Article(id=1200492475291922966, tenantId=1146029695717560320, journalId=1189873562199433220, issueId=1200492472695648768, articleNumber=null, orderNo=null, doi=10.19710/J.cnki.1003-8817.20240230, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1764149310181, onlineDateStr=2025-11-26, pubDate=1732032000000, pubDateStr=2024-11-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764149310181, onlineIssueDateStr=2025-11-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764149310181, creator=13701087609, updateTime=1764149310181, updator=13701087609, issue=Issue{id=1200492472695648768, tenantId=1146029695717560320, journalId=1189873562199433220, year='2024', volume='', issue='11', pageStart='1', pageEnd='72', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764149309561, creator=13701087609, updateTime=1764149309561, updator=13701087609, preIssue=null, nextIssue=null, ext=null, issueFiles=null}, startPage=58, endPage=62, ext={EN=ArticleExt(id=1200492475560358429, articleId=1200492475291922966, tenantId=1146029695717560320, journalId=1189873562199433220, language=EN, title=Research on Layout Optimization of Assembly Shop Based on Genetic Algorithm, columnId=null, journalTitle=Automobile Technology & Material, columnName=null, runingTitle=null, highlight=null, articleAbstract=

In order to rationally plan workshop layout, this paper proposes an assembly workshop layout planning method based on genetic algorithm. A mathematical model of workshop layout planning is constructed by linear programming, and the model is solved by genetic algorithm, then assembly workshop of an enterprise is taken as example to verify effectiveness of the model. The research findings indicate that the proposed method can effectively address the workshop layout problem resulting from logistics upgrading, which presents a general solution for the workshop layout planning in discrete manufacturing enterprises under similar circumstances.

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为合理规划车间布局,提出了基于遗传算法的装配车间布局规划方法。利用线性规划构建车间布局规划数学模型,采用遗传算法对模型进行求解,并以某企业装配车间为例进行验证。研究结果表明,所提出的方法能够有效解决物流升级改造带来的车间布局问题,为类似背景下的离散制造企业车间布局规划问题提出了一般性的求解方法。

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司宗刚(1983—),男,工程师,学士学位,研究方向为生产物流系统规划与设计。

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司宗刚(1983—),男,工程师,学士学位,研究方向为生产物流系统规划与设计。

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司宗刚(1983—),男,工程师,学士学位,研究方向为生产物流系统规划与设计。

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符号 定义
(x0, y0) 物料接驳点坐标(0, 65)
(xi, yi) 生产线i中心点坐标
L 车间的长度
W 车间的宽度
Li 生产线i的长度
Wi 生产线i的宽度
dxij 生产线i与生产线j之间的横向距离
dyij 生产线i与生产线j之间的纵向距离
C 总运输成本
fi0 生产线i与物料接驳点之间的物流量
di0 生产线i与物料接驳点之间的搬运距离
ci0 生产线i与物料接驳点之间的搬运成本
), ArticleFig(id=1200511841563693181, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1200492475291922966, language=CN, label=表1, caption=

车间布局规划模型变量定义

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符号 定义
(x0, y0) 物料接驳点坐标(0, 65)
(xi, yi) 生产线i中心点坐标
L 车间的长度
W 车间的宽度
Li 生产线i的长度
Wi 生产线i的宽度
dxij 生产线i与生产线j之间的横向距离
dyij 生产线i与生产线j之间的纵向距离
C 总运输成本
fi0 生产线i与物料接驳点之间的物流量
di0 生产线i与物料接驳点之间的搬运距离
ci0 生产线i与物料接驳点之间的搬运成本
), ArticleFig(id=1200511841672745088, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1200492475291922966, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
参数 取值
初始种群个体参数/个 100
迭代次数/次 3 000
交叉概率/% 80
变异概率/% 10
), ArticleFig(id=1200511841765019779, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1200492475291922966, language=CN, label=表2, caption=

