离散型制造业MES若干关键技术及其应用研究
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摘要
21世纪,我国要实现由“制造大国”向“制造强国”转变的目标,制造业必须实现由“生产规模能力”到“创新能力和快速响应能力”的重大转变,提升车间数字化制造执行能力已成为我国制造业发展的迫切需求。
为了提升企业的整体生产能力,必须解决产品工程设计信息、工艺信息,以及制造信息难以有效集成和及时反馈问题,实现车间制造执行层与设计层和管理层之间的实时、双向信息集成。论文在探讨产品物料清单的全生命周期管理模式的基础上,提出物料清单集成模型,建立了制造执行系统与计算机辅助设计系统双向互动的物料清单共享模型,实现车间制造执行层与设计层和管理层之间的实时、双向信息集成,满足了制造执行系统数据管理的准确性、一致性和共享性的管理目标。开发了原型系统,验证集成模式的有效性。
复杂信息环境下制造执行系统中设备需要采取有效的管理模式和方法。基于车间非常规的复杂动态信息环境,提出基于信息熵的设备管理复杂性描述方法和测度模型,并将测度模型应用于生产计划的可执行性分析。根据设备历史数据的采集和分析,利用统计建模原理,提出了面向调度设备事后维修时间分布的预测方法。考虑到零部件的工艺可替代性,采用最大树的模糊聚类方法,对设备加工能力相似性问题进行研究,解决了生产调度过程中设备可替代问题。通过实例研究,所提出的方法的实用性和有效性均得到了较好的验证。
生产单元是企业车间实际的生产调度的执行对象,为了突出生产调度技术的实用性,本文将生产调度的对象从设备上升为生产单元层次。将生产单元的调度归结为作业任务的分派问题,给出了一般条件下的作业分派调度算法。依据车间实际应用约束条件,提出虚拟生产单元和虚拟任务的概念,设计了生产单元与生产任务数量不匹配条件下的生产单元调度优化算法,克服了传统生产组织柔性不足的缺点,有效提高了设备的总效率。
制造资源重组能够将异地分布的车间资源整合起来,发挥各自车间的核心竞争力,是一种先进的管理技术。基于制造执行系统重构的本质是制造资源的重组和优化的分析,提出了MES资源重构的基本概念和特点;运用层次分析法原理,建立完全判断的MES单工序资源重组算法、可接受残缺判断的MES单工序资源重组算法、加权几何平均的MES多工序资源重组算法和加权算术平均的MES多工序资源重组算法,具体算例表明了算法的有效性。
作为面向车间的生产过程管理与实时信息系统,制造执行系统主要解决车间生产任务的执行问题,填补了上层生产计划与底层工业控制之间的鸿沟。制造执行系统通过对能流、物流、设备状态等进行实时监测与协调优化控制,达到快速响应制造及降低能耗的目标。
In the 21th century, China is supposed to transfer from "big manufacturing country" to "strong manufacturing country", accordingly, manufacturing enterprises must realize the great transformation from "production capability" to "innovation ability and rapid response ability ". It's great demand in our manufacturing enterprises to improve shop floor digital manufacturing execution capability.
In order to improve unitary production efficiency, enterprises must solve the following problems : product engineering designing information, production process information and manufacturing information are difficult to integrate and feedback timely, then it can be realized to integrate shop floor manufacturing executing layer and designing layer as well as management layer timely and bidirectionally. Integrated model of BOM is put forward in view of BOM life management mode, and bidirectional mutual BOM sharing model is built between MES and CAD system. So the goal of integration is realized among shop floor manufacturing executing layer and designing layer as well as management layer timely and bidirectionally, which satisfies MES data management in the aspect of data accuraty、data coherence and sharing. Prototype system is developed and the effectiveness of integrated model is verified.
In MES, equipment management needs appropriate management modes and methods within complex circumstances. For the irregular complex dynamic circumstance, the method of complexity description on equipment management based on information entropy is given, and the model of complexity measurement is set up, which is well applied into applicable analysis in production planing. By analyzing historical data, a method on the distribution forecasting of equipment maintenance time is put forward for production scheduling, with the usage of statistic modeling theory. Considering process interchangeability of the parts, by adopting max-tree fuzzy clustering method, the problem on manufacturing capability comparability among equipments is solved. Applicability and efficacy of the recommended methods above are verified by cases.
In fact, the executive object of enterprise product scheduling is production cell. To embody the validity of production scheduling, the object of production scheduling is changed from single equipment level to production cell level. Taking production cell scheduling as assignment problem, and the algorithm oriented to prodution cell scheduling is given out under general conditions. In view of actual practical limits in shop floor, two conceptions are introduced: virtul producion unit and virtul order, and then optimal algorithm on production cell scheduling is surposed, under the conditon that producion cell didn't match with production task in the aspect of number. By which the flexiblility of traditional production is solved, and OEE(Overall Equipment Efficiency) is improved greatly.
Manufacturing resources reconfiguration is an advanced management techonolgy, which is able to integrate distributed manufacturing resources, exploit the core competitive power of every shop floor. Based on the opinion that the origination of MES reconfigure is manufacturing resource reconfiguration and optimation, this paper introduces the basic concept and character of MES resources reconfiguration. The analytic hierarchy process (AHP) is explored and adopted for the manufacturing resources reconfiguration. Based on the principle of AHP, four algorithms on manufacturing resources reconfiguration are given, such as the algorithm on single procedure reconfiguration under the conditions of full information and deficient information, the geometrical mean algorithm and the arithmetic mean algorithm on multiple procedures reconfiguration , whose efficacy are proven by an illlustration.
