CN101706886A - Order-driven Single-piece small-batch combined flow production method for processing workshop - Google Patents
Order-driven Single-piece small-batch combined flow production method for processing workshop Download PDFInfo
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Abstract
The invention provides an order-driven single-piece small-batch combined flow production method for a processing workshop, which has high intellectualization degree and strong practicability. In the method, a manufacturing system of the processing workshop is divided into a planning module, a scheduling module, a system database, an upper RFID reader-writer and an equipment control layer, wherein the planning control module, the scheduling module and an equipment control unit are all realized by Agent (intelligent agent) technology. All the parts of the manufacturing system are connected into a multi-Agent (intelligent agent) manufacturing system through a network and a communication protocol. Under normal conditions, the system carries out machining according to a preset operation working procedure through static scheduling; and when the system is abnormal, the system completes a processing task through dynamic scheduling. Accordingly, staff members can dynamically master production process information in real time. The production method can effectively improve processing efficiency and reduce production cost.
Description
Technical field
The present invention relates to the production management and the control method of job shop, especially the workpiece mixed flow production method that drives towards order.
Background technology
Manufacturing system is to constitute by making resource (comprising facility, people, information etc.), these make resource by interdependences such as facility layout, the technological process of production and production scheduling plan (making the constraint condition between the resource), to realize the production specific products or specific service is provided.A kind of just typical manufacturing system of workshop.Along with progress of science and technology, the trend that the more and more fierce and oriented internationalization direction of market competition develops, the consumer becomes more diverse and personalization to the demand of product, thereby cause the life cycle of product shorter and shorter, progressively replaced in the Multi-varieties and Small-batch Production mode of order and traditional to be automated as the mass production method of representative, and become the main flow of modern manufacturing industry gradually with rigidity.
Traditionally to manufacturing system research, generally only at all levels in operation control, the manufacturing and the device control carried out respectively.With manufacturing resources planning MRPII (Manufacturing Resource Planning) and Enterprise Resources Plan ERP (Enterprise Resource Planning) is the management information system of representative, and be the automatic technology of representative with digital control processing, DNC (Direct Numerical Control) unit and flexible manufacturing system FMS (Flexible Manufacturing System), in manufacturing enterprise, obtained widespread use.But lack effective cooperation between the two, cause enterprise's upper strata plan to lack the scheduling and the coordination of effective real-time information support, lower floor's controlling unit shortage optimization.For this reason, people have proposed Manufacturing Executive System MES (Manufacturing Execution System) notion, in the hope of solving the disconnection problem of the production schedule and production run, but this integrated be isolatedly on three levels to carry out, lack continuity, do not consider influence and effect well, but have, lack of wisdom and agility poor and lack problems such as science decision method under the unconventional information condition such as integration to the overall situation or global optimization.Along with manufacturing system develops towards the comprehensive integrated automation direction from individual event, local improvement, need the management control system research of carrying out the collection production schedule, dispatching and be controlled in one badly.
Production planning (plan) is under the prerequisite that satisfies certain constraint, selects and scheduling job in order to reach some target; Scheduling is to give operation in the planning with time and resources allocation, and according to one group of rule and index planning is optimized selection, this group rule or retrain the time relationship that has reflected between operation and the resource; Production control is meant the strategy and the algorithm of manufacturing works or plant operations and operation.
Control structure is the basis of manufacturing system, its version and characteristic are directly determining the performance of manufacturing system. the control structure of manufacturing system can be divided into centralized, pass stepwise, version such as distributed and hybrid. centralized configuration is used for early stage simple manufacturing cell or the control between compact car mostly, because total data is managed by a main control computer, information processing rate is low, there is real-time, shortcoming such as extendability and poor fault tolerance, can't satisfy operation control in the large complicated manufacturing system, the requirement of the production schedule and control. pass and have strict master slave relation between the levels controlled entity of hierarchic structure, the control of the adjacent upper strata of the active receiving of lower floor's controlled entity controlled entity, adjacent layer can carry out message exchange, forbid communication between the peer entity. obtain widespread use owing to hierarchical control structure and manufacturing system institutional framework are similar, 3 to 7 layers multiple hierarchical structure has successively been proposed. but owing to be subjected to the restriction of its fixed sturcture and processing power, in violent environment and customer demand variation, facing severe challenge. distributed control is not as master slave relation in the hierarchical control and hierarchical relationship, each unit decision-making and behavior are autonomous, the entire system performance realizes by cooperation between the unit, but has compatibility between heterogeneous system and the problems such as contradiction between unit independence and the system global optimization. hybrid combination a kind of just between pass stepwise and distributed between compromise structure.
In producing towards the order task, the production run of each task all is made up of one or several production link (each production link is finished a procedure).After the multi-task enters system, people wish with the shortest time, the most constantly and minimum cost finish them.By different task and different operating are suitably planned and the sequence of operation arrangement, can adjust the length of above-mentioned some time variable (as the stand-by period), reach the desired optimization aim of people, problem that dispatching office will study that Here it is.Scheduling is operation to be sorted under (process sequence of operation, the deadline of requirement, earliest start time and resource capability etc.) condition satisfying some constraint, give the Task Distribution resource, arrange process time according to the order of being arranged, make some target (as total execution time, delivery date and producing cost etc.) reach optimization.
