CN110825055B - Hybrid production workshop energy-saving scheduling method considering continuous processing of heating furnace - Google Patents

Hybrid production workshop energy-saving scheduling method considering continuous processing of heating furnace Download PDF

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CN110825055B
CN110825055B CN201911175482.3A CN201911175482A CN110825055B CN 110825055 B CN110825055 B CN 110825055B CN 201911175482 A CN201911175482 A CN 201911175482A CN 110825055 B CN110825055 B CN 110825055B
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刘志峰
闫俊
程强
张彩霞
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Beijing University of Technology
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    • G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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Abstract

The invention discloses a hybrid production workshop energy-saving scheduling method considering heating furnace continuous processing, which aims at green manufacturing and energy-saving production, considers a continuous processing stage with heating furnace equipment and an intermittent processing stage with machining equipment, analyzes various states of the machining equipment in different manufacturing stages, and establishes an optimization function of the machining equipment and the heating furnace equipment aiming at energy consumption in production scheduling. The model is prepared by the following steps: establishing an energy consumption model of the intermittent processing equipment in various time states; establishing an energy consumption model of the heating furnace equipment in the continuous stage under various time states; and constructing an objective function of the energy-saving scheduling model of the hybrid production workshop. The energy consumption optimization model is established for the hybrid production workshop, and the energy-saving scheduling problem of the hybrid production workshop considering the continuous processing of the heating furnace is solved by applying the model.

Description

Hybrid production workshop energy-saving scheduling method considering continuous processing of heating furnace
Technical Field
The invention relates to a scheduling technology of a hybrid production workshop, in particular to a modeling method of an energy-saving scheduling model of the hybrid production workshop considering continuous processing and intermittent processing of a heating furnace, and belongs to the technical field of advanced manufacturing control and scheduling.
Background
Under the rapid development of modern manufacturing technology, the research focus in the field of production scheduling gradually focuses on intelligent manufacturing and green manufacturing, and particularly under the drive of sustainable development planning, energy has become one of the most important resources of manufacturing enterprises, and how to reduce energy loss in the manufacturing process is a manufacturing problem to be solved urgently.
The energy-saving scheduling problem of the processing workshop widely exists in an actual production workshop, the energy consumption of thermal processing equipment (such as a heating furnace) such as thermal treatment and the like is obviously higher than that of cold processing equipment such as machining and the like in the processing stage of a hybrid processing workshop, however, because the process of the heating furnace equipment is difficult to control and the energy loss cannot be accurately counted, most of research objects of the existing production energy-saving scheduling are intermittent machining production equipment, the research key points are mainly the on-off strategy of the machining equipment, for example, the modeling method of the energy-saving scheduling of the flexible working workshop considering the power-off restart strategy proposed by patent CN107844104A, the flexible working workshop scheduling method considering the energy consumption cost proposed by patent CN106020142A, the energy consumption optimization scheduling method of the flexible flow shop proposed by patent CN104808636A and the like.
The energy consumption of the heating furnace equipment in the production engineering is difficult to accurately calculate, so that the energy loss is serious, and meanwhile, the difficulty of production scheduling is increased due to the subsequent continuity of the heating furnace equipment processing. Therefore, the energy loss model of the heating furnace equipment in the production process is established, the overall energy consumption of the heating furnace equipment and the machining equipment is taken as the target, and the green manufacturing in the manufacturing process is realized through the production scheduling technology, so that the method is very valuable.
Disclosure of Invention
The energy-saving scheduling model of the hybrid production workshop considering the continuous processing of the heating furnace, which is established in the invention, aims at green manufacturing and energy-saving production, considers the continuous processing stage (such as a heat treatment stage) of heating furnace equipment and the intermittent processing stage of machining equipment, analyzes various states of the machining equipment in different manufacturing stages, and establishes an optimization function of the machining equipment and the heating furnace equipment aiming at energy consumption in production scheduling.
