自动化电镀车间生产管理系统的研发
摘要
电镀在整个制造业中占有重要地位,广泛应用于各个行业的金属、非金属表面精饰及防腐等。电镀生产是一类专业性强、综合性高、复杂性大的系统生产。目前在我国的电镀生产中,自动化水平普遍比较落后,作坊式的手工生产线和半自动生产线占绝大部分,已有的自动化生电镀生产线镀种单一,工艺固定,电镀生产管理落后,缺少先进的生产管理系统对电镀生产进行规范化的管理。
本文针对我国电镀工业落后的现状,结合横向课题“全自动电镀生产线的研制”,研发了一套柔性化全自动的电镀生产线的生产管理系统,以实现对多镀种、多工序、柔性化自动化电镀车间的生产管理以及对电镀生产过程中的所有变量进行维护、监控和记录。首先,分析了电镀的生产过程,结合MES理论,详细分析了电镀车间生产管理系统的系统框架和功能模块,并结合UML技术分析系统用例分析、结构和电镀加工业务。其次,针对柔性化电镀生产特点,采用XML描述电镀加工工艺等参数,并在此基础上设计了电镀生产管理系统的信息系统。然后,根据电镀生产零等待的要求,分别分析了单条混合流水线和多条混合流水线运料行车的调度问题,使电镀生产严格满足生产工艺约束和设备容量约束,并优化了电镀生产。同时,本文结合OPC技术,结合电镀车间的调度和生产工艺,设计了系统的通讯层,实现了生产管理系统对生产设备的监控。
在以上研究的基础上,基于C/S模式,依据面向对象的设计方法,选用SQL Server2005数据库系统,采用Visual C#2005开发工具实现了该系统的开发。实施结果表明,系统显著的实现了生产过程的可控性和生产结果的可追溯性,提高了电镀生产效率和电镀产品质量。系统的研发不仅提高了我国电镀工业的自动化水平和管理水平,也对其他自动化生产线的设计和实施提供了借鉴意义。
Electroplating industry, which is widely used in household products and defense industry of different areas,occupies an important position in the manufacturing industry. Currently, electroplating industry of China represents a phenomenon of low automation level. Most electroplating product lines are workshop-style manual and semi-automatic. And existing automatic lines are limited to single variety and fixed electroplating process. Also management in electroplating workshop is lacking of advanced management system to standardize the management of electroplating.
Considering the particularity of electroplating production, this paper researches and developes a set of management system for automatic felixible electroplating product lines based on the project“Design and Mamufacture of automatic electroplating lines”. The system is designed to manage flexible automatic electroplating workshops, which can process multi electroplate types. Besides, it should maintance, monitor and record every avaible. Firstly, framework and function of the system are presented based on MES and electroplate process. UML is applied to analysis demands, structure and process activity. Secondly, XML is employed to discribe electroplate craft and database is designed. Thirdly, single hoist schedule and multi-hoist schedule are researched to satify process routes constraints, tanks capacity constraints and hoists capacity constraints. Then, based on OPC technology, communication layout is designed to realize data exchange.
Based on C/S pattern and object-oriented designing method, SQL Server2005 database and Visual C# 2005 are selected to accomplish this system.The running results show that the system totally satifies the design requirement. It makes electroplate process controllable and recur process result. The research can not only rise the automation level of electroplating industry, but also provide some reference significance for other automation practice.