遗传算法参数

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参数 取值
初始种群个体参数/个 100
迭代次数/次 3 000
交叉概率/% 80
变异概率/% 10
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序号 生产线 长度×宽度
/m×m
面积
/m2
班产量/件 生产节拍/s 物流量
/次
1 装配-H/Y-1 22×8 176 450 80 54
2 装配-H/L-2 20×8 160 480 75 77
3 装配-H/L-3 19×8 152 480 75 76
4 装配-H/L-4 19×8 152 400 90 26
5 装配-H/L-5 21×8 168 550 65.5 34
6 装配-H/Y-2 21×8 168 480 75 62
7 装配-H/A-1 22×10 220 480 75 33
8 装配-H/A-2 20×10 200 480 75 47
9 装配-H/A-3 19×10 190 480 75 51
10 装配-H/A-4 19×10 190 400 90 55
11 装配-H/Z-1 22×10 220 480 75 34
12 装配-H/S-1 22×9 198 450 75 33
13 装配-H/S-2 20×9 180 400 90 64
14 装配-H/S-3 19×9 171 480 75 37
15 装配-H/S-4 19×9 171 500 72 31
16 装配-H/S-5 22×9 198 500 72 44
17 装配-H/D-1 23×13 299 500 72 30
18 装配-H/D-2 15×13 195 480 75 45
19 装配-H/D-3 19×13 247 480 75 28
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生产线数据信息

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序号 生产线 长度×宽度
/m×m
面积
/m2
班产量/件 生产节拍/s 物流量
/次
1 装配-H/Y-1 22×8 176 450 80 54
2 装配-H/L-2 20×8 160 480 75 77
3 装配-H/L-3 19×8 152 480 75 76
4 装配-H/L-4 19×8 152 400 90 26
5 装配-H/L-5 21×8 168 550 65.5 34
6 装配-H/Y-2 21×8 168 480 75 62
7 装配-H/A-1 22×10 220 480 75 33
8 装配-H/A-2 20×10 200 480 75 47
9 装配-H/A-3 19×10 190 480 75 51
10 装配-H/A-4 19×10 190 400 90 55
11 装配-H/Z-1 22×10 220 480 75 34
12 装配-H/S-1 22×9 198 450 75 33
13 装配-H/S-2 20×9 180 400 90 64
14 装配-H/S-3 19×9 171 480 75 37
15 装配-H/S-4 19×9 171 500 72 31
16 装配-H/S-5 22×9 198 500 72 44
17 装配-H/D-1 23×13 299 500 72 30
18 装配-H/D-2 15×13 195 480 75 45
19 装配-H/D-3 19×13 247 480 75 28
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序号 生产线 中心
横坐标
中心
纵坐标
物料运输
距离/m
1 装配-H/Y-1 87.4 58.0 94.4
2 装配-H/L-2 63.6 58.0 70.6
3 装配-H/L-3 19.5 58.0 26.5
4 装配-H/L-4 19.5 34.4 50.1
5 装配-H/L-5 42.3 34.4 72.9
6 装配-H/Y-2 66.1 34.4 96.7
7 装配-H/A-1 83.4 7.8 140.6
8 装配-H/A-2 59.6 7.8 116.8
9 装配-H/A-3 63.1 46.2 81.9
10 装配-H/A-4 19.5 46.2 38.3
11 装配-H/Z-1 86.4 46.2 105.2
12 装配-H/S-1 68.6 23.1 110.5
13 装配-H/S-2 20.0 23.1 61.9
14 装配-H/S-3 41.3 45.7 60.6
15 装配-H/S-4 41.3 57.5 48.8
16 装配-H/S-5 43.8 23.1 85.7
17 装配-H/D-1 93.9 25.1 133.8
18 装配-H/D-2 17.5 9.3 73.2
19 装配-H/D-3 37.3 9.3 93.0
合计 1 561.5
), ArticleFig(id=1200511842142507150, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1200492475291922966, language=CN, label=表4, caption=

优化后的生产线中心坐标

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序号 生产线 中心
横坐标
中心
纵坐标
物料运输
距离/m
1 装配-H/Y-1 87.4 58.0 94.4
2 装配-H/L-2 63.6 58.0 70.6
3 装配-H/L-3 19.5 58.0 26.5
4 装配-H/L-4 19.5 34.4 50.1
5 装配-H/L-5 42.3 34.4 72.9
6 装配-H/Y-2 66.1 34.4 96.7
7 装配-H/A-1 83.4 7.8 140.6
8 装配-H/A-2 59.6 7.8 116.8
9 装配-H/A-3 63.1 46.2 81.9
10 装配-H/A-4 19.5 46.2 38.3
11 装配-H/Z-1 86.4 46.2 105.2
12 装配-H/S-1 68.6 23.1 110.5
13 装配-H/S-2 20.0 23.1 61.9
14 装配-H/S-3 41.3 45.7 60.6
15 装配-H/S-4 41.3 57.5 48.8
16 装配-H/S-5 43.8 23.1 85.7
17 装配-H/D-1 93.9 25.1 133.8
18 装配-H/D-2 17.5 9.3 73.2
19 装配-H/D-3 37.3 9.3 93.0
合计 1 561.5
), ArticleFig(id=1200511842234781840, tenantId=1146029695717560320, journalId=1189873562199433220, articleId=1200492475291922966, language=EN, label=null, caption=null, figureFileSmall=null, figureFileBig=null, tableContent=
方案 物料运输
距离/m
总运输成本
/元
车间面积
利用率/%
优化前 1 742.5 77 278.9 82.92
优化后 1 561.5 65 658.4 73.08
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优化前后方案对比