The technical scheme adopted by the invention is the energy-saving scheduling method of the hybrid production workshop considering the continuous processing of the heating furnace, in a batch of tasks implemented by the method, the total energy consumption is divided into continuous processing stage energy consumption and intermittent stage energy consumption according to different types of processing stages, the continuous processing stage mainly takes heating furnace equipment as a main part, the heating furnace equipment is always in a heating state once being started until the final processing is finished, and for the equipment in the intermittent processing stage, the states of processing, standby, startup and shutdown and the like exist in the production, so the total energy consumption EaEnergy consumption by operation of the batch processing stage Ee-opeStandby energy consumption Ee-standbyEnergy consumption for turning on/off the power supply Ee-on/offAnd continuous phase furnace equipment energy consumption Ef-runComposition, described as the following formula:
Ea＝Ee-ope+Ee-standby+Ee-on/off+Ef-run (1)
s1, establishing an energy consumption model of intermittent processing equipment in various time states
The processing equipment can be in various different states in the production process, various different time factors are adopted to represent the production process state of the processing equipment, and the energy consumption of the processing equipment in different states is analyzed. The various time factors of the equipment in the intermittent processing stage are as follows: machining equipment interval time TgPreparation time TrMachining time TpAdjusting the time Ts. Under the state of preparing time and adjusting time, the equipment is in a standby state; in the machining time state, the equipment is in a working state; under the processing equipment interval time state, equipment adopts the switching on and shutting down strategy, and equipment will have two kinds of states: standby and on-off states.
1) Energy consumption of operation of the batch processing stage Ee-ope
The operating energy consumption of a machining device in the intermittent machining stage, mainly the energy consumption of the device in the normal machining state, is expressed as:
Figure GDA0002743545930000021
2) standby energy consumption E of the batch processing stagee-standby
The standby energy consumption of a single device for processing a single workpiece is the energy consumption generated under the standby power, namely the standby energy consumption E of the intermittent processing stage in the period from the time when the single device finishes processing the previous workpiece x to the time when the workpiece i starts to be preparede-standbyThe medicine consists of three parts: the preparation state of the equipment, the equipment adjustment state and the waiting state of the single equipment among the workpieces are represented as follows:
Figure GDA0002743545930000022
determining interval time parameter GijWhether the equipment is in a standby state when the equipment is used for processing two workpieces is indicated, if the actual interval time is less than or equal to the balance interval time, the equipment is in the standby state in the interval state, and the following conditions are indicated:
Figure GDA0002743545930000023
calculating the interval time T of each process of each workpiece on each deviceij gFor the ith workpiece to be processed on the jth processing stage, the xth workpiece represents the workpiece number before the ith workpiece on the apparatus, and the interval time represents the following:
Figure GDA0002743545930000031
calculating the equilibrium Interval time Tj bThe balance interval time is obtained by calculating the ratio of the energy of the device for switching on and off to the standby power of the device and is expressed as follows:
Figure GDA0002743545930000032
3) energy consumption for switching on and off the machine in the intermittent processing stage Ee-on/off；
For the power consumption of the equipment during the startup and shutdown, in the dispatching process, after the completion of the processing of a single equipment workpiece, the time period T before the next workpiece is conveyedij gExceeding the corresponding equilibrium time T of the stagej bAnd selecting a power-on and power-off strategy to save energy, wherein the strategy is represented as follows:
Figure GDA0002743545930000033
s2, establishing an energy consumption model of the heating furnace equipment in the continuous stage under various time states;
the heating process is set to the following stages according to the state of different time according to the controller of the heating furnace:
stage 1: heating the empty furnace, and after the temperature reaches the set temperature, adjusting the duty ratio of PWM by using a controller to ensure that the furnace temperature reaches the set temperature;
and (2) stage: finely adjusting the furnace temperature to ensure that the furnace temperature is stably kept at a set temperature;
and (3) stage: placing blank and taking out blank;
and (4) stage: a blank heating stage, wherein heating is carried out to enable the furnace temperature to be recovered to a set temperature;
and (5) stage: the blank is stably kept at a set temperature in a heat preservation stage;
and 6: and (4) closing the heating furnace after the heating of all the workpieces is completed, and reducing the furnace temperature to the room temperature.