本文针对我国电镀工业落后的现状,结合横向课题“全自动电镀生产线的研制”,研发了一套柔性化全自动的电镀生产线的生产管理系统,以实现对多镀种、多工序、柔性化自动化电镀车间的生产管理以及对电镀生产过程中的所有变量进行维护、监控和记录。首先,分析了电镀的生产过程,结合MES理论,详细分析了电镀车间生产管理系统的系统框架和功能模块,并结合UML技术分析系统用例分析、结构和电镀加工业务。其次,针对柔性化电镀生产特点,采用XML描述电镀加工工艺等参数,并在此基础上设计了电镀生产管理系统的信息系统。然后,根据电镀生产零等待的要求,分别分析了单条混合流水线和多条混合流水线运料行车的调度问题,使电镀生产严格满足生产工艺约束和设备容量约束,并优化了电镀生产。同时,本文结合OPC技术,结合电镀车间的调度和生产工艺,设计了系统的通讯层,实现了生产管理系统对生产设备的监控。
在以上研究的基础上,基于C/S模式,依据面向对象的设计方法,选用SQL Server2005数据库系统,采用Visual C#2005开发工具实现了该系统的开发。实施结果表明,系统显著的实现了生产过程的可控性和生产结果的可追溯性,提高了电镀生产效率和电镀产品质量。系统的研发不仅提高了我国电镀工业的自动化水平和管理水平,也对其他自动化生产线的设计和实施提供了借鉴意义。
Electroplating industry, which is widely used in household products and defense industry of different areas,occupies an important position in the manufacturing industry. Currently, electroplating industry of China represents a phenomenon of low automation level. Most electroplating product lines are workshop-style manual and semi-automatic. And existing automatic lines are limited to single variety and fixed electroplating process. Also management in electroplating workshop is lacking of advanced management system to standardize the management of electroplating.
Considering the particularity of electroplating production, this paper researches and developes a set of management system for automatic felixible electroplating product lines based on the project“Design and Mamufacture of automatic electroplating lines”. The system is designed to manage flexible automatic electroplating workshops, which can process multi electroplate types. Besides, it should maintance, monitor and record every avaible. Firstly, framework and function of the system are presented based on MES and electroplate process. UML is applied to analysis demands, structure and process activity. Secondly, XML is employed to discribe electroplate craft and database is designed. Thirdly, single hoist schedule and multi-hoist schedule are researched to satify process routes constraints, tanks capacity constraints and hoists capacity constraints. Then, based on OPC technology, communication layout is designed to realize data exchange.
Based on C/S pattern and object-oriented designing method, SQL Server2005 database and Visual C# 2005 are selected to accomplish this system.The running results show that the system totally satifies the design requirement. It makes electroplate process controllable and recur process result. The research can not only rise the automation level of electroplating industry, but also provide some reference significance for other automation practice.
引文
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[27]孙玥. MES环境中基于XML的系统集成技术研究与实现[D].华中科技大学硕士学位论文, 2007.
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[29]张迪,朱敏,张凌立.基于SAX的XML解析与应用[J].计算机与数字工程, 2008, 36(7): 103-106
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[31]詹英.数据库技术与应用.[M].北京:清华大学出版社. 2008.
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[33]王凌.车间调度及遗传算法[M].北京:清华大学出版社. 2003.
[34]王红娟.基于约束理论的混合流水线车间生产调度及应用[D].上海交通大学硕士学位论文,2008.
[35]史彬.队列竞争法在化工生产调度中的应用研究[M].武汉理工大学硕士学位论文. 2006.
[36]杨志才.化工生产中的间歇过程[M].北京:化学工业出版社. 2001.
[37]李凡华.基于遗传算法的间歇化工过程调度及其在线调整研究[M].青岛海洋大学硕士学位论文. 2006.
[38]周支立,李怀祖.单抓钩周期性排序的一种启发式算法[J].系统仿真学报. 2000.7. 12(7). 389-391.
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[41] Shapiro G W, Nuttle H W. Hoist Scheduling for a PCB Electroplating facility[J]. IIE Transactions, 1988, 20(2): 157-167.
[42] Baptiste P, Legeard B, Varnier C. Hoist Scheduling Problem: An Approach Based on Constraints Logic Problemming[J]. Proceedings of IEEE Conference on Robotics and Automation, 1992, 2: 1139-1144.
[43] Lim J M. A Genetic Algorithm for A Single Hoist Scheduling in the Printed-Circuit-Board Electroplating Line[J]. Computers & Industrial Engineering. 1997. 33: 789-792.
[44] Lei L, Wang J.J. Determining Optinal Cyclic Hoist Schedules in A Single-Hoist ElectroPlating Lines[J]. IIE Translations. 1994, 26(2): 25-33.
