混流轿车总装配线的动态规划与仿真研究
文献类型：学位论文
| 作者 | 曹振新 |
| 学位类别 | 博士 |
| 答辩日期 | 2005-05-30 |
| 授予单位 | 中国科学院沈阳自动化研究所 |
| 授予地点 | 中国科学院沈阳自动化研究所 |
| 导师 | 朱云龙 |
| 关键词 | 混流装配线 负荷平衡 投产排序 仿真评估 基因遗传算法 |
| 其他题名 | Research on Dynamic Planning and Simulation of the Mixed Model General Automobile Assembly Lines |
| 学位专业 | 机械电子工程 |
| 中文摘要 | 随着产品生产向多品种小批量发展，装配流水线的单品种大批量生产方式已逐渐变得不能适应市场多变与激烈竞争的需要，正面临适应性和敏捷性的挑战。混流装配线实现在一条生产线上装配多种不同型号的产品，提高企业对市场环境变化的快速响应能力。越来越多的生产企业选择多品种混合的精益制造模式。在分析轿车模块化总装工艺流程及特点的基础上，建立了目视化管理的混流装配工艺卡。混流装配线平衡的目的是实现工序同期化，改进了混流装配线负荷平衡的数学模型。建立了求解装配线平衡的基于作业序列的混合遗传退火算法MGASA，从作业顺序图生成初始群体，根据作业元素间的顺序关系构造交叉算子和变异算子，适应值中引入工位数目及工时的标准差。对一个实例进行验证与比较，取得了较优的结果。应用最小生产循环来研究流装配线的产品投产排序问题。依据装配线投产排序的运作情况，建立了基于闭环工位时间移动窗口的最小化装配线空闲与超载时间和JIT环境下零部件消耗速率均匀化的目标函数。混流装配线排序问题是类NP组合优化问题，分析了启发式法、倒数比法、品种特性逻辑计算法以及目标追踪法等优化算法。在阐述多目标遗传算法演变历程的基础上，引入了基于Pareto理论和小生镜单元的适应度函数及选择算子，通过一个混流装配线的排序实验和比较，结果表明该方法的有效性。研究了JIT环境下总装线上零部件配送的物料流，建立了看板运作流程和基于现场总线技术的物料ANDON系统。根据总装线旁物料的消耗情况，建立了工位库存的估算公式和现场物料出现MIN/MAX时的处理方式。产品的更新换代导致零部件的变化，提出了物料断点的概念并建立了实施流程。根据沈阳别克轿车总装配流水线的实际物料需求，设计了混流装配线分布式物料管理信息系统的功能模块及基于J2EE平台的软件架构。在比较了集中控制、分层控制和集散控制结构的基础上，建立了基于现场总线的网络化的协同控制结构。ANDON是广泛应用于汽车装配线上的具有声光效果的信息管理与控制系统。根据沈阳别克轿车总装车间系统结构和布局，设计了PROFIBUS和ASI等现场总线融合的轿车总装车间三层网络ANDON控制系统。详细阐述了其系统功所具有功能、构成、软硬件配置及关键工序的质量控制流程。运行实践表明，该系统具有良好的实时性和稳定性，提高了企业的生产效率。在分析数字化工厂软件eM-Power的体系结构及功能模块的基础上，建立了装配流水线仿真对象模型，并实现了物料流、信息流、控制流之间的控制逻辑，开发了轿车总装车间的底盘工段与分装工段部分工位的仿真系统，进行了生产评估与瓶颈分析。通过与实际运行情况和理论计算数据的比较，表明仿真结果的正确性。 |
| 索取号 | TH164/C23/2005 |
| 英文摘要 | With the trend of multi-product and small batch manufacturing, assembly line becomes to be unable to adapt to the variable market and intense competition. It is facing new question and challenge of adaptability and agility. The mixed model assembly lines (MMAL) are a type of production line where a variety of product models similar in product characteristic are assembled, which enhance the response ability to marking. The mixed assembly line is increasingly accepted in industry to cope with the trend of diversification of customer demand and leaning manufacturing. The process flow of general automobile modularization assembly and the production characteristic were analyzed. The technics card was built in order to visualization management. This assembly balancing made working procedure homochronous. The mathematical model of balancing problem was improved and summarized the regular methods to solve this NP problem. The mixed GASA genetic algorithms based on task sequences was developed to solve assembly balancing. In an experiment of a mixed model assembly line balance problem, the result of a case study with the algorithm is satisfactory. The minimal production set was introduced to the mixed model sequencing problem. The objective function of minimizing of total over and idle time based on the moving time windows of closed station and keeping a constant rate of part in JIT environment were build. The four kinds of optimization algorithms were analyzed such as heuristic arithmetic, reciprocal ratio method, variety characteristic logic arithmetic and goal chasing method. The multi-objective genetic algorithm is applied to sequencing mixed model assembly lines based on Pareto theory and niche technology. In an experiment of a mixed model assembly line sequencing problem, demonstrate the feasibility of this method. The ANDON system and the Kanban technique of material pull systems were designed under the condition of the material flow analyzed. How to deal with material by general assembly line when that was in MIN/MAX and the formula of station store were presented on the base of analyzing alarm condition. The definition of material breakpoint and material breakpoint control procedure were put forward. The function module and software architecture of material management information system were developed according to the material demand of actual automobile assembly line. The coordinated control structure of the mixed model automobile assemble line was designed on the base of comparing with centralized control, hierarchical control and distributed control system,. ANDON is an information management & control system used wildly for automobile general assembly line that has sound & light effect. The three layer control system of general automobile assembly line based on FROFIBUS & ASI was designed according to the layout of the Automobile Group. The system structure, configure and the powerful functions were detailed. The key procedure for quality control and the quality control proposal for assembly of Automobile are illustrated. The virtual simulation model and control logic of chassis group and sub-assembly of the general automobile shop were build on the base of the eM-Power software of digital factory according to the automobile assembly process. The production evaluation was developed and the result was feasible which was compared with practical data and academic computer. |
| 语种 | 中文 |
| 公开日期 | 2012-08-29 |
| 产权排序 | 1 |
| 分类号 | TH164 |
| 源URL | [http://ir.sia.ac.cn/handle/173321/9545]  |
| 专题 | 沈阳自动化研究所_工业信息学研究室_先进制造技术研究室 |
| 推荐引用方式 GB/T 7714 | 曹振新. 混流轿车总装配线的动态规划与仿真研究[D]. 中国科学院沈阳自动化研究所. 中国科学院沈阳自动化研究所. 2005. |
入库方式： OAI收割
来源：沈阳自动化研究所
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