CN1303560C - Integrated iron and steel enterprise production process on line planning and controlling system and method - Google Patents
Integrated iron and steel enterprise production process on line planning and controlling system and method Download PDFInfo
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Abstract
The present invention provides an on-line plan dispatching system for an integral production process of an iron and steel enterprise and a method, which is used for the planning and real-time dispatching for the production process of the iron and steel enterprise. The plan dispatching system is composed of a PCS layer (2) composed of a sensor (3) installed on a site and a controller (4), an interface management server (5), a database server (6), an application layer server (7), a Web server (8), a client end work stations (9, 10) and a computer network connected with each computer equipment, the controller and the sensor. The plan dispatching method comprises the steps of definition of process flow paths, generation of production order forms, edition of production plans, analog simulation, local adjustment of plans and on-line production dispatching. The present invention has the advantage that the on-line plan dispatching system automatically compiles a production plan which is combined with on-line real-time dispatching into a whole, and the present invention is suitable for the production process having a characteristic of a mixed flow path of the iron and steel enterprise.
Description
Technical field
The invention belongs to Iron and Steel Production planned dispatching technical field, a kind of incorporate iron and steel enterprise production run on-line planning dispatching system and method particularly are provided, be used for iron and steel enterprise's production process planning establishment and Real-Time Scheduling.
Background technology
At present, the planning of domestic most of iron and steel enterprises all is in the stage of manual establishment, and efficient is low and work out not science, and majority lacks Analog Simulation System as support, can not provide one and objectively judge before producing, and therefore brings very big production risk.Simultaneously, in production schedule implementation, lack, when the improper condition of production occurring, lack the effective Real-Time Scheduling decision support system (DSS) of a cover comprehensively monitoring and assessment of implementation of the plan.
The relevant production schedule arranging system and the method for present patent applied for, mainly realize a kind of production schedule form ordering system that runs on the single computer as " 99108440.3 (production schedule form ordering system) ", be used for the planned order system of discrete manufacturing." 94101993.4 (production schedule preparation method and device thereof) " mainly realized in a plurality of production runes, production schedule layout and appending." 94109469.3 (resources of production planning optimization) " have realized that a kind of being used for formulate MRP material requirement planning, carry out optimal resource allocation and formulate the method for the production schedule having under the restraint condition.Above-mentioned patent relates generally to the layout problem of the dispersed industry production schedule, does not relate to the plan layout and the Real-Time Scheduling problem of Iron and Steel Production, and is the off-line plan arranging system of realizing on single computer.The present invention then is primarily aimed at the singularity of steel industry planned dispatching, realize a kind of under distributed network environment, on many computing machines, the System and method for that production schedule layout combines with the software and hardware of assigning, the Real-Time Scheduling of the monitoring of planning execution state, production run is one.
The production run of steel industry has continuous and discrete character concurrently, and it is different from the continuous flow procedure of oil, chemical industry, also is different from the Discrete Manufacturing Process of mechanical industry, is between the mixed type production run between the two.Therefore, more brought the complicacy of steel industry plan layout and despatching work.
(1) the process for producing steel and iron flow process is put into the final products output from raw material, most operations have physics and chemical change simultaneously concurrently in the whole piece logistics, be high temperature, high energy consumption technological process, there are characteristics such as real-time, continuity and randomness in its activity in production, and the complicacy of Production Scheduling is very high.
(2) key of steel industry production is to guarantee production safety, stable, and logistics is unimpeded, brings into play the ability of bottleneck equipment to greatest extent, and at full capacity, high-quality, produce efficiently, MPS should be considered this target emphatically.
(3) production schedule of steel industry and scheduling not only will be considered information flow and streams, also must consider energy supply stream.Its scheduling decision function need provide optimum controling strategy to the material and the energy, and decision-making should be a target to enhance productivity and to reduce production costs not only, also targets such as saving the energy, minimizing pollution should be taken into account simultaneously.
(4) extremely important in temperature of articles and time status during the course.Temperature is too low, batch has to reheat, and causes the increase of energy cost and time; Temperature is too high, may destroy machine.Time is too early, and machine is occupied; And the time is late excessively, and the continuity of product can be destroyed.
