造船厂钢板堆场出库作业计划建模及优化研究
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摘要
随着世界产业结构的调整和我国造船技术的不断提升,中国造船业在全球市场上所占的比重逐步上升,中国已经成为全球重要的造船中心之一。钢板堆场作为造船厂生产物资的主要存放场地,负责全厂钢材原材料的进料、分类堆放、保管和供应,为保障企业生产运营的顺利开展发挥着重要作业。然而国内造船企业钢板堆场中存在的落后管理模式和粗放式作业方式并没有随着生产需求的增加和造船能力的提升而得到改善。提高堆场管理水平和作业效率,成为目前造船企业亟待解决的重要课题。
钢板堆场作业包括入库作业、在库作业和出库作业三种,堆场作业计划的内容包括作业钢板选择、空间资源分配和作业设备调度。本文针对不同的作业类型,对国内外学者在钢板堆场作业管理方面的研究现状进行了分析,并将钢板出库作业确定为本文的研究重点。
通过对钢板堆场的出库作业过程进行深入分析,提出了一个以出库作业时间最短为目标的多阶段决策数学优化模型。该模型由3部分组成:钢板选择模型、钢板排序模型和倒垛决策模型。
在此基础上设计并实现了一个两阶段多层嵌套优化算法。第一阶段是钢板出库方案优化,通过一个嵌套遗传算法求得一组优化的出库钢板集合;第二阶段是倒垛决策优化,针对前一阶段得到的出库钢板集合,通过优化算法为倒垛钢板选择倒板目标垛位,从而得到优化的钢板出库作业计划。
最后,根据造船厂实际作业情况,建立了一个模拟钢板堆场,并提出了算法性能评估指标,对本文提出的优化算法进行性能测试。通过与模拟人工作业决策得到的出库计划方案进行比较分析,证明该算法生成的出库作业计划,能够明显地减少钢板出库作业时间,提高作业效率。
With the regulation of the world industry structure and the improvement of shipbuilding technology of our country,the proportion of shipbuilding industry of China is increasing gradually in global market.And China has become one of the most important shipbuilding centers all over the world.As the main storage place of the production materials,steel plate stacking yard is responsible for the feed、classify stacking、storage and supply of raw materials of steels,and plays an important role in making the production operation develop successfully.However,the laggard management mode and extensive operation method of steel plate stacking yard in shipbuilding firms of our country are still remained while the production requirement and the ability of shipbuilding both nave improved.Improving the level of stacking yard management and operation efficiency becomes the key problem to be solved currently.
The operation of steel plate stacking yard includes warehousing operation,storing operation and pick-up operation.And the operation planning of steel plate stacking yard consists of selection of pick-up steel plate,allocation of space resource and scheduling of operation equipments.In view of different operation kinds,this paper analyzes the research status in operation management of steel plate stacking yard in home and abroad.And much more attention is paid to the pick-up operation of steel plates in this paper.
After a deep analysis on the pick-up operation process of steel plate stacking yard,a multi-stage decision optimization model is constructed.The objective of the optimization model is the shortest pick-up operation time.This model is decomposed into three small models:model of steel plate selection,model of sorting the pick-up plates and model of rehandlling decision.
On the basis of the work referred in the previous section,a two stage multi-level nested optimization algorithm is designed and implemented.The first stage is the optimization of pick-up operation scheme.A set of optimized pick-up steel plates is obtained based on nested genetic algorithm.The second stage is the optimization of rehandlling operation.Under the condition that the pick-up plates have been selected in the first stage,we confirm the objective positions for the rehandlling steel plates using optimization algorithm.As a result,the optimized pick-up operation plan of steel plate is gained.
At last,according to the practical operation situation of shipbuilding factory,a simulated steel plate stacking yard is built.And an evaluation index of algorithm performance is proposed to test the optimization algorithm proposed forward in this paper.Compared to the pick-up plan scheme obtained from the simulated manual operation decision,we verify that the scheme generated by our algorithm can reduce the unloading operation time and improve the operation efficiency obviously.