Generally speaking, each task all has certain process route, and promptly it must finish each procedure successively according to technologic requirement on the machine of appointment.The multimachine problem can be divided into two classes again according to the process route of each task is whether identical: if all tasks that are discharged in the system all have identical process route, then problem belongs to streamline production (Flow Shop) problem; Otherwise, belong to mixed flow production (JobShop) problem.That is to say that the process route of the different task during mixed flow is produced may be different, the operation that each task comprised may be different, and the per pass operation can be processed on a plurality of different machining cells, and process time may be different with the difference of machining cell.Task described here is meant the processing to a collection of identical workpiece (also can be a workpiece); Machining cell is meant one group of resource can finishing a specific function, and automation equipment, the logical equipment of a Daepori can be regarded a machining cell as together with operator a, work group etc.; Operation is meant the single treatment of a task on a machining cell, is called a procedure again.If the process route of each workpiece is identical, a Job Shop scheduling problem just is converted into comparatively simple Flow Shop scheduling problem, so Flow Shop scheduling problem is a kind of specific type of Job Shop scheduling problem.
Production scheduling problems can be divided into static scheduling and dynamic dispatching.Static scheduling is before task enters system, according to the requirement of aims of systems, adopts some algorithm, and the processing sequence of task on each machining cell arranged.Dynamic dispatching is in the manufacturing system operational process, variation according to the condition of production is carried out real-time adjustment again to original ready-made task arrangement, the main cause of carrying out dynamic dispatching is because the random perturbation of systems such as machining cell fault and the error of each production link of system, caused actual production progress and static scheduling plan not to be inconsistent, or because the uncertain factors such as insertion of hot job, and have to system is dispatched again.
The manufacturing system planning and scheduling is NP (Non-deterministic Polynomial) difficult problem, particularly because the running environment of modern manufacturing system more and more has been full of uncertainty, the manufacturing operation of system often is dynamic change, increases and the in short supply and introducing that reduces, some makes resource, the variation in manufacturing operation processing time etc. as unpredictable task.Simultaneously, enterprise must keep quality and reduce under the prerequisite of cost of investment in order to win competition, shorten product life cycle, accelerate product Time To Market, increase the diversity of product, meet the need of market etc. in real time.These uncertainties, dynamic and complicacy are combined, make planning and scheduling become difficult more, simultaneously, in order to handle this ever-increasing uncertainty and complicacy, the control system of manufacturing shop must have stronger adaptability, robustness and scalability.
Exist with the deficiency of several aspects in the existing Shop Floor Management and Control system:
1) existing programming dispatching research does not have fine and actual Shop floor control to combine, and only rests on theory or desirable aspect, also has suitable distance from the actual production demand; Even solve processing operation static optimization problem, but because processing uncertain (as fault, delay) makes this optimization operation ordering be difficult to carry out.
2) the most employing of existing research is pure passs the stepwise control structure, or pure distributed control structure, under existing soft or hard environment, is unfavorable for working control.
3) shortage effectively integrates in goods real-time information tracking and various information resource.Existing many workshops also are in traditional handwork or the semi-automatic management phase of computing machine, to parts, still need the operative employees at different levels of enterprise to carry out by hand in the information processing of goods, employing such as processing circuit list, planning sheet, account etc. are in artefact management, but it is big to fill in workload, bill is lost easily and is subjected to stained, be not easy to statistics and adjust, parts, can not in time gather and be delivered to the management information system (as MES, ERP etc.) on upper strata in information such as goods and product completions; Though also there are some workshops to adopt the papery bar code, but in production procedure, need repeatedly paste bar code, and storage information very finite sum can not write once more, the manual operation phenomenon is serious, drain sweep, that mistake is swept rate is higher, causes production information to lose, cause collection in worksite to data can not truly reflect the situation of carrying out of actual production, cause mutual serious hysteresis of production information, cause upper system can't demonstrate fully management effectiveness.
4) the workshop ubiquity is produced unbalanced phenomena, and for the flexible mixed flow production of different product, the parts dispensing is difficult synchronously, the product parts assembling easily makes mistakes, and causes production efficiency low.
5) parts are in production and assembling process, and jumping is stood, leaked the phenomenon of standing and happens occasionally, and causes unstable product quality.Quality information is distributed in each management link and even each station, owing to do not set up related between finished product and assemble products from parts, causes the difficult location of quality problems, the difficult tracking, can not be by factor location trackings such as time, station, personnel, to find root-cause.
Summary of the invention
The object of the present invention is to provide a kind of intelligent degree height, practical, with order drive, towards the single and mini-batch production mixed flow production method of engineering shop, to overcome the deficiency of stating existing Workshop Production.
For achieving the above object, the technical solution adopted in the present invention is: the manufacturing system of described job shop is divided schedule module, scheduler module, system database, upper rfid interrogator, device control layer, wherein schedule module, scheduler module and device control layer all realize that by Agent (intelligent body) technology the each several part of manufacturing system connects into the multi-Agent manufacturing system by network and communications protocol; Described schedule module is used for the evaluation work order, determines the dispatching priority of order, formulates process planning, and determines system's operation strategy according to relevant constraint condition; Described scheduler module is used to receive the work order of schedule module, according to shop floor status information and parts information to be processed, decompose the order task by intelligent algorithm optimization, generate the optimal scheduling scheme and workpiece operation information is write by upper rfid interrogator among the RFID label of corresponding workpiece; Described device control layer is made up of a plurality of machining cells, and each machining cell reads in corresponding workpiece RFID label information, and carries out corresponding processing operation; Described system database is used to store work order information and offers the correlation module use, and its concrete selectable existing database has SQL Server database, oracle database or Access database etc.
Described Agent is that a kind of being in neatly, independently moved computational entity or program under the specific environment, between each Agent by various technology interactive data and communicate, and the multi-Agent manufacturing system be meant by Agent encapsulate the simulation each functional entity of workshop (comprising the machining cell in schedule module, scheduler module, the device control layer), use the multi-Agent correlation theory again each function Agent is organized, form workshop multi-Agent manufacturing system.