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方案 物料运输
距离/m
总运输成本
/元
车间面积
利用率/%
优化前 1 742.5 77 278.9 82.92
优化后 1 561.5 65 658.4 73.08
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基于遗传算法的装配车间工艺布局优化研究
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司宗刚 1 , 杨亚琼 2
汽车工艺与材料 | 生产装备 2024,(11): 58-62
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汽车工艺与材料 | 生产装备 2024, (11): 58-62
基于遗传算法的装配车间工艺布局优化研究
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司宗刚1, 杨亚琼2
作者信息
  • 1 常州星宇车灯股份有限公司, 常州 213001
  • 2 中国矿业大学, 徐州 221116
  • 司宗刚(1983—),男,工程师,学士学位,研究方向为生产物流系统规划与设计。

Research on Layout Optimization of Assembly Shop Based on Genetic Algorithm
Zonggang Si1, Yaqiong Yang2
Affiliations
  • 1 Changzhou Xingyu Automotive Lighting Systems Co., Ltd., Changzhou 213001
  • 2 China University of Mining and Technology, Xuzhou 221116
出版时间: 2024-11-20 doi: 10.19710/J.cnki.1003-8817.20240230
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为合理规划车间布局,提出了基于遗传算法的装配车间布局规划方法。利用线性规划构建车间布局规划数学模型,采用遗传算法对模型进行求解,并以某企业装配车间为例进行验证。研究结果表明,所提出的方法能够有效解决物流升级改造带来的车间布局问题,为类似背景下的离散制造企业车间布局规划问题提出了一般性的求解方法。

生产物流系统  /  布局规划  /  遗传算法

In order to rationally plan workshop layout, this paper proposes an assembly workshop layout planning method based on genetic algorithm. A mathematical model of workshop layout planning is constructed by linear programming, and the model is solved by genetic algorithm, then assembly workshop of an enterprise is taken as example to verify effectiveness of the model. The research findings indicate that the proposed method can effectively address the workshop layout problem resulting from logistics upgrading, which presents a general solution for the workshop layout planning in discrete manufacturing enterprises under similar circumstances.