The furnace equipment energy consumption of the successive stages (E)f-run) Is represented as follows:
Figure GDA0002743545930000034
wherein the first half of equation (8)
Figure GDA0002743545930000035
The energy consumption consumed by empty furnace heating and empty furnace heat preservation required by heating each heating furnace to the set temperature is shown in the second half section
Figure GDA0002743545930000036
Represents the energy consumption required for heating the billets after the billets are in the heating furnace, wherein drp，dra，drfAnd the weighted average values respectively represent the duty ratios of the heating furnace in the empty furnace heating stage, the stable furnace temperature stage and the blank heating stage in the temperature regulation of the heating furnace through PWM.
S3, constructing an objective function of the energy-saving scheduling model of the hybrid production workshop
Aiming at a hybrid production workshop considering the continuous processing of the heating furnace, different processing stage types are analyzed, and a model of the energy consumption of machining equipment and the energy consumption of heating furnace equipment is established. From the viewpoint of power consumption, an optimization equation is established as follows:
f＝min(R) (9)
Figure GDA0002743545930000041
s.t.
Figure GDA0002743545930000042
Figure GDA0002743545930000043
Figure GDA0002743545930000044
the symbols used in the mathematical model are specifically as follows:
Figure GDA0002743545930000045
Figure GDA0002743545930000051
the method takes green manufacturing and energy-saving production as targets, considers the continuous processing stage of the heating furnace equipment and the intermittent processing stage of the machining equipment, analyzes various states of the machining equipment in different manufacturing stages, constructs an energy change model of the heating furnace equipment in the processes of starting, heating, material taking and discharging and the like, and establishes a total energy consumption optimization model of the heating furnace equipment and the machining equipment with energy consumption as targets in production scheduling. The model is used for solving the problem of energy-saving scheduling of the hybrid production workshop considering the continuous processing of the heating furnace.
Drawings
The invention is further illustrated with reference to the following figures and examples.
Fig. 1 is a schematic view of a process for processing a workpiece by the same machining apparatus.
FIG. 2 is a schematic view showing a state change process of the heating furnace.
Fig. 3 is a flow chart of an implementation of the present invention.
Detailed Description
The energy-saving scheduling model of the hybrid production workshop, which is established in the invention and considers the continuous processing of the heating furnace, takes green manufacturing and energy-saving production as targets, considers the continuous processing stage (such as a heat treatment stage) of heating furnace equipment and the intermittent processing stage of machining equipment, analyzes various states of workpieces and processing equipment in different manufacturing stages, and establishes the production scheduling model of the machining equipment and the heating furnace equipment which takes energy consumption as targets in production scheduling.
The total energy consumption of a batch of tasks is divided into continuous processing stage energy consumption and intermittent stage energy consumption according to different types of processing stages, wherein the continuous processing stage is mainly heating furnace equipment which is in a heating state once being started until the final processing is finished, and the equipment in the intermittent processing stage has the states of processing, standby, startup and shutdown in production, so the total energy consumption is determined by the operation energy consumption E of the intermittent processing stagee-opeStandby energy consumption Ee-standbyEnergy consumption for turning on/off the power supply Ee-on/offAnd continuous phase furnace equipment energy consumption Ef-runComposition, which can be described as the following formula:
Ea＝Ee-ope+Ee-standby+Ee-on/off+Ef-run (1)
the invention is further described with reference to the following drawings and detailed description:
step 1, establishing an energy consumption model of intermittent processing equipment in various time states
As shown in fig. 1, the relationship between the process of processing a workpiece and the energy consumption for the same machining apparatus. The processing equipment can be in various different states in the production process, various different time factors are adopted to represent the production process state of the processing equipment, and the energy consumption of the processing equipment in different states is analyzed. Equipment under intermittent processing stageThe various time factors of (2) are: machining equipment interval time (T)g) Preparation time (T)r) Machining time (T)p) Adjusting the time (T)s). Under the state of preparing time and adjusting time, the equipment is in a standby state; in the machining time state, the equipment is in a working state; under the processing equipment interval time state, equipment adopts the switching on and shutting down strategy, and equipment will have two kinds of states: standby and on-off states.