Described RFID (Radio Frequency Identification, be radio-frequency (RF) identification) be a kind of simple wireless system, form by a reader and label, it is by the automatic recognition objective object of radiofrequency signal and obtain related data, the identification workpiece need not manual intervention, can work in various rugged surroundings.
Each machining cell of described device control layer is made up of rfid interrogator, RFID label, workpiece, machine, display, communication interface, man-machine interface, the knowledge base of each station again; Wherein, the man-machine interface of described machining cell is used for operating personnel and consults the workpiece processing tabulation, revises the dynamic dispatching rule and manually adjusts the processing tasks tabulation in case of necessity; The knowledge base of described machining cell is used to store the status information of dynamic dispatching rule, manufacturing procedure tabulation and schedule module, scheduler module; The communication interface of described machining cell is used for communicating by letter with schedule module, scheduler module.
Described schedule module is called plan Agent again, realizes with Agent (intelligent body) technology, is made up of man-machine interface, knowledge base, communication interface, decision-making module and administration module: wherein communication interface realization and scheduler module and device control layer communicates by letter; Man-machine interface is used for the interaction with managerial personnel, to receive sequence information and workshop management relevant information (these information deposit in the system database after handling by decision-making module); Knowledge base is used to store algorithm, each Agent mailing address, workshop raw material, stock, the equipment state multidate information of fuzzy reasoning, decision-making; Administration module is used for the Fuzzy Logic Reasoning Algorithm according to knowledge base, checks in order related process, material information and order self-information from system database; Decision-making module is assessed order successively according to the information that administration module checks in, and determines the dispatching priority of each order and process constraint condition etc.
Order priority is by the client's importance degree in the order, client's friendliness and order deadline determine, client's importance degree is by client's scale, prestige determines, provide by managerial personnel, represent, as a minute Pyatyi with some ranks, five-star " 5 " representative is most important, and " 1 " representative is least important; Client's friendliness is determined by cooperative relationship, is provided by managerial personnel, and as also dividing Pyatyi, " 5 " representative is most important, and " 1 " representative is least important; Can calculate the urgency of order according to the order deadline, determine urgency by following fuzzy rule:
1) (8 hours) on duty to finish for the most urgent, with 5 the representative;
What 2) will finish within one day is urgent, with 4 representatives;
What 3) finish within two days is common, with 3 representatives;
4) finish within three days for not urgent, with 2 the representative;
5) finish within the week for least urgent, with 1 the representative.
Order priority is divided three classes, i.e. preferentially processing, and the normal process and the processing of delaying, after preferential Fabrication Order entered system, the current order of processing suspended, and the preferential order of processing is adapted to the urgent rule of inserting earlier.The normal process order is processed in regular turn, delay Fabrication Order when just processing during no aforementioned two kinds of orders in the system, the priority of order may promote in time, promptly as time goes by, originally the order of normal process may be for becoming preferential order, and the order of the processing of delaying originally may become with the normal process order.Order priority is established rules then as follows really:
1) the order urgency is 5, and importance degree or friendliness are the preferential Fabrication Order that is more than 4;
2) the order urgency is 1, and importance degree, and friendliness is the Fabrication Order of delaying below 5;
3) do not meet above-mentioned two rules for the normal process order;
The order of level that All factors being equal, preference will be give to is determined process sequence according to its flexible strategy, and the computing formula of flexible strategy is as follows:
Flexible strategy=urgency * 3+ importance degree * 2+ friendliness * 1
If flexible strategy are still identical, then to sort according to order number.
Described scheduler module, be called scheduling Agent again, realize with Agent (intelligent body) technology, be made up of man-machine interface, knowledge base, dispatching control module, display, communication interface: the man-machine interface of scheduler module is used for the management and running personnel dispatching algorithm being selected for use and parameter setting; Comprised the intelligent algorithm storehouse that is used for the workshop scheduling in the knowledge base of scheduler module, the mailing address and the multidate information thereof of schedule module and device control layer; The communication interface of scheduler module be used for schedule module, upper rfid interrogator, machining cell between communicate by letter; Described dispatching control module is used for the intelligent algorithm that dispatching priority according to equipment state, processing constraint, order calls the knowledge base of described scheduler module work order is carried out static scheduling optimization, and shows workpiece operation information with the Gantt chart form on described display.
After scheduler module is received the information that schedule module sends, according to equipment state and processing constraint and order dispatch priority, call the intelligent algorithm of knowledge base order is carried out static optimization, obtain the optimal scheduling scheme, by the management and running personnel scheduling result is revised in case of necessity; After scheduling result is confirmed, show, simultaneously through the workpiece operation information after the static scheduling optimization is written to the RFID label of corresponding workpiece by the upper rfid interrogator that is connected with described scheduler module among by display.
(1) optimizing scheduling
Consider n workpiece J
i(i=1,2 ..., n), at m platform machine M
k(k=1,2 ..., m) the processing job scheduling problem on.Knownly respectively operate the processing sequence constraint (being called the technological constraint condition) on machine of process time and each workpiece, require to determine to meet the processing sequence of all workpiece on each machine under the technological constraint condition, make processability index reach optimum, and supposition:
1) each workpiece can begin processing after preliminary work was finished;
2) each constantly can only have a workpiece processing on every machine, and process Once you begin just can not interrupt, and machine all is in effective status in whole process;
3) each workpiece must progressively be processed on the specified machine of its process route;
4) each workpiece has identical processing right of priority;
5) operation allows to wait for that promptly previous operation is not finished, and then the action need of back is waited for;
6) do not have under the situation of specified otherwise, remain unchanged the process time of workpiece in whole process, and the leading time of workpiece is included in workpiece processing in the time;
These supposition are at the static scheduling problem, and in actual production, some clause in the above-mentioned assumed condition can be broken under different situations, and this also is the reason that need carry out dynamic dispatching.