钢板堆场作业包括入库作业、在库作业和出库作业三种,堆场作业计划的内容包括作业钢板选择、空间资源分配和作业设备调度。本文针对不同的作业类型,对国内外学者在钢板堆场作业管理方面的研究现状进行了分析,并将钢板出库作业确定为本文的研究重点。
通过对钢板堆场的出库作业过程进行深入分析,提出了一个以出库作业时间最短为目标的多阶段决策数学优化模型。该模型由3部分组成:钢板选择模型、钢板排序模型和倒垛决策模型。
在此基础上设计并实现了一个两阶段多层嵌套优化算法。第一阶段是钢板出库方案优化,通过一个嵌套遗传算法求得一组优化的出库钢板集合;第二阶段是倒垛决策优化,针对前一阶段得到的出库钢板集合,通过优化算法为倒垛钢板选择倒板目标垛位,从而得到优化的钢板出库作业计划。
最后,根据造船厂实际作业情况,建立了一个模拟钢板堆场,并提出了算法性能评估指标,对本文提出的优化算法进行性能测试。通过与模拟人工作业决策得到的出库计划方案进行比较分析,证明该算法生成的出库作业计划,能够明显地减少钢板出库作业时间,提高作业效率。
With the regulation of the world industry structure and the improvement of shipbuilding technology of our country,the proportion of shipbuilding industry of China is increasing gradually in global market.And China has become one of the most important shipbuilding centers all over the world.As the main storage place of the production materials,steel plate stacking yard is responsible for the feed、classify stacking、storage and supply of raw materials of steels,and plays an important role in making the production operation develop successfully.However,the laggard management mode and extensive operation method of steel plate stacking yard in shipbuilding firms of our country are still remained while the production requirement and the ability of shipbuilding both nave improved.Improving the level of stacking yard management and operation efficiency becomes the key problem to be solved currently.
The operation of steel plate stacking yard includes warehousing operation,storing operation and pick-up operation.And the operation planning of steel plate stacking yard consists of selection of pick-up steel plate,allocation of space resource and scheduling of operation equipments.In view of different operation kinds,this paper analyzes the research status in operation management of steel plate stacking yard in home and abroad.And much more attention is paid to the pick-up operation of steel plates in this paper.
After a deep analysis on the pick-up operation process of steel plate stacking yard,a multi-stage decision optimization model is constructed.The objective of the optimization model is the shortest pick-up operation time.This model is decomposed into three small models:model of steel plate selection,model of sorting the pick-up plates and model of rehandlling decision.
On the basis of the work referred in the previous section,a two stage multi-level nested optimization algorithm is designed and implemented.The first stage is the optimization of pick-up operation scheme.A set of optimized pick-up steel plates is obtained based on nested genetic algorithm.The second stage is the optimization of rehandlling operation.Under the condition that the pick-up plates have been selected in the first stage,we confirm the objective positions for the rehandlling steel plates using optimization algorithm.As a result,the optimized pick-up operation plan of steel plate is gained.
At last,according to the practical operation situation of shipbuilding factory,a simulated steel plate stacking yard is built.And an evaluation index of algorithm performance is proposed to test the optimization algorithm proposed forward in this paper.Compared to the pick-up plan scheme obtained from the simulated manual operation decision,we verify that the scheme generated by our algorithm can reduce the unloading operation time and improve the operation efficiency obviously.
引文
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[5]Kim H J,Hwang S K,Lee J S.Automation of overhead magnet crane system in thick steel plate storage yard[C].The International Federation of Automatic Control,15th Triennial World Congress,Barcelona,Spain,2002.
[6]Stroo D,Van der Stricht W,Verstraete A,et al.Optimization of the slab yard logistics at Sidmar[J].Revue de M(?)tallurgie,2004(7-8):576-580.
[7]Corti C,Speranza L,Stocker D.Conversion to fully automatic operation at a hot strip mill slab yard[J].Iron & Steel Technology,2005,2(1):42-47.
