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流程工业间歇生产调度中并行列队竞争算法的应用研究
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摘要
流程工业是国民经济的重要基础工业。近年来,随着经济全球化的发展,传统流程工业受到了巨大的挑战。流程企业的经营环境更为复杂,市场竞争日趋激烈,每个企业都在寻求最佳的生产运营管理方案,以提高企业的生产经营效率,从而增强企业的竞争优势。生产调度是流程企业生产管理的核心,合理的生产调度不仅有助于提高企业的服务水平,而且还可以为企业带来显著的经济效益。目前,研究流程工业生产调度问题的瓶颈在于建模及求解的困难,现有的求解方法往往采用大量的整数变量和非线性关系式描述各种生产约束条件,致使所建立的模型规模庞大,求解难度高。当面临稍大规模的复杂调度问题时,一般的求解方法就很难在合理的时间内找到满意的调度方案。
     本文对流程工业间歇生产调度问题进行了研究。提出了新的建模及求解方法,较好地解决了较大规模复杂调度问题的求解。主要研究工作包括以下几个方面的内容:
     (1)将并行计算技术与列队竞争算法相结合,提出了一种求解大规模复杂优化问题的并行列队竞争算法。该算法采用有虚拟主节点的粗粒度并行模型作为基本并行框架,通过动态迁移拓扑、动态繁殖子代、多水平竞争等策略以实现局部搜索与全局搜索的对立统一。对典型测试函数的计算证实,并行列队竞争算法求解大规模优化问题的性能优于普通列队竞争算法。对复杂工程优化实例的求解表明,相对于文献中报道的一类进化算法,并行列队竞争算法具有更好的鲁棒性和求解质量。
     (2)建立了有并行生产设备的单阶段多产品间歇生产调度优化模型,该模型将调度优化问题分解为订单生产安排和排序两个子问题。对订单的生产安排,通过引入启发式订单分配规则和柔性生产约束处理方法来完成。而对排序子问题,则是基于对订单生产顺序和订单分配规则的变异,用并行列队竞争算法来求解。实例计算表明,对小规模调度问题,本文所提出的方法可快速求得与文献中相同的最优解;对文献中有不同复杂约束条件的各种50份订单的较大规模调度问题,本文所求得的结果均优于文献中报道的结果。
     (3)对有并行生产设备的多阶段多产品间歇生产调度问题进行了研究。提出了分级调度的新思想与正向-逆向订单分配策略,建立了该问题的调度优化模型。基于对订单生产序列实施的置换-反转混合变异策略和对订单分配规则实施的按比例分配搜索空间策略,用并行列队竞争算法对文献中有多种复杂约束条件与不同调度目标的问题进行了求解,结果表明:本文所提出的方法在求解文献中所有大于10份订单的调度问题时,都得到了优于文献所报道的解,并且解的质量随调度问题规模的增加而明显提高。
     (4)对有并行生产设备的多目的间歇生产调度问题进行了研究。建立了以加权生产完成时间为调度目标,以所有订单生产步骤排序和订单各阶段所选用分配规则为决策变量的调度优化模型。在使用并行列队竞争算法求解时,提出了新的混合变异及迁移操作策略,有效地提高了算法的求解效率。对文献中实例的求解表明,本文所提出的方法同时适用于序贯多目的生产调度问题和有并行设备的多目的生产调度问题的求解,并且在求解有并行设备的复杂调度问题时得到了比文献更好的解。另外,对虚拟实例的求解证实,采用本文提出的调度目标与求解方法可得到即能满足客户需求,又能有效提高生产效率的调度方案。
     (5)研究了涂料生产过程的调度问题。根据涂料企业生产实际提出了订单生产总时间和拖期总时间加权和最少的调度目标,并给合本文所提出的多阶段多产品调度问题的求解方法对一个涂料企业生调度的实例进行了求解,得到了既能最大限度满足顾客需求,又能最小化涂料订单生产总时间的优化调度方案。
Process industry is a major basic industry of national economy. In recent years, with the development of economic globalization, the traditional process industry is facing great challenges. With increasingly keen market competition and more complex business environment, each enterprise in process industry is searching for good solutions for production and operation to improve the efficiency of production operation, thereby enhance its own core competitive advantage. Production scheduling is the core content of enterprise management, and the reasonable production schedule not only can improve the service level of enterprises, but can bring significant economic benefits for enterprises. At present, the bottleneck problems for solving the production scheduling problem in process industry are modeling and optimization algorithms. The existing methods often used a large number of integer variables and nonlinear inequalities to represent various constraints in actual production, leading to large model size and computational intractable. Therefore, it is very difficult for the existing methods to obtain acceptable solutions to large-scale problems within reasonable time.