Production logistics system  /  Layout planning  /  Genetic algorithm
司宗刚, 杨亚琼. 基于遗传算法的装配车间工艺布局优化研究. 汽车工艺与材料, 2024 , (11) : 58 -62 . DOI: 10.19710/J.cnki.1003-8817.20240230
Zonggang Si, Yaqiong Yang. Research on Layout Optimization of Assembly Shop Based on Genetic Algorithm[J]. Automobile Technology & Material, 2024 , (11) : 58 -62 . DOI: 10.19710/J.cnki.1003-8817.20240230
为提高生产效率、降低生产成本,越来越多的企业开始向数字化转型,在生产物流方面多采用自动化模式,在制造工厂中配备自动运输系统,从而大幅提升生产效率。相对于传统人工介入的运输方式,自动导引车(Automated Guided Vehicle,AGV)运输能够有效降低人工成本、提高效率。针对车间运输工具的升级改造,合理的车间布局至关重要。
当前车间布局规划有多种求解方法,包括系统布置规划(Systematic Layout Planning,SLP)、建模优化、仿真分析等。Fahad等[1]运用SLP和精益工具设计布局备选方案,验证结果表明,通过布局改善,生产系统的节能效果显著增强。姜雨萌[2]以物流成本最小为目标函数,采用遗传算法(Genetic Algorithm,GA)求解车间布局,降低了车间资源的浪费。汤洪涛等[3]提出多决策变量优化算法求解多工艺路线和车间布局联合优化模型,以总物流费用最低为目标函数,运用遗传算法和粒子群算法分别求解路径规划和布局方案,并将联合优化结果与两者分开的优化结果进行对比,验证了所提出方法的有效性。张青雷等[4]针对大型关重件生产车间的多行布局问题,以物流费用和物流时间最小为优化目标,运用改进的自适应遗传算法求解车间布局问题,降低了车间的物流时间和物流费用。谢洁明等[5]以平均运输总成本最小为优化目标,提出了遗传网络自适应直接搜索算法(Genetic Mesh Adaptive Direct Search,GMADS)求解智能车间内具有单向多重闭合回路的AGV上下料口布局问题,并用Plant Simulation进行仿真验证。
目前求解车间布局有多种方法,相比于其他算法,遗传算法通过模拟自然进化的过程,能够进行全局搜索,有助于找到问题的全局最优解,且遗传算法天生具有并行性,在进化过程中可同时评估和改进多个个体,效率较高。因此,本文基于遗传算法对升级改造物流运输设备的车间进行规划。目前,遗传算法已广泛应用于组合优化、机器学习、函数优化等,求解布局规划、任务调度、背包问题等。因此,本文基于本领域已有成果,采用遗传算法对升级改造物流运输设备的车间进行布局规划。
本文的技术框架如图1所示。要构建基于遗传算法的装配车间布局规划模型,首先需要进行现状调研与分析,获取代表产品的结构、运输规格、质量、规划产能、车间可用空间尺寸等,分析布局需求。其次,以物料运输成本最小为优化目标,考虑AGV运输路径设计等约束建立车间布局线性规划模型。最后,采用遗传算法设计模型求解策略,基于Python对模型进行求解,得到装配车间布局规划最优方案。
对车间布局进行优化设计涉及运输通道方向、产线尺寸、面积等。为简化问题,本文将需要进行AGV路径设计的某前照灯装配车间布局规划问题建模为线性规划数学模型,并对模型做如下假设:
a. 车间每个生产线的长度、宽度已知,对车间产线的布局实际上是对每个矩形区域的中心坐标进行调整和布置。
b. 将车间设施视为在同一水平面上,且物流运输路线均为折线。
c. 生产线与物料接驳点之间的单位物料运输成本一致。
在构建装配车间布局模型前,需要定义模型中用到的各个变量,如表1所示。
参照上述建立车间布局模型设定的假设条件和模型变量定义,作出车间生产线布局模型坐标示意,如图2所示。
本布局规划以总物料运输成本最小为优化目标,建立目标函数为:
$min C={\sum }_{i=1}^{n}{c}_{i0}{f}_{i0}{d}_{i0}$
采用曼哈顿距离表示生产线i和生产线j之间的距离,即两生产线之间的直角距离。曼哈顿距离是两点在水平和垂直方向上的距离之和:
${d}_{i0}=\left|{x}_{i}-{x}_{0}\right|+\left|{y}_{i}-{y}_{0}\right|$
构建装配车间布局规划数学模型需要根据实际布局需求添加相应约束条件,以保证优化后布局方案的可行性。本文基于车间现状给出以下约束条件:
a. 生产线不重叠约束。在布局过程中,每个生产线均为独立的作业单元,生产线相互之间不可重叠,即
$\left|{x}_{i}-{x}_{j}\right|\ge \frac{{L}_{i}+{L}_{j}}{2}+{d}_{xij}$
$\left|{y}_{i}-{y}_{j}\right|\ge \frac{{W}_{i}+{W}_{j}}{2}+{d}_{yij}$
b. 车间范围约束。确保生产线在车间布局范围内,即生产线的长和宽不超出车间尺寸的上、下限:
${L}_{i}\le {x}_{i}+\frac{{L}_{i}}{2}L$
${W}_{i}\le {y}_{i}+\frac{{W}_{i}}{2}W$
c. 运输通道宽度约束。为实现AGV自动上料功能,需设置满足AGV运输条件的通道宽度。根据车间规划,设置生产线之间横向距离和纵向距离均为2.8 m,即dxij=2.8 m、dyij=2.8 m。
d. 固定宽度约束。仓储车间出入口物料流动量大,由于装配车间左侧靠近仓储车间,设置生产线与左侧墙体之间间隔为10 m。