The present invention adopts static scheduling and the dynamic dispatching method that combines, and static scheduling realizes that by intelligent algorithm dynamic dispatching realizes there is not special declaration by heuristic scheduling rule, and scheduling only refers to static scheduling usually.Why to carry out dynamic dispatching, be because the random perturbation of systems such as machining cell fault and the error of each production link of system, caused actual production progress and static scheduling plan not to be inconsistent, need carry out real-time adjustment again to original ready-made task arrangement, or because the uncertain factors such as insertion of hot job, and have to system is dispatched again.
Make O
IjRepresent that i workpiece (is workpiece J
i) j road operation, w
IjBe the stand-by period that workpiece carries out the operation of j road, C
iBe workpiece i completion of processing time, T
IjBe operation O
IjProcess time on specified machine, then have
So, the minimizing the maximum deadline processability index of each workpiece and can be expressed as of Job Shop scheduling problem:
Above-mentioned Job Shop scheduling problem can be used n/m/J/C
MaxSuccinct representation, wherein n represents the workpiece number, and m represents number of machines, and J represents Job Shop scheduling problem, C
MaxThe maximum deadline of expression, that is:
C
max＝max(C
1，C
2，…，C
n)
The per pass operation of each workpiece can only be processed on the lathe of an appointment in the Job Shop scheduling problem, and like this, the machining path of each workpiece is determined, and had only a machining path.Different with Job Shop scheduling problem is, in the flexible Job Shop scheduling problem, the per pass operation of each workpiece can be its processing by one or many machines, and therefore, each workpiece has many machining paths.In identical operation, but because the processing characteristics difference of the processing machine of its correspondence, like this, same procedure is also just different the process time on different machines, and therefore, different machining path correspondences different process times.
Flexible Job Shop scheduling problem can be divided into full flexible JobShop scheduling problem and partially flexible Job Shop scheduling problem according to resource limit condition difference.In full flexible Job Shop scheduling, the per pass operation can select any machine to process; And in the partially flexible Job Shop scheduling, some operation can be chosen in processes on any machine, and some operation can only selection portion divide machine to process.Scheduling problem in the actual production process generally has some restriction aspect machine choice, so partially flexible Job Shop scheduling problem has more ubiquity.
(2) dynamic dispatching
Dynamic dispatching certain class incident promptly occurs by Event triggered, just calls the corresponding dynamic programming of certain class incident.The dynamic dispatching rule should be according to the difference of object and different, and following is the dynamic dispatching rule of promptly inserting under order and these two kinds common uncertain situations of mechanical disorder.
1) promptly insert the order rule:
1. when hot job entered, the task of not beginning to process was postponed temporary transient indefinite duration, and the task of processing continues processing;
2. insert the hot job after optimizing;
3. will remain operation under the prerequisite that does not change processing machine to allow the process time rule to be inserted in the corresponding machine the earliest.
2) dynamic programming of mechanical disorder:
1. when machine broke down, the unaffected operation of other machine continued processing;
2. when but the fault machine does not have the free time promptly not have manufacturing procedure, the machinable operation of first this machine in the undressed operation tabulation in the fault machine is inserted in the operation tabulation of this machine;
2. after fault mechanical disorder is removed,, then continue processing if its undressed sequence table is not empty.
System in the inventive method finishes this station processing tasks automatically according to the set operation on the RFID label, or finish corresponding operation processing tasks according to the label information that shows on the display by operating personnel, after the operation operation is finished, information such as the job number of the rfid interrogator write operation person by this station, activity duration, machine state.When relevant issues occurring, the process information of RFID label that can be by reading each workpiece is analyzed product (promptly finish processing tasks after part), and by factor location trackings such as time, station, personnel, to find root-cause.
Beneficial effect of the present invention mainly shows:
(1) but utilize the function of RFID online in real time read-write electronic labeling information, make managerial personnel Real-time and Dynamic grasp production run, make whole flow process reach transparence and visual, thereby greatly enhance productivity, reduce production costs.Compare with bar code, RFID radio RF recognition technology advantage is that decipherment distance is long, be suitable for rugged surroundings, can discern moving target, label is read-write, advantages such as portability mass data, broken through " bottleneck " problem of the data typing and the data acquisition of production run, can be from motion tracking in the goods real-time distribution situation of (product of making comprises member, semi-manufacture, finished product etc.), carry out product and in the authentication and the sign of goods.
(2) be schedule module, scheduler module and mechanical floor with the workshop system divides, and they are connected into a multi-Agent manufacturing system by network and communications protocol, adopt Agent system theory and method that cooperation, negotiation, scheduling, control, the conflict resolution problem of Agent in this manufacturing system are found the solution, make system have better adaptability, robustness and scalability, and the Agent system can its control decision of dynamic coordinate, autonomous its behavior of adjustment is made intelligentized reaction to incidents such as urgent workpiece insertion, equipment failures.
(3) on the approaching mixed flow theories and methods of scheduling basis of employing and actual production, combine by static scheduling and dynamic dispatching and to solve the actual production problem, and solve the NP difficult problem that static scheduling is optimized by intelligent algorithm, realize the Real-time and Dynamic scheduling by the dynamic dispatching rule again, thereby realize the complicated Workshop Production scheduling problem under the uncertain environment.
(4) realized the integrated of production planning, scheduling and device control, and adopt to mix control structure, the peer entity of hierarchical structure can not be communicated by letter, the compatible and unit independence of distributed control between isomerized sub-system and the problems such as contradiction between the system global optimization solved.
(5) adaptation is used for the multiple mode of production, all is suitable for from increasingly automated manufacturing system to the manually-operated manufacturing system.