     This thesis focuses on the batch production scheduling problems in process industry. New ways of modeling and algorithm are presented for solving the large-scale complex scheduling problems in batch plants effectively. The key problems addressed in the thesis are as follows.
     Based on the combination of conventional line-up competition algorithm (CLCA) and parallel computing, a parallel line-up competition algorithm (PLCA) for solving large-scale complex optimization problems is proposed. An improved coarse-grained parallel model with virtual master node has been presented to implement the parallelization. A new dynamic migration topology, dynamic offspring reproduction scheme and multilevel competition model are employed to balance well global search and local search, leading to the rapid convergence of the proposed algorithm. Comparative study on a group of benchmark functions show that PLCA is superior to CLCA for solving large-scale problems. Computational results on several high-constrained real-life engineering design examples further demonstrate PLCA has good performance as well as good robustness compared with other evolutionary algorithms in literature.
     A new model for single-stage multi-product scheduling problem (SMSP) in batch plants with parallel units is proposed. In this model the complex scheduling problem is decomposed into order assignment and order sequencing subproblems. The assignment subproblem is solved using a group of heuristic order assignment rule and flexible constraint handling strategies, while the sequencing subproblem is solved using parallel line-up competition algorithm that mutates the sequence of orders and the order assignment rule simultaneously to search the better solutions. Computational results on examples in literature show that the proposed approach can quickly obtain the same optimal solutions as obtained by the approaches in the literature for solving medium-scale and small-scale problems. However, for all 50-order problems with different complex constraints, the proposed approach has obtained better solutions than those of literature.
     The multi-stage multi-product scheduling problem (MMSP) in batch plants with parallel units is studied. The decomposition scheduling method and forward-backward assignment strategy are proposed to solve the MMSP. In this basis, a new model for MMSP in batch plants with parallel units is presented. Based on a mixed swap-reverse mutation strategy for the order sequence and a proportion-based search space allocation strategy for the order assignment rules, PLC A is used to solve the high-constrained examples with different scheduling objectives in literature. Computational results indicate that the proposed approach has obtained the better solutions than those of the literature for all scheduling problems with more than 10 orders. Moreover, with the problem size increasing, the solutions obtained by the proposed approach are improved remarkably.
     A new model for multi-purpose scheduling problem (MSP) in batch plants with parallel units is proposed. The objective function of this new model is the weighted production completion time, and the variables are sequence of order process steps and order assignment rules in each stage. To solving this model, more effective mixed mutation strategy and migration strategy are proposed to improve the performance of PLCA. Computational results on examples in literature show that the proposed approach is suitable for both sequential MSP and MSP with parallel units. Especially, for the complex MSP with parallel units, the proposed approach has obtained better results than those of the literature. On the other hand, the computational results on virtual examples show that a reasonable scheduling scheme that can meet the customer needs and improve production efficiency simultaneously can be obtained.
     The scheduling problem in paint production process is studied. According to the actual situation in paint enterprise, a new weighted scheduling objective consisting of total completion time of orders and total tardiness is proposed. The approach for solving MMSP with parallel units is applied to the actual paint plant. And then scheduling schemes that can maximize customer satisfaction and minimize the total completion time of orders simultaneously can be obtained.
引文
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