遗传算法受启发于生物群体的遗传过程,是应用最为广泛的元启发式算法,其核心思想是通过基因表示备选方案、模拟种群演化、选择、交叉、变异等操作,模拟生物进化的过程,以逐步改进解的质量。车间布局属于典型的离散优化问题,目的是寻找满足约束的最优区域布置方式,在满足生产需求的前提下,为解决某装配车间布局规划问题,本文选择实数编码方法对染色体进行编码,适应度方法选择取倒数法,选择、交叉、变异分别为轮盘赌选择法、局部匹配交叉和逆转变异。算法具体的参数取值如表2所示。
某前照灯工厂正在规划数字化标杆工厂,标杆工厂建设重点涉及生产物流系统的升级和改造,其中包括将物料搬运方式由人工搬运转变为自动化、智能化的AGV搬运,生产布局需要调整。因此,本文选取该工厂装配车间为研究对象,针对生产物流系统升级改造涉及的工厂车间布局问题进行研究。
根据车间布局设计特点和实际布局需求,所需数据有产品信息、生产线信息等,选取的数据均来源于该工厂装配车间。装配车间现有布局如图3所示,车间长度为118 m,宽度为65 m,占地面积为7 670 m2。各生产线之间不存在物流关系,仅与仓储车间存在物流关系,因此,在仓储车间进出口处设置物料接驳点,即装配车间左上角处,用来表示仓储车间与各产线之间的物流量,生产线右下角数据即为具体的物流量。
该装配车间现有19条生产线,各生产线的尺寸、面积、班产量、生产节拍与物料接驳点之间的物流量如表3所示。通过曼哈顿距离计算和装配车间布局图,可得总物料运输距离为1 742.5 m。人工搬运与AGV搬运成本均视为1元/m。车间内原物料搬运方式为人工运输,通过搬运距离与物流量数据获得人工搬运成本为77 278.9元。
基于以上对遗传算法参数及生产物流数据,本文结合Pycharm软件和Python编程语言实现遗传算法的计算,以获取该大灯工厂装配车间最优布局方案。使用遗传算法最终得到的种群迭代曲线如图4所示。
图4可知,遗传算法在迭代2 100次后开始收敛,获得的装配车间最优布局,如图5所示,图中蓝色数字为生产线长和宽。
根据Python编程求解遗传算法得出的装配车间布局方案,布局图如图6所示。其中,生产线与车间左侧墙壁间隔为10 m,空白区域为AGV运输通道,通道宽度为2.8 m,车间左上角为物料接驳点,矩形的右下角数据是该生产线与物料接驳点之间的物流量,矩形的上方数据为生产线的长度,左方数据为生产线的宽度。生产线宽度不同,较窄的生产线边的空白区域作为AGV避障。AGV的移动方式为在车间物流通道上设置二维码节点,通过识别二维码运输物料,且物流路线为折线。AGV移动路径首先是从充电区至物料接驳点处装载物料,然后送至生产线上料点,完成后如有运输任务则继续执行,若无则返回充电区。
同时,模型输出最新生产线中心坐标值,并利用曼哈顿距离公式计算出生产线与物料接驳点之间的距离,总运输距离为1 561.5 m,如表4所示,坐标值保留1位小数。算法求解得出的总物料运输成本如图7所示。
在满足智能工厂规划需求的情况下,设计合理的AGV通道宽度约束,利用遗传算法获得最优布局方案、各产线中心坐标和总运输成本,并利用曼哈顿距离公式计算出各生产线与物料接驳点之间的距离,然后对各生产线与物料接驳点间的距离、总运输成本和车间面积利用率进行优化前后对比,验证方案的有效性。
由上文可知,原物料运输距离为1 742.5 m,总运输成本为77 278.9元。车间面积利用率S为车间布局面积Si与车间总面积ST之间的比值,车间布局面积指包含所有生产线的最大矩形区域,车间总面积指装配车间面积,为7 670 m2。原车间布局长度为106 m,宽度为60 m,面积为6 360 m2,面积利用率为82.92%。优化后的车间布局长度为95 m,宽度为59 m,面积为5 605 m2,面积利用率为73.08%。
方案优化前后的对比结果如表5所示,优化后的单次物料运输距离减少了181 m,与原方案相比降低了10.39%;总运输成本降低了11 620.5元,降低了15.04%;占地面积率降低了9.84%。优化后的装配车间留有更大的空闲区域,可根据生产实际需求用作新产线放置区、设备和工装放置区等。根据该车间目前拥有的19条生产线占地面积,计算得出生产线平均占地面积为226 m2,结合优化后的车间布局,可推断出该装配车间目前还可在右侧放置2~3条装配生产线。
本文基于遗传算法提出了车间布局规划求解模型,有效解决了企业物流运输设备升级带来的车间布局问题。通过分析某装配车间实际案例可知,本文结果不仅降低了运输成本,同时提高了车间面积利用率。在未来车间布局问题研究中,可深度考虑更为复杂的车间生产状况和需求,建立更加完善且与实际生产更加贴近的布局优化模型,提高方案输出的可靠性。
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2024年第卷第11期
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doi: 10.19710/J.cnki.1003-8817.20240230
  • 首发时间:2025-11-26
  • 出版时间:2024-11-20
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    1 常州星宇车灯股份有限公司, 常州 213001
    2 中国矿业大学, 徐州 221116
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
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Genus
种数
Number of
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占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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