whole condition from all of the design parameter. The paper expatiate the function, requirement, structure and the class of the automated warehouse in detail. Introduce the working process of TRMB-AS/RS especially. Design TRMB-AS/RS with scientific method by the requirement of the system.
Base on the theory of Agent, the control method of product according to the needed of the tobacco factory base on Agent theory is put forward. This paper analyses the problems in the production and operation process of the tobacco enterprise and put forward the necessity for the enterprise to develop the production and management system. Put forward the theory of the product according to the needed of the tobacco enterprise base on the properties and the characteristics of Agent. Build the whole frame of the product according to the needed of the tobacco factory. This frame divides the departments of the factory to be the Agents, by the cooperation between which to finish the more and more complicated production work. Build a fuzzy neural network model, by which the enterprise could study the ways dealing with the accident to empress the retractility and agility of the network model. By the method above, keep the production and management system of the enterprise to work stably and efficiently.
Basing on the designing theory and the working optimization principle of the stacker, explain the working principle and the optimization design of the stacker, which is the most important part in the automated warehouse. At the same time of optimizing the working efficiency and balance of the stacker, consider the min-path principle and the first come first go principle. By increasing the in and our warehouse guideline such as working priority, when the in and our warehouse plan is receiving, the tobacco packages in and out warehouse list is created, in the condition of considering the factors such as the ware-location situation of the automated warehouse, optimization of the total working time of the stacker and the working balance between the stackers. By the optimization method, the standard deviation between each stacker is reduced and the working conditions of the stackers are more balance. Study the working efficiency of the stackers and put forward the way to improve the stacker efficiency by the real condition of the warehouse. Decrease the whole and single working time of the stackers, and increase the working efficiency of the automated warehouse.
Study the composition, wording principle and working position characteristic of the AGV transportation system in the warehouse. Put forward the computation method of the warehouse in and out efficiency when using the AGV system. Describe the scheduling problem of the AGV system and put forward the feasible AGV system scheduling model. Save the problem of building the AGV system scheduling model by genetic algorithm. Explain the designing of the algorithm process, the creating of the algorithm coding and the operation of the algorithm in the process using genetic algorithm. Describe some kinds of problems appearing in the AGV transportation system of tobacco leaf warehouse comprehensively, and build a scheduling model which could reflect the working condition in the true. Analysis the scheduling and optimization algorithm differences between the single AGV and the Multi-AGVs. Supply the theory principle to the tobacco enterprise to use or improve the automated warehouse.
Imitate TRMB-AS/RS basing on the eM-Plant imitation software. Basing on the optimizing design of the tobacco raw material in and out the warehouse, the optimizing design of the stackers in the warehouse and the optimizing design of the AGV automated transportation system, build up the integrated imitation model of tobacco leaf raw material automated warehouse. In the imitating environment, the potential accidents and the part needed improved, which may appear in the warehouse, are estimated in detail. The design and the collocation of the warehouse are improved again and again in the eM-Plant software, by which the imitating design of the automated warehouse comes true. Put forward the dynamic characteristics modeling method of the TRMB-AS/RS. Create the designing steps of the TRMB-AS/RS from imitation physics modeling to the imitation dynamic characteristic modeling. Study the imitating operation strategy and the promoting method of the imitation clock of the TRMB-AS/RS. Put forward the imitation model example of the TRMB-AS/RS basing on the eM-Plant. Support the theoretical basis for the designing and building of the automated warehouse of the tobacco enterprise.
研究了TRMB-AS/RS系统规划设计的指导思想、设计依据、设计原则、设计规范、设计内容和设计步骤,规划了TRMB-AS/RS的物料单元和相关参数,阐述了TRMB-AS/RS的功能区域划分,提出了TRMB-AS/RS入库和出库区域的工艺流程设计,规划并选择了TRMB-AS/RS的高层货架、堆垛机、往复式穿梭车(有轨固定路径AGV)和托盘输送机等设备及其参数。
分析了烟草行业生产运行中存在的问题和开发烟草行业生产管理系统的必要性,提出了基于多Agent理论的烟厂按需生产控制方法,建立了烟厂的按需生产运行系统整体框架,定义了各分Agent系统,建立了基于Agent的烟厂按需生产模糊神经网络模型,以便企业可通过对各种突发事件的应变措施的不断学习来提高该网络模型的可伸缩性与敏捷性,保障企业生产管理系统的稳定、高效运行。
为了提高烟叶原料立体仓库堆垛机的作业效率,解泱多台堆垛机作业不均衡问题,基于堆垛机出入库优先原则,采用了堆垛机在全速和减速运行状态下联合作业和单作业两种模式的作业时间计算方法,提出了以各堆垛机作业时间总和最小和作业时间均衡为目标的出入库作业优化模型,提高了出入库的作业效率。针对一个具体烟叶立体仓库实例,在相同参数下,进行了作业优化前后的比较,结果表明:通过采用优化作业方法,作业效率得到了提高,各堆垛机的作业不均衡性大为减小。
基于出入库优先原则,进行了TRMB-AS/RS的调度运行的作业描述,提出了AGV在出入库作业时遵循的原则和建模假设条件,分析了有轨固定路径AGV的时间处理模型,建立了基于作业时间最短,所有等待时间最小的AGV调度模型,提出了基于遗传算法的求解策略,阐述了算法实现的设计流程,遗传编码、遗传操作处理内容。针对多AGV的作业调度特点,分析了多AGV与单AGV作业调度及优化求解过程的不同点。为烟草企业进一步应用和改进自动化仓库提供了可靠的理论依据。
使用eM-Plant仿真软件,对烟叶配方自动化立体仓库进行虚拟仿真。基于烟叶原料出入库优化设计,自动化立体仓库堆垛机工作优化设计,以及自动化立体仓库AGV自动运输系统的工作优化设计,建立起完整的烟叶配方自动化立体仓库虚拟模型。对仓库中可能出现的各种状况和需要改进的部分,在虚拟的环境下做出详细的判断,在eM-Plant软件中不断改进仓库的设计与配置,实现烟叶配方自动化立体仓库的虚拟化设计。提出了TRMB-AS/RS的动态特性建模方法,给出了TRMB-AS/RS从虚拟物理建模到虚拟动态特性建模的设计步骤,确定了TRMB-AS/RS仿真运行策略、仿真钟的推进方法,并给出了基于eM-Plant的TRMB-AS/RS仿真模型实例。为烟草企业自动化立体仓库设计和建造提供可靠的理论依据。