(5) the main technique route of Iron and Steel Production and equipment are constant substantially, and whole process flow has very strong continuity or piecewise continuity, a plurality of process routes are also arranged sometimes and deposit.Operation/mission duration depends on preorder and follow-up operation.
From current research situation, front is at home walked in external development far away, and large-scale company is used widely achievement in research in countries in the world.Comparatively speaking, domesticly be in the starting stage at its research and development.The planned dispatching product that present domestic special exploitation is used for Iron and Steel Production is still rare.Some universities and R﹠D institution have developed some special-purpose planning and scheduling systems as academic research in conjunction with specific iron and steel enterprise, and versatility is restricted.
Summary of the invention
The objective of the invention is to present situation at planned dispatching in the present steel manufacturing enterprise production run, a kind of incorporate iron and steel enterprise production run on-line planning dispatching system and method are provided, satisfy the requirement of the multiple technological process of production of iron and steel enterprise, for the daily Production Scheduling problem of iron and steel enterprise provides general, extendible decision support platform.
The present invention is by being installed in on-the-spot sensor 3, PCS layer 2, interface management server 5, database server 6, application layer services device 7, Web server 8, the client station 9,10 that controller 4 (PLC, DCS) constitutes, the computer network formation that connects each computer equipment, controller and sensor.
Interface management server 5 links by network and field controller, various status informations and process data process data processing and format conversion with collection in worksite, deposit in the database, for planning scheduling system provides reference frame in real time, simultaneously, the production order that ERP layer 1 is assigned is changed, be stored in the database.
The relational database management system of database server 6 operation specialties, real-time process data and plan marshal data and various system configuration data etc. with the production scene are stored in the database.
Application server 7 is core components of total system, and assemblies such as main operational plan method of combination, real-time scheduling method call the data in the database server as required, and the production schedule and scheduling scheme are write database.
The main task of Web server 8 is with application server processing, handles the result of back gained, dynamically is published on Internet and the Intranet in the mode of the Web page, is convenient to the user and shows by browser and consult in client.
Client is divided into 10 two kinds of professional client 9 and thin-clients.The specialty client is the professional client software of operation in computing machine, realizes complicated data and graphic presentation, and certain data are kept at local computer, realizes the off-line analysis of data.Thin-client is an operation standard browser program in computing machine, carries out conventional data display and inquiry.
Data acquisition is as follows: the duty of the main production equipments of on-the-spot operation and the technological parameter of operational factor and production run etc., it is done pre-service such as filtering, buffering, conditioning, amplification by sensor according to different signals, after then signal being isolated by photoelectricity, send into corresponding data acquisition and control device (PLC, DCS), be used for uploading of control in real time and information.
This system is according to process route and device parameter, in computing machine, carry out corresponding plan editor, by selecting different plan arranged modes, according to guaranteeing delivery date, process time is the shortest, plant factor is maximum and guarantees that rule such as continuous casting ability carries out planning, and the production schedule is issued to the production implementation controller.
This system is by being installed in sensor and the controller on the on-site producing devices, monitor the duty and the key parameter of various technological parameters, major equipment in the production run in real time, as the time of tapping, cast start time or the like, the abnomal condition of production run is in time reported to superior system.
This system is by the various pictures on the client computer display, the various status informations that show production run, mainly be that the actual implementation status of the production schedule is monitored and followed the tracks of, allow the user can in time understand rhythm of production, serious improper situation is reported to the police.Realization is monitored in real time to actual production process.Various status informations are carried out data necessary handles and adds up.
This system is to the improper situation that occurs in the production run and the improper situation of planning execution, according to production line reality, in computing machine, carry out relevant Real-Time Scheduling program, process model in conjunction with predefined scheduling rule and on-line study, create the emergency scheduling scheme, can carry out Real-Time Scheduling as soon as possible, provide an automatic or automanual dynamic dispatching decision scheme, fast quick-recovery steady production to the dispatcher.
The software of this system has open, distributed structure/architecture, based on distributed component technology and Object-oriented Technique, adopt the mode of multi-layer framework, the main functional modules of system and the algorithm mode with assembly is deployed in the application server of middle layer, thereby provide a kind of general extendible, satisfy the planned dispatching plateform system of kinds of processes flow process.
