CN102354311A - Balance method for reconfigurable assembly line customized on large scale - Google Patents
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Abstract
The invention relates to a balance method for a reconfigurable assembly line customized on a large scale. The method comprises the following steps of: establishing a mathematical model for balancing the reconfigurable assembly line customized on a large scale, encoding genes, performing genetic operation, selecting initial temperature, annealing, iterating repeatedly and the like. By the method, the number and loads of workstations and the efficiency of the assembly line can be considered comprehensively, and idle time of each workstation can be eliminated as far as possible so as to fulfill the aim of minimizing cost or maximizing output. Simultaneously, the invention also provides a mixed genetic algorithm for optimizing the balance of the assembly line. In the algorithm, by combining a simulation annealing algorithm and a genetic algorithm and adopting a self-adaption reconfiguration strategy of cross probability and mutation probability, the defects of local searching, low convergence and the like of the genetic algorithm in actual application can be effectively avoided, and the problems that the conditions of integral searching space is not known much and operation efficiency is low in the simulation annealing algorithm can be solved.
Description
Technical field
The present invention relates to a kind of restructural assembly line balancing method, and can this arrange production, belong to production line control and areas of information technology automatically towards mass customization.
Background technology
Restructural assembly line towards mass customization is the assembly system for the complicacy that adapts to mass customization Assembling Production needs; Be based on the mixed-model assembly line of the dynamic need variation of order production; Characteristics such as have the customer demand variation, assembly technology is complicated, and data scale is big.For mixed-model assembly line, the balance of assembly line is that it needs problems of at first solving, and the restructural assembly line compares to traditional single variety assembly line and mixed-model assembly line, aspect difficulty, all has bigger different in the scale of problem.See from the document situation; Research for assembly line balancing at present mainly concentrates on single variety assembly line and mixed-model assembly line; For the research of restructural assembly line balancing but seldom; And the balance model that proposes assembly line is mostly from influencing assembly line balancing in a certain respect, considers equilibrium problem like the efficient of the quantity of workstation, pitch time, the load of machinery systems, assembly line.Yet the assembly line balancing process will receive the influence of many-sided factor, should do influence factor and take all factors into consideration.In addition; Assembly line balancing problem is a discrete type network mathematical optimization problem; It also is a typical NP-hard difficult problem; The demand optimum solution is difficulty relatively; Handle this type problem intelligent heuristics method commonly used; Like genetic algorithm, simulated annealing and tabu search algorithm etc., but shortcomings such as Local Search and the poor astringency of algorithm appear in genetic algorithm easily in practical application.Simulated annealing is understood few for the situation of whole search volume, operation efficiency is low, and the tabu search algorithm shortcoming is that not only it has stronger dependence to initial solution, and the process of search is serial, but not parallel search.Therefore, press for a kind of mixed-model assembly line that can satisfy the dynamic need variation of order production and solve the problem that faces at present.
Summary of the invention
The technical matters that the present invention will solve is to propose a kind of restructural assembly line balancing method towards mass customization; The mathematical model of the restructural assembly line balancing that this method proposes; Can take all factors into consideration workstation quantity; The factor of production efficiency three aspects of balancing the load degree and assembly line; Make it solve the deficiency that exists in the background technology; The line balancing that adapts to the restructural assembly line; Thereby can obtain than having the optimization method that various balance methods more adapt to now; For example can make the workstation minimum number; The production line balancing the load is best, and can enhance productivity greatly.