[8]杨春,刘杰.船厂信息化建设的原则及实施措施[J].武汉船舶职业技术学院学报,2008(3):12-15.
[9]张维荣.大连造船厂CIMS及其支撑平台的研究[D]:(工程硕士学位论文).哈尔滨:哈尔滨工程大学,2001.
[10]陈强.论中国造船企业的核心竞争力[J].中国造船,2004,45(1):1-7.
[11]李薇.扬子江船厂物流管理信息系统[J].船舶工业技术经济信息,2002(7):38-39.
[12]陈宇辉,李丽,殷宏伟,等.邯钢板材区成品库管理系统的设计与实现[J].中国高新技术企业,2008(11):54-56.
[13]董绍华.板坯库管理专家决策系统[J].冶金设备,1994(1):5-9.
[14]王冰洁,李苏剑.武钢二热轧板坯库实时生产物流管理系统研究与设计[J].物流技术,2004(12):61-63.
[15]李苏剑,陈宗海.宝钢板坯库入库决策模型[J].物流技术,1995(6):25-27.
[16]蒋如宏,钟宏才,谭家华.船厂钢板堆场管理的数字化仿真[J].上海交通大学学报,2003,37(8):1242-1245.
[17]李耀华.热轧生产计划与板坯库优化管理模型及算法研究[D]:(博士学位论文).大连:大连理工大学,2005.
[18]Kim H J,Hwang S K,Lee J S.Control of lifting desired number of steel plates and automatic crane operation crane operation[J].Iron and Steel Institute of Japan International,2003(43):230-237.
[19]Hansen J,Kristensen T F.Crane scheduling for a plate storage in a shipyard:Modelling the problem[R].Informatics and Mathematical Modelling,Technical University of Denmark,IMM-TR-4,2003.
[20]Hansen J,Kristensen T F.Crane scheduling for a plate storage in a shipyard:Solving the problem[R].Informatics and Mathematical Modelling,Technical University of Denmark,IMM-TR-11,2003.
[21]Hansen J,Kristensen T F.Crane scheduling for a plate storage in a shipyard:Experiments and results[R].Informatics and Mathematical Modelling,Technical University of Denmark,IMM-TR-12,2003.
[22]唐立新,杨自厚,胡国奋.板坯最优倒垛问题的有效启发式算法[J].系统工程学报,2001,16(2):121-127.
[23]李耀华,王伟,胡国奋,等.热轧板坯库出库计划编制模型与算法研究[J].计算机集成制造系统,2006,12(3):377-381.
[24]黄红选,韩继业.数学规划[M].北京:清华大学出版社,2006.
[25]Papadimitriou C H,Steiglitz K.Combinatorial Optimization:Algorithms and Complexity [M].New York:Courier Dover Publications,1998.
[26]Balev S,Yanev N,Fr(?)ville A,et al.A dynamic programming based reduction procedure for the multidimensional 0-1 knapsack problem[J].European Journal of Operational Research,2008,186(1):63-76.
[27]Costa L,Oliveira P.Evolutionary algorithms approach to the solution of mixed integer non-linear programming problems[J].Computers and Chemical Engineering,2001,25(2):257-266.
[28]Fisher M L.The lagrangian relaxation method for solving integer programming problems [J].Management Science,2004,50(12):1861-1871.
[29]邢文训,谢金星.现代优化计算方法[M].北京:清华大学出版社,2003.
[30]Martello S,Pisinger D,Toth P.New Trends in Exact Algorithms for the 0-1 Knapsack Problem[J].European Journal of Operation Research,2000,123(2):325-332.
[31]Holland J H.Adaptation in natural and artificial systems[M].Ann Arbor,MI:University of Michigan Press,1975.
[32]Ramsey C L,De Jong K A,Grefenstette J J,et al.Genome length as an evolutionary self-adaptation[J].Lecture Notes in Computer Science,1998,1498:345-354.
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