1) Energy consumption for operation of the batch processing stage (E)e-ope)
The operating energy consumption of a machining device in the intermittent machining stage, mainly the energy consumption of the device in the normal machining state, can be expressed as:
Figure GDA0002743545930000061
2) standby energy consumption of the batch processing stage (E)e-standby)
The standby energy consumption of a single device for processing a single workpiece is the energy consumption generated under the standby power in the period from the time when the device finishes processing the previous workpiece x to the time when the workpiece i starts to be prepared, and consists of three parts: the preparation state of the apparatus, the apparatus adjustment state, and the waiting state of the apparatus between the workpieces are expressed as follows:
Figure GDA0002743545930000062
determining interval time parameter GijWhether the equipment is in a standby state when the equipment processes two workpieces is indicated, if the actual interval time is less than or equal to the balance interval time, the equipment is in the standby state in the interval state, and the indication is as follows:
Figure GDA0002743545930000071
calculating the interval time T of each process of each workpiece on each deviceij gFor the ith workpiece to be processed on the jth processing stage, the xth workpiece represents the workpiece number before the ith workpiece on the apparatus, and the interval time represents the following:
Figure GDA0002743545930000072
calculating the equilibrium Interval time Tj bThe balance interval time is obtained by calculating the ratio of the energy of the device for switching on and off to the standby power of the device and is expressed as follows:
Figure GDA0002743545930000073
3) energy consumption for switching on and off the batch processing stage (E)e-on/off)
For the power consumption of the equipment during the startup and shutdown, in the dispatching process, after the completion of the processing of a single equipment workpiece, the time period T before the next workpiece is conveyedij gExceeding the corresponding equilibrium time T of the stagej bThen, the power-on/off strategy can be selected to save energy, which is expressed as follows:
Figure GDA0002743545930000074
step 2, establishing an energy consumption model of the heating furnace equipment in the continuous stage under various time states
The heating process is mainly set to the following stages according to the state of different time according to the controller of the heating furnace:
stage 1: heating the empty furnace, and after the temperature reaches the set temperature, adjusting the duty ratio of PWM by using a controller to ensure that the furnace temperature reaches the set temperature;
and (2) stage: finely adjusting the furnace temperature to ensure that the furnace temperature is stably kept at a set temperature;
and (3) stage: placing blank and taking out blank;
and (4) stage: a blank heating stage, wherein heating is carried out to enable the furnace temperature to be recovered to a set temperature;
and (5) stage: the blank is stably kept at a set temperature in a heat preservation stage;
and (6) final stage: and (4) closing the heating furnace after the heating of all the workpieces is completed, and reducing the furnace temperature to the room temperature.
As shown in fig. 2, the temperature and energy consumption change process in different stages of the heating furnace is shown.
The furnace equipment energy consumption of the successive stages (E)f-run) Can be expressed as follows:
Figure GDA0002743545930000081
the first half of the formula represents the energy consumption consumed by empty furnace heating and empty furnace heat preservation required by each heating furnace to reach the set temperature, and the second half represents the energy consumption required by the heating furnace after blanks exist in the heating furnace, wherein drp，dra，drfAnd the weighted average values respectively represent the duty ratios of the heating furnace in the empty furnace heating stage, the stable furnace temperature stage and the blank heating stage in the temperature regulation of the heating furnace through PWM.
Step 3, constructing an objective function of the energy-saving scheduling model of the hybrid production workshop
Aiming at a hybrid production workshop considering the continuous processing of the heating furnace, different processing stage types are analyzed, and a model of the energy consumption of machining equipment and the energy consumption of heating furnace equipment is established. From the viewpoint of power consumption, an optimization equation is established as follows:
f＝min(R)(9)
Figure GDA0002743545930000082
s.t.