For solving the problems of the technologies described above, the technical scheme that the present invention adopts is:
A kind of restructural assembly line balancing method towards mass customization is characterized in that described restructural assembly line balancing method carries out according to following steps:
(1) foundation is towards the restructural assembly line balancing model of mass customization
1) set up the idle status evaluation index of assembly line:
The idle situation of whole production line can be measured with following index:
Formula (1) in
for a given assembly line of maximum working hours,
are
workstations working hours,
is the number of workstations;
2) set up the balancing the load evaluation index of assembly line:
Assembly line can utilize the evaluation index of the standard deviation of each workstation load as balancing the load;
(2)
Formula (2) in the
for a given assembly line beats,
are
workstations working hours,
is the number of workstations;
3) set up the production efficiency evaluation index of assembly line:
As far as the restructural assembly line, the demand of production is that the order by the client spurs, and can consider the production efficiency of assembly line with the production cycle of order requirements;
Wherein: T is the production cycle of order requirements;
the number of types of products;
4) set up the mathematical model of restructural assembly line balancing:
Comprehensive step 1), 2), 3) promptly obtain the mathematical model of restructural assembly line balancing, be shown below:
Formula (4) in the weight values
can according to the actual situation in the assembly line or expert judgment method to get; formula (4) in the
reaction assembly line idle state,
reaction assembly line load balance,
reaction assembly line production efficiency; due
The same dimensionless through different weight values
, by linear combination of the three parts, the assembly line can be considered a minimum idle time, load balancing and assembly lines maximum production efficiency three objectives, in order to evaluate the entire balance of reconfigurable assembly line, the adaptation function value is smaller, the better the balance of the assembly line;
Satisfy constraint condition simultaneously:
Formula (5) for the occurrence of constraint to ensure that any job elements can only be assigned to a workstation that can not repeat the same job elements assigned to multiple workstations; formula (6) to ensure that all job elements are assigned; formula (5) and Formula (6) Guarantee element set into mutually exclusive and completeness; formula (7) for the beat constraint, which means that all assigned to either a workstation operating time of job elements and must be no larger than the beat
; formula (8) is Operating element takes precedence relation constraints, ensure job elements assigned to meet assembly precedence relations, there is no element is assigned to a job than their previous job yuan;
(2) gene code
Encoded using genetic algorithms in the form of real numbers, each bit represents a job elements gene, chromosome length is equal to the number of job elements, store them in the order of priority to meet the assembly sequence constraint relationships, and in subsequent operations to meet each job elements The serial number can not be repeated; assembly first sequence diagram with priority matrix
said that in order to accelerate the convergence speed, in order to meet the first assembly diagram based on the use of heuristic rules and random search sorting method to generate the initial population;
(3) genetic manipulation
Select two chromosomes as parents from population at random, and select a mating zone thereon arbitrarily, obtain two new child chromosome; Because parent is feasible solution, the filial generation after therefore intersecting also is a feasible solution, and simultaneously, this method still can produce variation effect to a certain degree under the identical situation of two father's chromosomes, and this has certain effect to keeping variation certain in the colony;
In line balancing, since the assembly sequence constraint legal solutions in order to increase the number of mutation, using the displacement variation and combination of swap mutation, crossover probability
and mutation probability
The impact of genetic algorithm selection is the key to behavior and performance a direct impact on convergence of the algorithm; in the standard genetic algorithm,
and
general rule of thumb is taken as a fixed value, establishes a crossover probability and mutation probability adaptive reconfiguration strategy;
Formula (10), (11) in,
is a constant, whose value is (0,1);
is the largest population fitness value,
for every generation population average fitness value;
want to cross two individuals larger fitness value;
for the population variance of the individual to the fitness value;
(4) the temperature operation is selected and moved back to initial temperature
The initial temperature selection
in the form of optional
= 10,20,100 ... other test values; wherein
as the initial population of the largest objective function value,
as the initial population of the smallest objective function value; retreat temperature commonly used functions
form, where
;
(5) iterate
If, then repeating the operating process of (2)-(5) less than the predefined algebraically that falls, can accomplish subalgebra.
After using the above technical scheme of the present invention over the prior art has obvious advantages, the proposed mass customization of reconfigurable assembly line balancing method takes into account the number of workstations, workstation loading and assembly line efficiency three factors that can make possible to eliminate idle time on each workstation, to minimize costs or maximize output, while an optimized assembly line balancing hybrid genetic algorithm, simulated annealing and genetic algorithms are combined and used crossover probability and The adaptive mutation probability reconstruction strategy, can effectively avoid the application of genetic algorithms prone local search and convergence defects and poor; but also can solve the simulated annealing conditions for the entire search space is poorly understood, the operation inefficient issue.
Description of drawings
Fig. 1 is a genetic algorithm process flow diagram of the present invention;
Fig. 2 preferentially schemes for the assembling of uniting of product.
Embodiment
Below in conjunction with accompanying drawing and embodiment the present invention is done further detailed explanation:
A special vehicle assembly line with certain special vehicle manufacturing enterprise is an example; In this assembly line, mainly accomplish certain special vehicle chassis general assembly, its main assembly process has: the ground plate rail is reached the standard grade, wire harness and auxiliary stand are installed, fall to adorning front axle assy, fall to adorning rear axle assy, the mounted engine assembly that falls, oil bunkering case, adorn each auxilitary unit, wheel assembling, fall to adorning pilothouse, dress rotation axis assembly, chair mounted etc.Three kinds of products of existing order requirements assembling, the basic function module of these three kinds of products is identical, and different demands is just arranged in some aspects, therefore can be regarded as mass customization production, realizes through the restructural assembly line.