[45] Ada Che, Chengbin Chu and Feng Chu. Multicyclic Hoist Scheduling with Constant Processing Times[J]. IEEE Transactions on Robotics and Automation. 2002. 18(1): 69-80.
[46] Lei L, Wang T J. The Minimun Common-cycle Algorithm for Cyclic Scheduling of Two Material Handing Hoist with Times Windows Constraints[J]. Management Science. 1991. 37(12): 1629-1639.
[47] A. Che, C.Chu. Single-track Muli-Hoist Scheduling Problem: A Collision-free Resolution Based on a Branch-and-bound Approach[J]. International Jounrnal of production research. 2004. 42(12): 2434-2456.
[48]王小平,曹立明.遗传算法-理论、应用与软件实现[M].西安:西安交通大学出版社. 2002.
[49]许晋.基于遗传模拟退火算法的生产调度过程中工作量规划[D].福州大学硕士学位论文. 2005.
[50] L.M. Schmitt. Theory of Genetic Algorithms[J]. Theoretical Computer Science. 2001. 259: 1-61.
[51]潘明,钱宇,李秀喜.一种改进的顺序型多目的间歇工厂生产调度的MILP模型[J].化工学报. 2006. 4(57): 861-866.
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[2]安茂忠,李丽波,杨培霞著.电镀技术与应用[M].北京:机械工业出版社,2007
[3]冯立明著.电镀工艺与设备[M].北京:化学工业出版社,2005
[4]张欲非,戚秀云,孙志武.我国表面处理产业现状及集群化发展对策研究[J].中国环保产业, 2006,7.
[5]管涛.我国电镀工业的现状[J].金属世界, 2005 (1): 8-9.
[6]赵迎春.基于PLC的自动化电镀生产线控制系统[J].中国高新技术企业, 2009(5).
[7]段春霞,李小光.基于PLC的电镀生产线监控系统设计[J].电脑开发与应用, 2005. 21(6): 8-9
[8]史先焘,周靖,陈拓霖.电镀生产中的微机控制系统[J].电镀与涂饰, 2005,7. 24(7): 54-56
[9]何清刚.浅谈制造执行系统[J]. CAD/CAM与制造业信息化,2005,5:32-34
[10] MESA International. Controls Defination & MES to Controls Data Flow Possibilities. MESA International White Paper 3, 1997.
[11] MESA International. Execution-Driven Manufacturing Management for Competitive Advantage. MESA International White Paper Number 5, 1997.
[12]黄剑.制造执行系统体系结构与生产调度算法研究[D].华中科技大学硕士学位论文, 2006
[13] MESA International. MES Software Evaluation/Selection. MESA International White Paper Number 1, 1997.
[14]冯辉,张勇,张林森著.电镀理论与工艺[M].北京:化学工业出版社, 2008.
[15]王宇清.镀液交叉污染的原因及预防[J].电镀与环保, 2004,11. 24(6): 36-37
[16]舒余德,张昭,唐瑞仁等.电镀添加剂作用机理的发展概况[J].电镀与环保, 1999,11. 19(6): 5-10
[17]尹胜.车用空调类制造企业装配车间作业管理系统的研究与应用[D].重庆大学硕士学位论文, 2008
[18]于海斌,朱云龙.可集成的制造执行系统[J].计算机集成制造, 2000 , 9(12): 1-6
[19]柴天佑,金以慧,任德祥.基于三层结构的流程工业现代集成制造系统[J].控制工程, 2002 , 43(13): 5-6
[20]徐宝文,周毓明,卢红敏著. UML与软件建模[M].北京:清华大学出版社, 2006.
[21] Hans-Erik Eriksson, Maguns Penker, Brian Lyons, David Fado. UML 2 Toolkit[M]. New York: John Wiley & Sons, Ins, 2004.
[22] Joseph Schmuller. Sams Teach Your UML in 24 Hours, Third Edition[M]. Sams Publishing, 2002.