This system can and carry out on-line study to the production run simulation.Set up the various mathematical models of production equipment and technological process, and can carry out on-line study and correction,, set up specific model bank specific enterprise, specific technological process and equipment to model.After planning finishes, plan and scheduling scheme are compared optimization.
Planned dispatching method provided by the invention is as follows:
(1) definition of technological process
Actual conditions according to enterprise's technological process of production, on client computer, utilize patterned tool software, adopt the mode of drag and drop and line, the sequencing and the processing route of each operation of definition production line, and be crucial production equipment and production link input basic data, for the establishment of the production schedule provides foundation.
(2) producing order generates
Concentrate the sales order of certain period, then according to factors such as kind, specification, quantity, and according to the degree of concern to each factor, determine corresponding priority level, carry out the like terms merger, it is single to draw the production schedule at last.By inspection to each production equipment production capacity, the production schedule is singly carried out production capacity assessment and material requirement assessment, after inspection is passed through, the production schedule singly is transformed into the production order.
(3) production schedule layout
The plan of establishment heat is at first smelted recovery rate and continuous casting billet yield according to the weight of producing order requirements and in conjunction with each steel grade, calculate the general assembly (TW) of required molten steel, determine the process route of steel-making then according to factors such as the kind of steel in the order, technical conditions, adopt the method for Combinatorial Optimization at last, with all kinds of cost minimums in the STEELMAKING PRODUCTION is target, with resource capability and technological requirement is constraint, and the Combinatorial Optimization that carries out multiple goal, multiple constraint finally forms the heat plan.Main constraint in the Combinatorial Optimization comprises: parameters such as the steel grade of order, specification, base type, delivery date want identical or approaching in the same heat; Meet the restriction of main equipment productive capacity; Assurance is connected with subsequent handling; Restriction is the surplus material amount etc. of common kind not.
The establishment casting plan is at first preferably identical according to forming the same steel grade composition that waters time; The same time width of middle slab that waters can not frequently change, and generally according to the non-series arrangement that increases of width, and can not change too big; Heat quantity is subjected to the conditions such as restriction in big water-coating port and tundish serviceable life, suboptimization model is watered in foundation, and in the light of actual conditions, model parameter is carried out initialization, adopt rule-based heuristic and comprehensive intelligent optimization method to find the solution then and water suboptimization model, last dispatcher can manually revise according to actual conditions.
Working out rolling batch plan is according to the jump amplitude that reduces hardness, thickness, width as far as possible, reduce the principle of the number of times of roll change in the operation of rolling, at first will produce order and be combined into rolling unit according to requirements such as kind, specification, delivery date, priority, arrange the production order of each order in the rolling unit then, the rolling order of arranging each rolling unit at last.
(4) analogue simulation
Analogue simulation mainly is the planning chart that produces according to production schedule layout, according to predefined production equipment mathematical model and production run model, by the actual production run of simulation software simulation, draw corresponding simulation result and Performance Evaluation, as plant factor histogram, Gantt chart, flow process dynamic similation, material time parameter etc.
(5) plan is local adjusts
Mainly be according to the plan of preprogrammed and the result of analogue simulation, carry out the part and adjust, and analogue simulation once more planning inappropriate place, if the planning personnel think by, then approval enters next link.If that changes is too much local, can regroup plan.According to the structure of the such closed loop of establishment-simulation-adjustment, solve the effective layout problem of the production schedule in the actual production.
(6) online production scheduling
The online production scheduling all has the incident monitoring capacity to each production process of production line, can be according to predefined rule base, and whether judgement is in normal or malfunction from the event information of the control point of each PCS layer sensor and controller transmission.When fault takes place, time length and fault category according to fault effects production, the method that adopts Model Calculation and rule-based reasoning to combine, produce the production scheduling guidance program, production scheduling personnel are according to guidance program, corresponding coordination instruction is assigned at the scene, strengthened ability of regulation and control, reach the purpose of coordinating production produced on-site.