The assembling of uniting of three kinds of products is preferentially schemed, shown in accompanying drawing 2.The production cycle of order is 3 days, and calculated by 8 hours every day, and the order volume of three kinds of products does, A=5 spare, and B=10 spare, C=10 spare, productive temp is decided to be 265s.Require to seek a kind of more excellent operation element assembled scheme, make that workstation minimum number, workstation load balancing, the production line efficiency of assembly line are higher.The present invention can be made by using reconfigurable assembly line balance model (equation (4) in the weight values according to the actual situation of the factory from each 1/3) and mixed heritage algorithm (written using VC + +6.0), the problem is solved Select the initial temperature coefficient
, back temperature coefficient
, crossover and mutation probability coefficient
= 0.45,
= 0.03,
= 0.65,
= 0.5.Population size
= 80, if successive iterations 40 times the minimum evolutionary population objective function value
no change, then the algorithm terminates.
Concrete solution procedure is following:
(1) gene code
Coding adopts the form of real number; Each gene position is represented an operation element; Chromosomal length equals the operation element prime number, and its order of depositing will satisfy the precedence constraint relation of assembling sequence, and the sequence number that will satisfy each operation element in operation subsequently can not repeat to occur.Assembly first sequence diagram with priority matrix
said that in order to accelerate the convergence speed, in order to meet the first assembly diagram based on the use of heuristic rules and random search sorting method to generate the initial population.
The random search ranking method produces the process of initial population:
Step1: The priority matrix
form an initial set of job elements, called ordered set
; generate a new, empty set, called the free set
;
Step2: Set the sort
the job elements listed as 0 (pre-order elements, or those who do not have pre-order elements, but pre-order elements have been assigned to the workstation those elements) into free collection
in;
Step5: if the middle All Jobs element of ordering collection
is assigned with finish, just finish; Otherwise change Step2.
(2) genetic decoding
The process of decoding is exactly that operation element is assigned to workstation and is arranged in the process on the assembly line.To the characteristics of assembly line balancing, to satisfy following principle during decoding:
1) gene order in the coding will satisfy the precedence relationship constraint.
2) the All Jobs element time sum of a workstation will satisfy the beat constraint.
3) distribution of operation element has uniqueness, promptly can only be assigned to a workstation.
According to mentioned above principle,, just obtained a feasible solution when all operations all assign.
(3) relevance grade function
Employing formula (12) is as the relevance grade function, and objective function of the present invention is to minimize, for satisfy the fitness function value on the occasion of, it is transformed, the computing formula that obtains is:
Where
is the same generation groups in the objective function value is the maximum of the objective function value of chromosomes.
(4) genetic manipulation
Genetic operators, including selection, crossover and mutation operators, which in turn acts on the population
, resulting in new species
.
Select two chromosomes as parents from population at random, and select a mating zone thereon arbitrarily, obtain two new child chromosome.Because parent is feasible solution, the filial generation after therefore intersecting also is a feasible solution, and simultaneously, this method still can produce variation effect to a certain degree under the identical situation of two father's chromosomes, and this has certain effect to keeping variation certain in the colony.In assembly line balancing, because the constraint of assemble sequence, in order to increase the legal quantity of separating in variation back, this paper adopts the displacement variation and exchanges the mode that variation combines.In order not violate precedence constraint relation, the position that element can insert can only be the element or the back back of element tightly before it is tight.
The process flow diagram of genetic algorithm as shown in Figure 1.
Concrete algorithm steps is following:
Step1: determine the population size
, and the control algorithm coefficients, ever-temperature coefficient
, retreat temperature coefficient
, crossover and mutation operations coefficient,
,
,
,
, to generate the initial population
, and to make an initial optimal solution
, the number of iterations
.
Step2: on population
Calculate the fitness function value
, determine whether the termination condition is reached, and if so, over, the output optimal solution.Otherwise change Step3.
Step3: adopt tournament method to carry out colony and select, implement elite's retention strategy simultaneously.
Step4: recomputate the chromosome target function value, intersect respectively and mutation operation, carry out elite's retention strategy simultaneously by crossover probability and variation probability.
Step5: After crossover and mutation on the group, in the neighborhood of chromosomes randomly generated new individuals
and
, using the Metropolis criterion, ie if
, when
or
when individuals
Copy to the next generation, otherwise, will
Copy to next-generation groups.
Step7: whether reach the iterations of regulation, if then export optimum solution, otherwise change Step2.