[23] W3C. Extensible Markup Language (XML) 1.0 ( Fourth Edition). W3C Recommendation 2006-09-29, http://www.w3.org/TR/REC-xml
[24] Dinar Dalvi, Joe Gry等著. .Net XML高级编程[M].北京:清华大学出版社, 2002.
[25]刘轶斐.基于MES的炼铁厂生产管理系统应用研究[D].大连理工大学硕士学位论文, 2005.
[26]刘迪成.基于XML的钢铁企业综合生产管理系统设计与应用[D].中南大学硕士学位论文, 2008.
[27]孙玥. MES环境中基于XML的系统集成技术研究与实现[D].华中科技大学硕士学位论文, 2007.
[28]华栓平,张玉宝编著. XML语言及应用[M].北京:机械工业出版社. 2007.
[29]张迪,朱敏,张凌立.基于SAX的XML解析与应用[J].计算机与数字工程, 2008, 36(7): 103-106
[30]张彬. XML数据交换在电信行业SID中的应用研究[D].中南大学硕士学位论文. 2008.
[31]詹英.数据库技术与应用.[M].北京:清华大学出版社. 2008.
[32]刘云生.数据库系统分析与实现[M].北京:清华大学出版社. 2009.
[33]王凌.车间调度及遗传算法[M].北京:清华大学出版社. 2003.
[34]王红娟.基于约束理论的混合流水线车间生产调度及应用[D].上海交通大学硕士学位论文,2008.
[35]史彬.队列竞争法在化工生产调度中的应用研究[M].武汉理工大学硕士学位论文. 2006.
[36]杨志才.化工生产中的间歇过程[M].北京:化学工业出版社. 2001.
[37]李凡华.基于遗传算法的间歇化工过程调度及其在线调整研究[M].青岛海洋大学硕士学位论文. 2006.
[38]周支立,李怀祖.单抓钩周期性排序的一种启发式算法[J].系统仿真学报. 2000.7. 12(7). 389-391.
[39] Lei L, Wang T J. A proof: the cyclic hoist scheduling problem is NP-complete [Z]. Working paper #89-0016. Rutgers University, August, 1989.
[40] Philliph L W, Unger P S. Mat hematical programming solution of a hoist scheduling program[J]. AIIE Trans, 1976, 8(2): 219-225.
[41] Shapiro G W, Nuttle H W. Hoist Scheduling for a PCB Electroplating facility[J]. IIE Transactions, 1988, 20(2): 157-167.
[42] Baptiste P, Legeard B, Varnier C. Hoist Scheduling Problem: An Approach Based on Constraints Logic Problemming[J]. Proceedings of IEEE Conference on Robotics and Automation, 1992, 2: 1139-1144.
[43] Lim J M. A Genetic Algorithm for A Single Hoist Scheduling in the Printed-Circuit-Board Electroplating Line[J]. Computers & Industrial Engineering. 1997. 33: 789-792.
[44] Lei L, Wang J.J. Determining Optinal Cyclic Hoist Schedules in A Single-Hoist ElectroPlating Lines[J]. IIE Translations. 1994, 26(2): 25-33.
[45] Ada Che, Chengbin Chu and Feng Chu. Multicyclic Hoist Scheduling with Constant Processing Times[J]. IEEE Transactions on Robotics and Automation. 2002. 18(1): 69-80.
[46] Lei L, Wang T J. The Minimun Common-cycle Algorithm for Cyclic Scheduling of Two Material Handing Hoist with Times Windows Constraints[J]. Management Science. 1991. 37(12): 1629-1639.
[47] A. Che, C.Chu. Single-track Muli-Hoist Scheduling Problem: A Collision-free Resolution Based on a Branch-and-bound Approach[J]. International Jounrnal of production research. 2004. 42(12): 2434-2456.
[48]王小平,曹立明.遗传算法-理论、应用与软件实现[M].西安:西安交通大学出版社. 2002.
[49]许晋.基于遗传模拟退火算法的生产调度过程中工作量规划[D].福州大学硕士学位论文. 2005.
[50] L.M. Schmitt. Theory of Genetic Algorithms[J]. Theoretical Computer Science. 2001. 259: 1-61.
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