Description of drawings
Fig. 1 is an exemplary The general frame of the present invention.
Fig. 2 is an exemplary plan module frame chart of the present invention.
Fig. 3 is an exemplary scheduler module block diagram of the present invention.
Fig. 4 is an exemplary machining cell block diagram of the present invention.
Fig. 5 is that the interface is found the solution in intelligent scheduling optimized Algorithm storehouse.
Fig. 6 is the Job Shop production example Gantt chart of facing machine.
Fig. 7 is the Job Shop production example Gantt chart towards workpiece.
Fig. 8 is the Job Shop production exemplary plot of optimizing by static scheduling.
Fig. 9 is the flexible Job Shop production example Gantt chart of facing machine.
Figure 10 is the flexible Job Shop production example Gantt chart towards workpiece.
Figure 11 is a dynamic dispatching production exemplary plot under the promptly insertion work.
Figure 12 is a dynamic dispatching production example under the mechanical disorder.
Embodiment
Below in conjunction with drawings and Examples the specific embodiment of the present invention is described further.
Fig. 1 is an exemplary The general frame of the present invention, it is made up of schedule module 100, scheduler module 200, system database 300, upper REID read write line 400, device control layer, and wherein the device control layer specifically is made up of machining cell 500, the rfid interrogator 501 that begins unit 600S, end unit 600F, each station, RFID label 502 etc. in the middle of example.
100 pairs of orders of schedule module are assessed successively, determine the dispatching priority of each order, work out the production schedule and system operation strategy, send to scheduler module 200 according to dispatching priority, process planning and the constraint condition etc. of order by communication interface; 200 pairs of receptions of scheduler module are from the shop order of schedule module 100, according to parts information to be processed and status information of equipment, the algorithm (as genetic algorithm) that calls the intelligent algorithm storehouse is optimized decomposition to task, generate scheduling scheme and utilize upper REID read write line 400 to write among the REID label 502 (smart card), the REID label 502 that is loaded with production technology information is attached on the workpiece to be processed (part or parts); The workpiece to be processed (part or parts) that has REID label 502 is delivered to the beginning unit 600S in workshop, rfid interrogator 501 among the beginning unit 600S reads in the content on this REID label 502, automatically workpiece is transported to first flow chart place (if flexible automation production line) of this workpiece, or alert arrives first flow chart place (if workshop hand-manipulated) with this workpiece handling; By the rfid interrogator 501 that is equipped with on the corresponding machining cell 500, read in RFID label 502 information, system finishes the processing tasks (if flexible automation production line) of this station automatically according to the set operation on the RFID label 502, or carries out corresponding operation by operating personnel by 502 promptings of RFID label and process (manual operations); After the current operation operation completion, information such as the job number by the 501 write operation persons of the rfid interrogator on this station, completion date, machine state, simultaneously these information are returned workshop management system by network, and change next flow chart over to, if do not take place unusual, just undertaken, till all processing flow charts are finished by the set optimal scheduling operation scheme that writes in the RFID label 502; When unusual when take place disturbing (as equipment failure or rush order etc. is arranged), then finish processing tasks by dynamic dispatching; Processing is read in the information that is written to RFID label 502 at end unit 600F after operation finishes, and product (promptly finish processing tasks after part) is analyzed, and positioned tracking by time, station, personnel etc., to find root-cause.
As shown in Figure 2, schedule module 100 is made up of man-machine interface 101, knowledge base 102, decision-making module 103, display 104, communication interface 105 and administration module 106, and realize with the Agent technology, it is responsible for system database 300 mutual, dynamically obtain, storage system operation multidate information, and the daily basic management work in workshop etc.; Man-machine interface 100 is used for the interaction with managerial personnel, if when systematic uncertainty is excessive, exceeds its ability to solve problem scope, right to make decision is transferred to managerial personnel exercise; Knowledge base 102 is used to store multidate informations such as the mailing address, current state of fuzzy inference rule and algorithm and scheduler module, device control layer; Decision-making module 103 is realized by the artificial intelligence reasoning, and is shown its result with display 104; Communication interface 105 is used for communicating with scheduler module 200, device control layer; Administration module 106 management that realizes a plan.
In system's operational process, sequence information can reach system database 300 storages by man-machine interface 101, and administration module 106 and system database 300 exchanges obtain sequence information and workshop information; After obtaining order, administration module 106 is according to the fuzzy inference rule in the knowledge base 102, from system database 300, check in order related process, material information and order self-information, as completion date, the processing tasks tabulation, client's importance degree, client's friendliness etc., and assess successively by 103 pairs of orders of decision-making module, determine the dispatching priority of each order and process constraint condition etc.; According to the dispatching priority of order pack successively corresponding sequence information and constraint condition (as certain workpiece operation must be at a time between before processing, must be in certain machining etc.) send to scheduler module 200 by communication interface 105.
As shown in Figure 3, be exemplary scheduler module 200 of the present invention, form by man-machine interface 201, knowledge base 202, dispatching control module 203, display 204, communication interface 205, also realize with the Agent technology; Man-machine interface 201 is used for the management and running personnel dispatching algorithm being selected for use and parameter setting; Comprised the intelligent algorithm storehouse that is used for the workshop scheduling in the knowledge base 202, the mailing address and the multidate information thereof of schedule module 100, device control layer; Communication interface 205 be used for schedule module 100, upper rfid interrogator 400 and machining cell 500 between communicate by letter; Described dispatching control module 203 is used for the intelligent algorithm that dispatching priority according to equipment state, processing constraint, order calls the knowledge base of described scheduler module work order is carried out static scheduling optimization, and shows workpiece operation information with the Gantt chart form on described display 204.