As production management system and real-time information system for shop floor, MES primarily solves execution problem of production task, and fills up the gap between the upper production planning and lower industry control. Through timely monitoring and harmonious optimized control on powerflow, logistics and equipment states, MES arrives to the goals of responsing manufacturing rapidly and decline energy.
为了提升企业的整体生产能力,必须解决产品工程设计信息、工艺信息,以及制造信息难以有效集成和及时反馈问题,实现车间制造执行层与设计层和管理层之间的实时、双向信息集成。论文在探讨产品物料清单的全生命周期管理模式的基础上,提出物料清单集成模型,建立了制造执行系统与计算机辅助设计系统双向互动的物料清单共享模型,实现车间制造执行层与设计层和管理层之间的实时、双向信息集成,满足了制造执行系统数据管理的准确性、一致性和共享性的管理目标。开发了原型系统,验证集成模式的有效性。
复杂信息环境下制造执行系统中设备需要采取有效的管理模式和方法。基于车间非常规的复杂动态信息环境,提出基于信息熵的设备管理复杂性描述方法和测度模型,并将测度模型应用于生产计划的可执行性分析。根据设备历史数据的采集和分析,利用统计建模原理,提出了面向调度设备事后维修时间分布的预测方法。考虑到零部件的工艺可替代性,采用最大树的模糊聚类方法,对设备加工能力相似性问题进行研究,解决了生产调度过程中设备可替代问题。通过实例研究,所提出的方法的实用性和有效性均得到了较好的验证。
生产单元是企业车间实际的生产调度的执行对象,为了突出生产调度技术的实用性,本文将生产调度的对象从设备上升为生产单元层次。将生产单元的调度归结为作业任务的分派问题,给出了一般条件下的作业分派调度算法。依据车间实际应用约束条件,提出虚拟生产单元和虚拟任务的概念,设计了生产单元与生产任务数量不匹配条件下的生产单元调度优化算法,克服了传统生产组织柔性不足的缺点,有效提高了设备的总效率。
制造资源重组能够将异地分布的车间资源整合起来,发挥各自车间的核心竞争力,是一种先进的管理技术。基于制造执行系统重构的本质是制造资源的重组和优化的分析,提出了MES资源重构的基本概念和特点;运用层次分析法原理,建立完全判断的MES单工序资源重组算法、可接受残缺判断的MES单工序资源重组算法、加权几何平均的MES多工序资源重组算法和加权算术平均的MES多工序资源重组算法,具体算例表明了算法的有效性。
作为面向车间的生产过程管理与实时信息系统,制造执行系统主要解决车间生产任务的执行问题,填补了上层生产计划与底层工业控制之间的鸿沟。制造执行系统通过对能流、物流、设备状态等进行实时监测与协调优化控制,达到快速响应制造及降低能耗的目标。
In the 21th century, China is supposed to transfer from "big manufacturing country" to "strong manufacturing country", accordingly, manufacturing enterprises must realize the great transformation from "production capability" to "innovation ability and rapid response ability ". It's great demand in our manufacturing enterprises to improve shop floor digital manufacturing execution capability.
In order to improve unitary production efficiency, enterprises must solve the following problems : product engineering designing information, production process information and manufacturing information are difficult to integrate and feedback timely, then it can be realized to integrate shop floor manufacturing executing layer and designing layer as well as management layer timely and bidirectionally. Integrated model of BOM is put forward in view of BOM life management mode, and bidirectional mutual BOM sharing model is built between MES and CAD system. So the goal of integration is realized among shop floor manufacturing executing layer and designing layer as well as management layer timely and bidirectionally, which satisfies MES data management in the aspect of data accuraty、data coherence and sharing. Prototype system is developed and the effectiveness of integrated model is verified.
In MES, equipment management needs appropriate management modes and methods within complex circumstances. For the irregular complex dynamic circumstance, the method of complexity description on equipment management based on information entropy is given, and the model of complexity measurement is set up, which is well applied into applicable analysis in production planing. By analyzing historical data, a method on the distribution forecasting of equipment maintenance time is put forward for production scheduling, with the usage of statistic modeling theory. Considering process interchangeability of the parts, by adopting max-tree fuzzy clustering method, the problem on manufacturing capability comparability among equipments is solved. Applicability and efficacy of the recommended methods above are verified by cases.
In fact, the executive object of enterprise product scheduling is production cell. To embody the validity of production scheduling, the object of production scheduling is changed from single equipment level to production cell level. Taking production cell scheduling as assignment problem, and the algorithm oriented to prodution cell scheduling is given out under general conditions. In view of actual practical limits in shop floor, two conceptions are introduced: virtul producion unit and virtul order, and then optimal algorithm on production cell scheduling is surposed, under the conditon that producion cell didn't match with production task in the aspect of number. By which the flexiblility of traditional production is solved, and OEE(Overall Equipment Efficiency) is improved greatly.
Manufacturing resources reconfiguration is an advanced management techonolgy, which is able to integrate distributed manufacturing resources, exploit the core competitive power of every shop floor. Based on the opinion that the origination of MES reconfigure is manufacturing resource reconfiguration and optimation, this paper introduces the basic concept and character of MES resources reconfiguration. The analytic hierarchy process (AHP) is explored and adopted for the manufacturing resources reconfiguration. Based on the principle of AHP, four algorithms on manufacturing resources reconfiguration are given, such as the algorithm on single procedure reconfiguration under the conditions of full information and deficient information, the geometrical mean algorithm and the arithmetic mean algorithm on multiple procedures reconfiguration , whose efficacy are proven by an illlustration.
As production management system and real-time information system for shop floor, MES primarily solves execution problem of production task, and fills up the gap between the upper production planning and lower industry control. Through timely monitoring and harmonious optimized control on powerflow, logistics and equipment states, MES arrives to the goals of responsing manufacturing rapidly and decline energy.
引文
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