The invention has the advantages that:
Automatic establishment of the production schedule and online in real time scheduling are combined together, be applicable to iron and steel enterprise's production run with mixture length characteristics.
Based on distributed component technology and Object-oriented Technique, adopt the mode of multi-layer framework, main functional modules and the algorithm mode with assembly is deployed in the application server of middle layer, thereby provide a kind of general extendible, satisfy the planning scheduling system that multiple process for producing steel and iron flow process requires.
At the strong coupling between each process procedure of steel industry, the present invention provides based on model and regular online in real time scheduling decision support for the workshop management personnel, is convenient to timely process for producing fault, resumes production fast.
Have planning interface flexibly, the establishment of conventional plan in the daily production can be provided, the planning to hot job can be provided again.
According to practical condition, can be applicable to all kinds of iron and steel enterprises by the User Defined process route with different production procedures.
Open model bank, algorithms library and rule base structure are convenient to that the user expands and integrated with third party software.
Description of drawings
Fig. 1 is a system construction drawing of the present invention.Wherein the PCS layer 2 that constitutes of sensor 3, controller 4 (PLC, DCS), interface management server 5, database server 6, application layer services device 7, Web server 8, client station 9,10.
Fig. 2 is a software function exploded view of the present invention, comprises flow definition 12, graphical interfaces 13, planning 14, analogue simulation 15, Real-Time Scheduling 16, model bank 17, algorithms library 18, rule base 19, interface management 11 etc.
Planning 14: this module is utilized multiple optimum theory and intelligent optimization algorithm, sets up optimum heat plan, optimum casting plan and the rolling group of mathematical model of criticizing plan, and the planning for steel industry is produced provides a good solution.
Analogue simulation 15 comprises: the analogue simulation module mainly is to carry out emulation according to the production schedule that compiling module produces, and provides corresponding simulation result and Performance Evaluation.As plant factor histogram, Gantt chart, flow process dynamic similation, material time parameter etc.
Stage by stage mathematical model provides various parameter interfaces in the flow process dynamic similation, can make amendment according to the feedback of actual production, so that make simulate effect more accurate.Analogue simulation also comprises and will provide forecast model to the alarm parameters or the eliminating time of various device fault, make prediction result can with actual production match preferably.
Real-Time Scheduling 16 comprises:
(1) monitoring in real time
Monitoring in real time mainly is that the actual implementation status of the production schedule is monitored and followed the tracks of, and the various abnormal conditions that particularly occur in the production run are monitored, and feeds back to traffic department with graphics mode intuitively then.The data that real-time monitoring module can monitor first floor system feed back to administration and supervision authorities, so that the management and running personnel can in time grasp manufacturing schedule and to controlling unusually.
(2) dynamic dispatching
Dynamic dispatching mainly is to handle in real time at the information that has influence on production that real-time monitoring obtains, and by analog simulation and scheduling rule, to the adjustment that the production schedule gears to actual circumstances, perhaps regroups the production schedule.The dynamic dispatching module will provide automatic or automanual Real-Time Scheduling decision scheme for the workshop management personnel, so that assist the workshop management personnel to realize dynamic dispatching.
Model bank 17: refer to constitute by the multiple mathematical model relevant in main production equipments in the steel manufacture process and the technological process with planned dispatching.Adopt methods such as statistical regression, parameter identification, data fusion, neuroid, fuzzy logic, production, test, experimental data and expertise combination are fitted to the mutual relationship that characterizes each parameter and its influence factor.Mathematical model in the model bank can on-line study and correction in actual production process, and model accuracy is progressively improved.
Algorithms library 18: refer to the Different Optimization algorithm in solve optimizing problem such as row's product, used.Conventional have Gantt figure method, structure type method, dynamic programming, branch and bound method, a waiting line theory method etc.; The method of artificial intelligence is as simulated annealing, genetic algorithm, tabu search, evolutional programming, evolution strategy, neural net method, Lagrange relaxation and chaos optimization etc.Various algorithms all encapsulate in the mode of assembly, are convenient to from now on upgrading and expansion.
Rule base 19: refer to the various Expert Rules that produce and use during Real-Time Scheduling plan row, as smelt rule of rule, the rule of combined schedule order, the processing of improper situation or the like.Above-mentioned rule is pressed certain mode formation rule storehouse, and can constantly expand, upgrade and revise according to actual conditions.