After scheduler module 200 (scheduling Agent) is received the information that schedule module 100 sends by its communication interface 205, according to equipment state and processing constraint and order dispatch priority, call the intelligent algorithm of knowledge base 202 order is carried out static optimization, obtain the manufacturing procedure tabulation of optimal scheduling scheme and each machining cell, and by display 204 demonstrations, the management and running personnel revise scheduling result in case of necessity; After scheduling result is confirmed, in the interface of scheduler module 200, show with the Gantt chart form, pass to schedule module 100 with integral form by communication interface 205 on the one hand, after schedule module 100 is received scheduling result, show with the Gantt chart form, deposit backup in the system database 300 in the tables of data form simultaneously; Write by upper rfid interrogator 400 among the RFID label of each workpiece with workpiece task list form on the other hand.
As shown in Figure 4, be the machining cell 500 component relationship figure of device control layer, machining cell 500 is positioned at system bottom, and its quantity is determined by the process unit quantity that the workshop comprises.It is made up of rfid interrogator 501, RFID label 502, workpiece 503, machine 504, display 505, communication interface 506, man-machine interface 507, knowledge base 508 and the adjusting module 509 of each station.Machine 504 is a dotted line with communication interface 506 connecting lines among the figure, is expressed as: when machine 504 is when having the robotization numerical control equipment (as numerically-controlled machine) of interface, can be connected with communication interface 506, otherwise machine 504 not to be connected with communication interface 506.
When the workpiece that posts the RFID label enters into rfid interrogator 501 scopes of machining cell 500 outfits, attend school inserting RFID tags 502 contents, system finishes the processing tasks (as flexible automation production line) of this station automatically according to the set operation on the RFID label 502, or carries out corresponding operation by operating personnel by the RFID label 502 information indication that shows on the display 505 and process (as manual operations); After this operation operation completion, information such as the job number by the 501 write operation persons of the rfid interrogator on this station, completion date, machine state, simultaneously these information are returned workshop management system by network, and change workpiece 503 (together with RFID label 502) over to next flow chart; When taking place to disturb unusual (incuring loss through delay or equipment failure) as equipment, each machining cell 500 is coordinated according to knowledge base 508 corresponding dynamic scheduling rules, dynamically adjust processing tasks, to remove uncertainty, can manually confirm dynamically to adjust the result by man-machine interface 507 in case of necessity with correction.
Beginning unit 600S and end unit 600F and machining cell 500 are similar, just the above two do not have processing machine, beginning unit 600S is mainly used in first flow chart place that workpiece is transported to this workpiece, end unit 600F is used to read in the information that is written to the RFID label after workpiece completes, so that workpiece information is analyzed.
6 production of machinery examples of an embodiment 1:6 workpiece
The Fabrication Order of existing one 6 workpiece.This order is non-preemptive type processing, is finished by 6 machinings, and order is by normal process, and each workpiece has identical processing right of priority, and performance index are that maximum machines the time.
6 workpiece numberings are respectively J
1, J
2, J
3, J
4, J
5, J
6, and the M in workshop
1, M
2, M
3, M
4, M
5, M
6Totally 6 machines are processed these 6 workpiece, and process time and processing sequence are as shown in table 1.
Table 1 embodiment production technology tables of data
As can be seen from Table 1, different workpieces J
jThe process route difference, the process sequence difference that each workpiece comprised, process time is different with the difference of machining cell. his-and-hers watches 1 decompose obtain process time matrix T and processing constraint matrix M be respectively:
Scheduler module 200 receive workpiece order that schedule module 100 sends, process time matrix T and information such as processing constraint matrix M after, order is carried out production plan finds the solution.
From as can be known aforementioned, this example is a 6/6/J/C
MaxScheduling problem, and satisfy following condition:
(1) each workpiece can begin processing after preliminary work was finished;
(2) each constantly can only have a workpiece processing on every machine, and process Once you begin just can not interrupt, and machine all is in effective status in whole process;
(3) each workpiece must progressively be processed on the specified machine of its process route;
(4) each workpiece has identical processing right of priority;
(5) operation allows to wait for that promptly previous operation is not finished, and then the action need of back is waited for;
(6) in whole process, remain unchanged the process time of workpiece, and the leading time of workpiece is included in workpiece processing in the time;
Now find the solution:
Wherein
Intelligent scheduling optimized Algorithm storehouse among the present invention provides genetic algorithm (GA), simulated annealing (SA), particle cluster algorithm (PSO) and PSOSA (in conjunction with the hybrid algorithm of particle cluster algorithm and simulated annealing).Fig. 5 is interface, optimized Algorithm storehouse, and A1 is that order is selected drop-down list box, and A2 is that Job Shop optimized Algorithm is selected the district, A3 is that flexible Job Shop optimized Algorithm is selected the district, A4 is corresponding selected algorithm parameter setting area, and A5 is the keypress function district, and A6 is for optimizing result's processing Gantt chart viewing area.
In the A2 district of Fig. 5, select GA algorithm optimization and set algorithm parameter (the GA population number is 100, evolutionary generation 50, crossover probability are 0.85, variation probability be 0.05), press the " RUN " button in the A5 district, try to achieve the Gantt chart of facing machine as shown in Figure 6 and Fig. 7 shown in the Gantt chart towards workpiece, the numeral by 2 intervals on the Gantt chart " workpiece. operation. machine ", operate on the 1st machine and carry out as the 2nd road of the 1st workpiece of " 1.2.1 " expression.
