【摘要】：制造業(yè)在將資源轉(zhuǎn)變?yōu)楫a(chǎn)品或服務的過程中消耗了大量能量。機械加工作為制造業(yè)的主要生產(chǎn)過程,機床是機械加工制造過程的重要耗能制造資源。為應對全球氣候變暖,提高制造業(yè)發(fā)展的可持續(xù)性,針對機械產(chǎn)品零件的機械加工制造過程能耗進行優(yōu)化對于節(jié)約能源,實現(xiàn)低碳制造具有重要意義。為此,本文提出了通過集成工藝規(guī)劃與生產(chǎn)調(diào)度進行機械加工制造過程能耗優(yōu)化的方法,著重研究了機床設(shè)備資源狀態(tài)建模與量化評估、機械加工制造過程能耗的定量計算、面向低碳制造的工藝規(guī)劃與生產(chǎn)調(diào)度集成等內(nèi)容。針對機床設(shè)備資源狀態(tài)建模與量化評估問題,首先討論了資源能力與狀態(tài)的區(qū)別,對機床設(shè)備狀態(tài)進行了形式化的建模描述;然后建立了機床設(shè)備狀態(tài)量化評價指標體系;結(jié)合建立的機床狀態(tài)模型和評價指標體系,利用基于層次分析法的二級模糊綜合評判法實現(xiàn)了機床設(shè)備狀態(tài)量化分析,得到了機床設(shè)備狀態(tài)總評分數(shù),從而支持工藝規(guī)劃資源決策。針對機械加工制造過程能耗的定量計算問題,在界定的研究范圍內(nèi),通過合理假設(shè),利用基于動素的機床能耗模型,建立了機械產(chǎn)品零件的機械加工制造過程能耗計算模型。針對面向低碳制造的工藝規(guī)劃與生產(chǎn)調(diào)度集成問題,本文基于非線性工藝規(guī)劃這一典型的工藝規(guī)劃與生產(chǎn)調(diào)度集成模型開展研究。首先分析了非線性工藝規(guī)劃的特點,結(jié)合AOS樹理論介紹了表達它的AOS樹建立過程和如何基于非線性工藝規(guī)劃AOS樹獲得零件可選工藝路線。然后,借鑒現(xiàn)有柔性作業(yè)車間調(diào)度研究,通過合理假設(shè),建立了以全部加工任務選擇機床的綜合平均狀態(tài)、總完工時間以及機械加工制造過程能耗為優(yōu)化目標,面向低碳制造的工藝規(guī)劃與生產(chǎn)調(diào)度集成模型,給出了其數(shù)學表達。采用了基于智能算法的工藝規(guī)劃與生產(chǎn)調(diào)度集成實現(xiàn)方法,利用染色體分層編碼遺傳算法求解建立的集成模型。當通過非線性工藝規(guī)劃為每個零件生成的可選工藝方案給定時,該集成模型能權(quán)衡優(yōu)化目標,決策出適合各零件的工藝路線、機床選擇方案和相應的生產(chǎn)調(diào)度方案。為驗證本文提出的機械加工制造過程能耗優(yōu)化方法節(jié)能效果,進行了案例研究。以某制造企業(yè)為背景,通過對比某批次機械產(chǎn)品零件在工藝規(guī)劃與生產(chǎn)調(diào)度集成模式和傳統(tǒng)串行工作模式下的機械加工制造過程能耗,驗證了所提節(jié)能方法的有效性。使用基準實例測試驗證了基于染色體分層編碼遺傳算法實現(xiàn)工藝規(guī)劃與生產(chǎn)調(diào)度集成的可行性。最后,對全文的主要研究內(nèi)容和創(chuàng)新點進行了歸納總結(jié),并對后續(xù)研究方向進行了展望和探討。
[Abstract]:Manufacturing consumes a lot of energy in the process of transforming resources into products or services. As the main production process of manufacturing industry, machine tool is an important energy-consuming resource in the process of machining and manufacturing. In order to deal with global warming and improve the sustainability of manufacturing development, it is of great significance to optimize the energy consumption of mechanical manufacturing process for mechanical parts to save energy and realize low carbon manufacturing. In this paper, an integrated process planning and production scheduling method for optimization of energy consumption in machining manufacturing process is proposed. The modeling and quantitative evaluation of machine tool equipment resource state and the quantitative calculation of energy consumption in machining manufacturing process are emphatically studied, and the energy consumption of machining manufacturing process is optimized by means of integrated process planning and production scheduling. Integration of process planning and production scheduling for low carbon manufacturing. In view of the modeling and quantitative evaluation of machine tool equipment resource state, the difference between resource capability and state is discussed, and the formalized modeling description of machine tool equipment state is given, and then the quantitative evaluation index system of machine tool equipment state is established. Combined with the established machine tool state model and evaluation index system, the quantitative analysis of machine tool equipment state is realized by using the two-stage fuzzy comprehensive evaluation method based on analytic hierarchy process (AHP), and the total evaluation score of machine tool equipment state is obtained. Thus supporting process planning resource decision-making. Aiming at the problem of quantitative calculation of energy consumption in machining and manufacturing process, the energy consumption model of mechanical parts in machining process is established by means of reasonable assumption and dynamic element-based energy consumption model of machine tool. Aiming at the integration of process planning and production scheduling for low carbon manufacturing, this paper studies the integration model of process planning and production scheduling based on nonlinear process planning. Firstly, the characteristics of nonlinear process planning are analyzed. Combined with the theory of AOS tree, the process of establishing AOS tree to express it and how to obtain the optional process route of parts based on AOS tree of nonlinear process planning are introduced. Then, referring to the existing research on flexible job shop scheduling, through reasonable assumptions, the optimization objectives of selecting the comprehensive average state of machine tool, the total completion time and the energy consumption of machining manufacturing process with all machining tasks are established. The integrated model of process planning and production scheduling for low carbon manufacturing is presented, and its mathematical expression is given. The integration method of process planning and production scheduling based on intelligent algorithm is adopted. The integration model is solved by using the genetic algorithm of chromosome hierarchical coding. When the optional process plan generated for each part is timed by nonlinear process planning, the integrated model can weigh the optimization objective and decide the process route, machine tool selection scheme and corresponding production scheduling scheme suitable for each part. In order to verify the energy saving effect of the optimization method of energy consumption in machining manufacturing process, a case study was carried out. Based on the background of a manufacturing enterprise, the effectiveness of the proposed energy-saving method is verified by comparing the energy consumption of a batch of mechanical parts under the integration mode of process planning and production scheduling and the traditional serial working mode. The feasibility of integration of process planning and production scheduling based on chromosome hierarchical coding genetic algorithm is verified by benchmark examples. Finally, the main research contents and innovation points are summarized, and the future research direction is prospected and discussed.
【學位授予單位】：浙江大學
【學位級別】：博士
【學位授予年份】：2016
【分類號】：TH186

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