Figure GDA0002743545930000083
Figure GDA0002743545930000084
Figure GDA0002743545930000085
the symbols used in the mathematical model are specifically as follows:
Figure GDA0002743545930000086
Figure GDA0002743545930000091

Claims (1)

1. the energy-saving scheduling method of the hybrid production workshop considering the continuous processing of the heating furnace is characterized by comprising the following steps of: in a batch of tasks implemented by the method, the total energy consumption is divided into continuous processing stage energy consumption and intermittent stage energy consumption according to different types of processing stages, the continuous processing stage is mainly heating furnace equipment, the heating furnace equipment is always in a heating state once being started until the final processing is finished, and the equipment in the intermittent processing stage has processing, standby and on-off states in production, so the total energy consumption EaEnergy consumption by operation of the batch processing stage Ee-opeStandby energy consumption Ee-standbyEnergy consumption for turning on/off the power supply Ee-on/offAnd continuous phase furnace equipment energy consumption Ef-runComposition, described as the following formula:
Ea＝Ee-ope+Ee-standby+Ee-on/off+Ef-run (1)
s1, establishing an energy consumption model of intermittent processing equipment in various time states
The processing equipment can be in various different states in the production process, various different time factors are adopted to represent the production process state of the processing equipment, and the energy consumption of the processing equipment in different states is analyzed; the various time factors of the equipment in the intermittent processing stage are as follows: machining equipment interval time TgPreparation time TrMachining time TpAdjusting the time Ts(ii) a Under the state of preparing time and adjusting time, the equipment is in a standby state; in the machining time state, the equipment is in a working state; under the processing equipment interval time state, equipment adopts the switching on and shutting down strategy, and equipment will have two kinds of states: standby and power on/off states;
s2, establishing an energy consumption model of the heating furnace equipment in the continuous stage under various time states;
the heating process is set to the following stages according to the state of different time according to the controller of the heating furnace:
stage 1: heating the empty furnace, and after the temperature reaches a set temperature, adjusting the duty ratio of PWM by using a controller to ensure that the furnace temperature reaches the set temperature;
and (2) stage: finely adjusting the furnace temperature to ensure that the furnace temperature is stably kept at a set temperature;
and (3) stage: placing blank and taking out blank;
and (4) stage: a blank heating stage, wherein heating is carried out to enable the furnace temperature to be recovered to a set temperature;
and (5) stage: the blank is stably kept at a set temperature in a heat preservation stage;
and 6: after the heating of the heating furnace is completed, all the workpieces are closed, and the furnace temperature is reduced to room temperature;
the furnace equipment energy consumption of the successive stages (E)f-run) Is represented as follows:
Figure FDA0002743545920000011
wherein the first half of equation (8)
Figure FDA0002743545920000012
The energy consumption consumed by empty furnace heating and empty furnace heat preservation required by heating each heating furnace to the set temperature is shown in the second half section
Figure FDA0002743545920000021
Indicating the inside of the heating furnaceEnergy consumption for heating the blanks after they are present, drp，dra，drfRespectively representing weighted average values of duty ratios of the heating furnace in an empty furnace heating stage, a stable furnace temperature stage and a blank heating stage in the temperature regulation of the heating furnace through PWM;
s3, constructing an objective function of the energy-saving scheduling model of the hybrid production workshop
Aiming at a hybrid production workshop considering the continuous processing of a heating furnace, analyzing different processing stage types, and establishing a model of energy consumption of machining equipment and energy consumption of heating furnace equipment; from the viewpoint of power consumption, an optimization equation is established as follows:
f＝min(R) (9)
Figure FDA0002743545920000022
s.t.