Each machinery operation situation as can see from Figure 6 is as at M
1(the 1st machine) goes up the processing operation " 1.2.1 ", " 4.2.1 ", " 3.4.1 ", " 6.4.1 ", " 2.5.1 ", " 5.5.1 ", if M
1Be the process equipment of numerically-controlled machine and so on, also can the job sequence of correspondence be downloaded M by interface
1Among.Each workpiece processing order, processing beginning and ending time and stand-by period as can see from Figure 7, optimizing scheduling result towards workpiece can be write by upper rfid interrogator 400 among the RFID502 label of corresponding workpiece, in addition, also need to write the information such as processing priority level of workpiece, be convenient to carry out dynamic dispatching, in addition, also can in label, write corresponding nc program filename or operation indication etc. as required, so that find nc program how operation of processing or indication operating personnel automatically by filename.
The RFID label 502 that is loaded with production technology information is attached to workpiece J to be processed
i(i=1,2, ..., 6) on, and be transported to the beginning unit 600S of workshop, read in RFID label 502 contents of each workpiece by the rfid interrogator on this station 501, automatically workpiece be transported to first flow chart place (if automatic production line) of this workpiece, or alert with this workpiece handling to first flow chart place (if manual workshop); By corresponding machine M
k(k=1,2 ..., 6) the rfid interrogator 501 (M that are equipped with
kForm a machining cell 500 with rfid interrogator, as shown in Figure 4), read in RFID label 502 information, system finishes the processing tasks (if flexible automation production line) of this station automatically according to the set production plan on the RFID label 502, or carries out corresponding operation processing (if manual operations) by operating personnel by 502 promptings of RFID label; After the current operation operation completion, information such as the job number by the 501 write operation persons of the rfid interrogator on this station, completion date, machine state, simultaneously these information are returned workshop management system by network, and change next flow chart over to, if do not take place unusual, just undertaken, till all processing flow charts are finished, as shown in Figure 8 by the set optimal scheduling operation scheme that writes in the RFID label 502.
Embodiment 2: the flexible production example
In flexible Job Shop scheduling problem, the machining path of different workpieces is uncertain, in case the machining path of workpiece is determined that so, flexible Job Shop scheduling problem just can be converted into general Job Shop scheduling problem.Therefore, when finding the solution flexible Job Shop scheduling, the method that can adopt substep to find the solution is at first determined the machining path of different workpieces under certain machining path, Job Shop scheduling problem to be optimized then.
Determining of the machining path of each workpiece, promptly the per pass operation of determining each workpiece is processed on which platform machine, belong to resource allocation problem, under certain machining path, Job Shop scheduling problem belongs to task or job order problem, therefore, flexible Job Shop scheduling problem needs to solve resource allocation problem and task or job order problem simultaneously.
At the flexible Job Shop problem shown in the table 2, in optimizing scheduling algorithms library (see figure 5), select particle cluster algorithm (PSO) for use, try to achieve as Fig. 9 and optimization result shown in Figure 10, similar with aforesaid general Job Shop, the optimization result can be write among the corresponding RFID label of workpiece.
The machining path and the process time of the flexible Job Shop of table 2 problem workpiece
Embodiment 3: insert the rush order example
Existing rush order, 100 pairs of rush order of schedule module are assessed, and show and need make emergency treatment, by its communication interface 105 dispatching priority, process planning and constraint condition are sent to scheduler module 200 for this reason; 200 pairs of receptions of scheduler module are from the rush order of schedule module 100, according to parts information to be processed and status information of equipment, the algorithm (as genetic algorithm) that calls the intelligent algorithm storehouse is optimized decomposition to task, and the generation scheduling scheme also writes among the RFID label 502; The RFID label 502 that is loaded with various production informations is attached on the urgent workpiece to be processed.
Suppose current 3 workpiece J that carrying out common grade
i(i=1,2,3) 3 machine M
k(k=1,2,3) flexible processing operation now will be inserted a urgent workpiece J that priority level is higher
4, as shown in figure 11, Figure 11 (a) is not for inserting the static work scheme of critical activity, Figure 11 (b) enters the moment of system of processing for inserting urgent workpiece, figure on the numeral of point separation as previously described " workpiece. operate. machine ".
Urgent insertion order rule is as follows:
(1) when hot job enters, the task of not beginning to process is postponed temporary transient indefinite duration, and the task of processing continues processing;
(2) hot job after insertion is optimized;
(3) will remain operation under the prerequisite that does not change processing machine to allow the process time rule to be inserted in the corresponding machine the earliest.
Can obtain the result shown in 11 (b) figure according to (1) bar rule, obtain the result shown in Figure 11 (c), obtain dynamic dispatching result shown in Figure 11 (d) according to (3) bar rule according to (2) bar rule.
Embodiment 4: dynamic dispatching production example under the mechanical disorder
Suppose 3 workpiece J
i(i=1,2,3) 3 machine M
k(k=1,2,3) processing operation is undertaken by Gantt chart shown in Figure 12 (a), but at a time, M
3Break down, shown in Figure 12 (b), operation " 2.2.3 " and " 1.3.3 " can't process M
2Operation " 2.3.2 " influenced also by it can't to process.
Dynamic dispatching rule after the mechanical disorder:
1) when certain machine breaks down, the unaffected operation of other machine continues processing;
2) but when the fault machine does not have the free time promptly not have manufacturing procedure, the machinable operation of first this machine in the undressed operation tabulation in the fault machine is inserted in the operation tabulation of this machine;
3) after the fault machine is removed fault,, then continue processing if its undressed sequence table is not empty.
By the dynamic dispatching rule after the above-mentioned mechanical disorder, M
2Processing the no operation in operation " 1.2.2 " back can process, and then gets fault M
3Its first operation " 2.2.3 " that can process is processed in the unprocessed operation tabulation, and this moment is owing to forward M to
2Last processing just is called " 2.2.2 "; M
1Processing the no operation in operation " 3.3.1 " back can process, and then gets the remaining undressed operation " 1.3.3 " of fault machine and processes, and this moment is owing to forward M to
1Last processing just is called " 1.3.1 ", shown in Figure 12 (c); M
2After processing operation " 2.2.2 ", reprocess and formerly arranged to process thereon but because of M
3Fault and the operation " 2.3.2 " of failing to process, last dynamic dispatching result is shown in Figure 12 (d).