The result that is optimized at last is as shown in table 1.Identical being provided with under the parameters conditions; Algorithm of the present invention and GA, SA algorithm are contrasted, and as shown in table 2, the result shows; The minimum workstation quantity that algorithm of the present invention is asked, the evolutionary generation the when standard deviation of workstation load, convergence and all be better than GA and SA algorithm working time.
Table 1 Optimization result
Table 2 algorithm of the present invention and the contrast of other arithmetic result
The above is a simple embodiment of the present invention, does not constitute the restriction to flesh and blood of the present invention, and protection scope of the present invention is as the criterion with claims.
Claims (1)
1. restructural assembly line balancing method towards mass customization is characterized in that described restructural assembly line balancing method carries out according to following steps:
(1) foundation is towards the restructural assembly line balancing model of mass customization
1) set up the idle status evaluation index of assembly line:
The idle situation of whole production line can be measured with following index:
Formula (1) for a given assembly line maximum working time,
are
workstations working hours,
is the number of workstations;
2) set up the balancing the load evaluation index of assembly line:
Assembly line can utilize the evaluation index of the standard deviation of each workstation load as balancing the load;
Formula (2) in the
for a given assembly line beats,
are
workstations working hours,
is the number of workstations;
3) set up the production efficiency evaluation index of assembly line:
As far as the restructural assembly line, the demand of production is that the order by the client spurs, and can consider the production efficiency of assembly line with the production cycle of order requirements;
Wherein: T is the production cycle of order requirements;
is the number of workstations;
4) set up the mathematical model of restructural assembly line balancing:
Comprehensive step 1), 2), 3) promptly obtain the mathematical model of restructural assembly line balancing, be shown below:
Formula (4) in the weight values
can according to the actual situation in the assembly line or expert judgment method to get; formula (4) in the
reaction assembly line idle state,
reaction assembly line load balance,
reaction assembly line production efficiency; due
the dimension of the same, with different weight values
, by a linear combination of the three parts, you can also consider the assembly line idle least time, load balancing and assembly lines maximum productivity three goals, in order to evaluate the entire balance of reconfigurable assembly line, the fitness function value is smaller, the better the balance of the assembly line;
Satisfy constraint condition simultaneously:
Formula (5) for the occurrence of constraint to ensure that any job elements can only be assigned to a workstation that can not repeat the same job elements assigned to multiple workstations; formula (6) to ensure that all job elements are assigned; formula (5) and Formula (6) Guarantee element set into mutually exclusive and completeness; formula (7) for the beat constraint, which means that all assigned to either a workstation operating time of job elements and must be no larger than the beat
; formula (8) for the job element takes precedence relation constraints, ensure job elements assigned to meet assembly precedence relations, there is no element is assigned to a job than their previous job yuan;
(2) gene code
Encoded using genetic algorithms in the form of real numbers, each bit represents a job elements gene, chromosome length is equal to the number of job elements, store them in the order of priority to meet the assembly sequence constraint relationships, and in subsequent operations to meet each job elements The serial number can not be repeated; assembly first sequence diagram with priority matrix
said that in order to accelerate the convergence speed, in order to meet the first assembly diagram based on the use of heuristic rules and random search sorting method to generate the initial population ;
(3) genetic manipulation
Select two chromosomes as parents from population at random, and select a mating zone thereon arbitrarily, obtain two new child chromosome; Because parent is feasible solution, the filial generation after therefore intersecting also is a feasible solution, and simultaneously, this method still can produce variation effect to a certain degree under the identical situation of two father's chromosomes, and this has certain effect to keeping variation certain in the colony;
In line balancing, since the assembly sequence constraint legal solutions in order to increase the number of mutation, using the displacement variation and combination of swap mutation, crossover probability
and mutation probability
choice affect the behavior and performance of genetic algorithm key directly affects convergence of the algorithm; in the standard genetic algorithm,
and
general rule of thumb is taken as a fixed value, establishes a crossover probability and mutation probability adaptive reconstruction strategy;
Formula (10), (11) in,
is a constant, whose value is (0,1);
is the largest population fitness value,
as each generation population average fitness value;
as to intersect the larger of the two individual fitness value;
for the population variance of the individual to the fitness value;
(4) the temperature operation is selected and moved back to initial temperature
The initial temperature selection
form, optionally
= 10,20,100 ... other test values; wherein
as the initial population of the largest objective function value,
is the initial population of the smallest objective function value; retreat temperature function used commonly
form, where
;
(5) iterate
If, then repeating the operating process of (2) ~ (5) less than the predefined algebraically that falls, can accomplish subalgebra.
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Application publication date: 20120215 |