Figure FDA0002743545920000023
Figure FDA0002743545920000024
Figure FDA0002743545920000025
the symbols used in the mathematical model are specifically as follows:
n number of workpieces;
i workpiece number, i ═ 1,2, …, n;
m number of processing stages;
j is the number of the processing stage, j is 1,2, …, m;
x numbering the previous workpiece of the i workpiece on the same machining equipment;
y numbering the next workpiece of the i workpiece on the same machining equipment;
k device numbers in the same phase;
kjnumber of devices in the j stage;
njkthe j stage is a continuous processing stage and represents the number of workpieces to be processed by the k heating furnace;
Dj Dj0 means that the j-th stage is a batch processing stage; dj1 denotes that stage j is a continuous processing stage;
Figure FDA0002743545920000026
the preparation time of the ith workpiece in the jth stage;
Figure FDA0002743545920000027
the processing time of the ith workpiece in the jth stage;
Figure FDA0002743545920000028
adjusting time of the ith workpiece in the jth stage;
Figure FDA0002743545920000031
the interval time of the ith workpiece on the jth stage;
Figure FDA0002743545920000032
the equipment energy consumption balance time at the j stage;
Gijjudging interval time parameters of the ith workpiece in the jth stage;
stijthe starting time of the ith workpiece on the jth stage;
rtijstarting time of preparation time of the ith workpiece in the jth stage;
ptijthe machining start time of the ith workpiece in the jth stage;
sutijithStarting time of adjusting time of the workpiece in the j stage;
etijthe end time of the ith workpiece in the jth stage;
Figure FDA0002743545920000033
heating the ith workpiece on the jth stage for the first-stage full heating time of the furnace;
Figure FDA0002743545920000034
heating the ith workpiece in a heating furnace at the j stage for adjusting the heating time at the first stage;
Figure FDA0002743545920000035
heating the ith workpiece in the second stage of the heating furnace in the j stage for the heating time;
Figure FDA0002743545920000036
the processing power of the equipment at the j stage;
Figure FDA0002743545920000037
standby power of the device at the j stage;
Figure FDA0002743545920000038
the startup and shutdown energy consumption of the equipment at the j stage;
drpduty ratio weighted average value in the empty furnace heating stage;
drastabilizing the weighted average value of the duty ratio of the furnace temperature stage;
drfa blank heating stage duty ratio weighted average value;
r total energy consumption required for all manufacturing equipment to produce n workpieces;
1) energy consumption of operation of the batch processing stage Ee-ope
The operating energy consumption of a machining device in the intermittent machining stage, mainly the energy consumption of the device in the normal machining state, is expressed as:
Figure FDA0002743545920000039
2) standby energy consumption E of the batch processing stagee-standby
The standby energy consumption of a single device for processing a single workpiece is the energy consumption generated under the standby power, namely the standby energy consumption E of the intermittent processing stage in the period from the time when the single device finishes processing the previous workpiece x to the time when the workpiece i starts to be preparede-standbyThe medicine consists of three parts: the preparation state of the equipment, the equipment adjustment state and the waiting state of the single equipment among the workpieces are represented as follows:
Figure FDA00027435459200000310
determining interval time parameter GijWhether the equipment is in a standby state when the equipment is used for processing two workpieces is indicated, if the actual interval time is less than or equal to the balance interval time, the equipment is in the standby state in the interval state, and the following conditions are indicated:
Figure FDA0002743545920000041
calculating the interval time T of each process of each workpiece on each deviceij gFor the ith workpiece to be processed on the jth processing stage, the xth workpiece represents the workpiece number before the ith workpiece on the apparatus, and the interval time represents the following:
Figure FDA0002743545920000042
calculating the equilibrium Interval time Tj bThe balance interval time is obtained by calculating the ratio of the energy of the device for switching on and off to the standby power of the device and is expressed as follows:
Figure FDA0002743545920000043
3) energy consumption for switching on and off the machine in the intermittent processing stage Ee-on/off；
For the power consumption of the equipment during the startup and shutdown, in the dispatching process, after the completion of the processing of a single equipment workpiece, the time period T before the next workpiece is conveyedij gExceeding the corresponding equilibrium time T of the stagej bThen, the power on/off strategy is selected to save energy, which is expressed as follows:
Figure FDA0002743545920000044
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