The traditional tobacco raw material warehouse has some disadvantage factors, such as low efficiency of goods in and out warehouse, high cost of operation and service, errors caused by human operation, which would be negative for cigarette enterprise to improve efficiency and market competitiveness. The theme of the paper is the "Design and optimizing operation of Tobacco Raw Material Blending of Automatic Storage and Retrieval System", which is combined with the actual requirement of the automated warehouse of the cigarette enterprise. The results of this study would impulse the improvement of efficiency, cost-reducing of operating and servicing, and development of the market competitiveness of the enterprise.
Base on the modern advantage design technique, this paper consider the warehouse function with the whole condition from all of the design parameter. The paper expatiate the function, requirement, structure and the class of the automated warehouse in detail. Introduce the working process of TRMB-AS/RS especially. Design TRMB-AS/RS with scientific method by the requirement of the system.
Base on the theory of Agent, the control method of product according to the needed of the tobacco factory base on Agent theory is put forward. This paper analyses the problems in the production and operation process of the tobacco enterprise and put forward the necessity for the enterprise to develop the production and management system. Put forward the theory of the product according to the needed of the tobacco enterprise base on the properties and the characteristics of Agent. Build the whole frame of the product according to the needed of the tobacco factory. This frame divides the departments of the factory to be the Agents, by the cooperation between which to finish the more and more complicated production work. Build a fuzzy neural network model, by which the enterprise could study the ways dealing with the accident to empress the retractility and agility of the network model. By the method above, keep the production and management system of the enterprise to work stably and efficiently.
Basing on the designing theory and the working optimization principle of the stacker, explain the working principle and the optimization design of the stacker, which is the most important part in the automated warehouse. At the same time of optimizing the working efficiency and balance of the stacker, consider the min-path principle and the first come first go principle. By increasing the in and our warehouse guideline such as working priority, when the in and our warehouse plan is receiving, the tobacco packages in and out warehouse list is created, in the condition of considering the factors such as the ware-location situation of the automated warehouse, optimization of the total working time of the stacker and the working balance between the stackers. By the optimization method, the standard deviation between each stacker is reduced and the working conditions of the stackers are more balance. Study the working efficiency of the stackers and put forward the way to improve the stacker efficiency by the real condition of the warehouse. Decrease the whole and single working time of the stackers, and increase the working efficiency of the automated warehouse.
Study the composition, wording principle and working position characteristic of the AGV transportation system in the warehouse. Put forward the computation method of the warehouse in and out efficiency when using the AGV system. Describe the scheduling problem of the AGV system and put forward the feasible AGV system scheduling model. Save the problem of building the AGV system scheduling model by genetic algorithm. Explain the designing of the algorithm process, the creating of the algorithm coding and the operation of the algorithm in the process using genetic algorithm. Describe some kinds of problems appearing in the AGV transportation system of tobacco leaf warehouse comprehensively, and build a scheduling model which could reflect the working condition in the true. Analysis the scheduling and optimization algorithm differences between the single AGV and the Multi-AGVs. Supply the theory principle to the tobacco enterprise to use or improve the automated warehouse.
Imitate TRMB-AS/RS basing on the eM-Plant imitation software. Basing on the optimizing design of the tobacco raw material in and out the warehouse, the optimizing design of the stackers in the warehouse and the optimizing design of the AGV automated transportation system, build up the integrated imitation model of tobacco leaf raw material automated warehouse. In the imitating environment, the potential accidents and the part needed improved, which may appear in the warehouse, are estimated in detail. The design and the collocation of the warehouse are improved again and again in the eM-Plant software, by which the imitating design of the automated warehouse comes true. Put forward the dynamic characteristics modeling method of the TRMB-AS/RS. Create the designing steps of the TRMB-AS/RS from imitation physics modeling to the imitation dynamic characteristic modeling. Study the imitating operation strategy and the promoting method of the imitation clock of the TRMB-AS/RS. Put forward the imitation model example of the TRMB-AS/RS basing on the eM-Plant. Support the theoretical basis for the designing and building of the automated warehouse of the tobacco enterprise.
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