Foregoing description is to be used to realize the present invention and embodiment, and scope of the present invention should not described thus and limit, and any modification or the replacement of those skilled in the art in not breaking away from the utility model scope all belongs to claim restricted portion of the present invention.
Claims (9)
1. job shop single and mini-batch production mixed flow production method that drives with order, the manufacturing system that it is characterized in that described job shop is divided schedule module, scheduler module, system database, upper rfid interrogator, device control layer, wherein schedule module, scheduler module and device control layer are realized by the Agent technology that all the each several part of manufacturing system connects into the multi-Agent manufacturing system by network and communications protocol:
Described schedule module is used for the evaluation work order, determines the dispatching priority of order, formulates process planning, and determines system's operation strategy according to relevant constraint condition;
Described scheduler module is used to receive the work order of schedule module, according to shop floor status information and parts information to be processed, decompose the order task by intelligent algorithm optimization, generate the optimal scheduling scheme and workpiece operation information is write among the corresponding workpiece to be processed RFID label by upper rfid interrogator;
Described device control layer is made up of a plurality of machining cells, beginning unit and end unit, each machining cell reads in corresponding workpiece RFID label information, and carry out corresponding processing operation, the beginning unit is used for workpiece is transported to first flow chart place of this workpiece, and end unit is used to read in the information that is written to the RFID label after workpiece completes;
Described system database is used to store work order information and workshop information and offers the correlation module use.
2. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 1, it is characterized in that: described schedule module comprises man-machine interface, knowledge base, communication interface, decision-making module and administration module; Wherein, described man-machine interface is used for managerial personnel's interaction and receives sequence information, workshop management information; Described knowledge base is used to store mailing address, stock, the equipment state multidate information of algorithm, scheduler module and the device control layer of fuzzy reasoning, decision-making; Described communication interface is used to realize and the communicating by letter of scheduler module and device control layer; Administration module is used for the Fuzzy Logic Reasoning Algorithm according to knowledge base, checks in order related process, material information and order self-information from system database; Decision-making module is assessed order successively according to the information that administration module checks in, and determines the dispatching priority and the process constraint condition of each order.
3. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 1, it is characterized in that: described scheduler module comprises man-machine interface, knowledge base, dispatching control module, display, communication interface; Wherein, the man-machine interface of described scheduler module and management and running personnel interaction realize the setting of the selecting for use of dispatching algorithm, scheduling parameter; The intelligent algorithm that the knowledge base of described scheduler module is used for dispatching between storage cart, and the mailing address and the multidate information thereof of schedule module and device control layer; Described dispatching control module is used for the intelligent algorithm that dispatching priority according to equipment state, processing constraint, order calls the knowledge base of described scheduler module work order is carried out static scheduling optimization, and shows workpiece operation information with the Gantt chart form on described display; The communication interface of described scheduler module be used for described schedule module, upper rfid interrogator, machining cell between communicate by letter, described workpiece operation information after static scheduling optimization is written among the corresponding workpiece RFID label by the upper rfid interrogator that is connected with described scheduler module.
4. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 1, it is characterized in that: each machining cell of described device control layer is made up of rfid interrogator, RFID label, workpiece, machine, display, communication interface, man-machine interface, the knowledge base of each station again; Wherein, the man-machine interface of described machining cell is used for operating personnel and consults the workpiece processing tabulation, revises the dynamic dispatching rule and manually adjusts the processing tasks tabulation in case of necessity; The knowledge base of described machining cell is used to store the status information of dynamic dispatching rule, manufacturing procedure tabulation, schedule module and scheduler module; The communication interface of described machining cell is used for communicating by letter with schedule module, scheduler module.
5. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 2, it is characterized in that: the dispatching priority of described order was determined jointly by the client's importance degree in the order, client's friendliness and order deadline; The dispatching priority of order is divided into preferential processing, normal process, three ranks of processing of delaying; And All factors being equal, preference will be give to the level order, determine process sequence according to its weighted number, for the order of equal flexible strategy, determine process sequence according to the order sequence number again.
6. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 5 is characterized in that the dispatching priority of described order is established rules then as follows really:
1) the order urgency is 5, and importance degree or friendliness are the preferential Fabrication Order that is more than 4;
2) the order urgency is 1, and importance degree, and friendliness is the Fabrication Order of delaying below 5;
3) do not meet above-mentioned two rules for the normal process order;
Wherein, the order of level that All factors being equal, preference will be give to is determined process sequence according to its flexible strategy, and the computing formula of flexible strategy is as follows:
Flexible strategy=urgency * 3+ importance degree * 2+ friendliness * 1.
7. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 3, it is characterized in that: according to the actual production problem, the mode that described scheduler module combines by static scheduling and dynamic dispatching generates the optimal scheduling scheme; When causing actual production progress and operation plan not to meet because of system's random perturbation, by the dynamic dispatching of dynamic dispatching rules enforcement, described system random perturbation comprises the machining cell fault, promptly inserts order.
8. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 7, it is characterized in that: system finishes this station processing tasks automatically according to the set operation on the workpiece RFID label, or finishes corresponding operation processing tasks by operating personnel according to the label information that shows on the display.
9. a kind of job shop single and mini-batch production mixed flow production method that drives with order according to claim 7, it is characterized in that: after the operation operation is finished, write machine state and operator's relevant information by the rfid interrogator of this station, comprise operator's job number, date, worker's item and the activity duration.
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