Interface management 11 comprises the transmission of following message: the downlink data that exists between system and the ERP layer mainly contains information such as various device working ability information, Workshop Production calendar, contractor plan, operation card and route sheet, human resources, stock material.
The upstream data that exists between system and the ERP layer mainly contains the contents such as completion report of contractor plan, and to the correction advisory information of the various manufacturing parameters of production technology.
The solicited message that the upstream data that exists between system and the PCS layer mainly contains real-time information such as various device state and production status and carries out Real-Time Scheduling.
The downlink data that exists between system and the PCS layer mainly contains the production schedule that plan layout module formulates and from the strain operation plan of Real-Time Scheduling module, these are planned all by the interface module unified management, and carry out message exchange between the PCS layer.
Claims (2)
1, a kind of incorporate iron and steel enterprise production run on-line planning dispatching system is characterized in that: by be installed in PCS layer (2), interface management server (5), database server (6), application layer services device (7), Web server (8), the client station (9,10) that on-the-spot sensor (3), controller (4) constitute, the computer network that connects each computer equipment, controller and sensor constitutes; Particular content is as follows:
A, interface management server (5) link by network and field controller, various status informations and process data process data processing and format conversion with collection in worksite, deposit in the database, for planning scheduling system provides reference frame in real time, simultaneously, the production order that ERP layer (1) is assigned is changed, be stored in the database;
The relational database management system of b, database server (6) operation specialty, real-time process data and plan marshal data and various system configuration data with the production scene are stored in the database;
Assemblies such as c, application server (7) operational plan method of combination, real-time scheduling method call the data in the database server as required, and the production schedule and scheduling scheme are write database;
D, Web server (8) with application server processing, handle the result of back gained, dynamically be published on Internet and the Intranet in the mode of the Web page;
E, client are divided into (10) two kinds of professional client (9) and thin-clients: professional client is the professional client software of operation in computing machine, realize complicated data and graphic presentation, and certain data are kept at local computer, realize the off-line analysis of data; Thin-client is an operation standard browser program in computing machine, carries out conventional data display and inquiry.
2, a kind of method of using the described system of claim 1 to carry out iron and steel enterprise's production run on-line planning scheduling is characterized in that:
The definition of a, technological process:
Actual conditions according to enterprise's technological process of production, on client computer, utilize patterned tool software, adopt the mode of drag and drop and line, the sequencing and the processing route of each operation of definition production line, and be crucial production equipment and production link input basic data, for the establishment of the production schedule provides foundation;
B, production order generate:
Concentrate the sales order of certain period, reach degree of concern according to kind, specification, quantity factor then to each factor, determine corresponding priority level, carry out the like terms merger, it is single to draw the production schedule at last, by the inspection to each production equipment production capacity, the production schedule is singly carried out production capacity assessment and material requirement assessment, after inspection is passed through, the production schedule singly is transformed into the production order;
C, production schedule layout comprise: the plan of establishment heat, casting plan, rolling batch plan;
D, analogue simulation:
Analogue simulation mainly is the planning chart that produces according to production schedule layout, according to predefined production equipment mathematical model and production run model, by the actual production run of simulation software simulation, draws corresponding simulation result and Performance Evaluation;
E, the local adjustment of plan:
According to the plan of preprogrammed and the result of analogue simulation, carry out the part and adjust planning inappropriate place, and analogue simulation once more, according to the structure of the such closed loop of establishment-simulation-adjustment, the effective layout problem of the production schedule in the solution actual production;
F, online production scheduling:
The online production scheduling all has the incident monitoring capacity to each production process of production line, can be according to predefined rule base, and whether judgement is in normal or malfunction from the event information of the control point of each PCS layer sensor and controller transmission; When fault takes place, time length and fault category according to fault effects production, the method that adopts Model Calculation and rule-based reasoning to combine, produce the production scheduling guidance program, production scheduling personnel are according to guidance program, corresponding coordination instruction is assigned at the scene, strengthened ability of regulation and control, reach the purpose of coordinating production produced on-site.
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