CN-121979140-A - Balanced control system and control method for production load

CN121979140ACN 121979140 ACN121979140 ACN 121979140ACN-121979140-A

Abstract

A balanced control system of production load and a control method thereof belong to the technical field of production scheduling and are used for solving the problem of unbalanced production load of multiple varieties and small batches of products, wherein the control system comprises a top layer module, a middle layer module and a bottom layer module, information can be communicated among the three modules, the top layer module is used for inputting and analyzing orders, the orders are converted into a frequency domain through a Fourier load smoothing algorithm, the middle layer module is used for arranging order optimal sequences, the order optimal sequences are arranged by adopting a three-dimensional evaluation matrix method on the premise of ORR optimal rule ordering, order throwing sequences are generated, and the bottom layer module is used for dispatching an operation vehicle layer to realize that order tasks generated through the top layer module and the middle module are delivered to each operation device. The invention suppresses the problem of excessive production from the source, and realizes the balance of the full chain load of the order received and delivered to the dispatching through the layered ladder control architecture.

Inventors

QIU JIANBIN
YANG JUN
Zhang Bengshan
SUN NA
WANG YONGYONG
MA LING
ZHANG YING
BAI JINCHENG

Assignees

北京铸云网络科技有限公司

Dates

Publication Date: 20260505
Application Date: 20260119

Claims (7)

1. The production load balancing control system is characterized by comprising a top layer module, a middle layer module and a bottom layer module, wherein the three modules can communicate information; The top layer module is used for inputting and analyzing orders and converting the orders into a frequency domain through a Fourier load smoothing algorithm; the middle layer module is used for arranging the optimal order, and on the premise of ordering the ORR optimal rule, arranging the optimal order by adopting a three-dimensional evaluation matrix method to generate an order release sequence; the bottom module is used for dispatching the operation workshop layer, and order tasks generated through the top module and the middle module are issued to each operation device.
2. A control method of a production load balancing control system according to claim 1, comprising, Inputting a customer order set in a top-level module, and generating an admission order set according to a Fourier load smoothing algorithm; inputting the admission order set in a middle layer module, and generating an order release sequence according to a three-dimensional evaluation matrix; And inputting a process route of the placed order in the bottom layer module according to the order placement sequence, and matching the order with the operation equipment according to a dynamic rule base engine to generate a machine-level operation instruction.
3. The control method of a production load balancing control system according to claim 2, wherein the balancing control system is further provided with cooperative logic of a control method, the cooperative logic including a forward condition transmission path and a reverse state feedback path; the forward condition transmission path comprises a top layer module, a middle layer module, a bottom layer module, a plurality of operation devices, a plurality of control modules and a plurality of control modules, wherein the top layer module transmits order information to the middle layer module, the middle layer module transmits the delivery priority of orders to the bottom layer module, and the bottom layer module dispatches production tasks to each operation device; The direction state feedback path comprises a bottom layer module, a middle layer module, a top layer module and an equilibrium control system, wherein the bottom layer module feeds back the load of the operation equipment and the state of the operation device to the middle layer module, and the bottom layer module feeds back the inventory of products to the top layer module to realize feeding back production actual information to the equilibrium control system.
4. The method for controlling a load balancing control system according to claim 2, wherein the generating method of the admission order set in the top-level module is, Inputting a customer order set O; Calculating the promised period of the client order set O based on a historical capacity regression model by adopting a CTP promised period promised algorithm; converting the load sequence of the customer order set to a frequency domain by adopting a Fourier load smoothing algorithm; an admitted order set O ́ for the customer order set O and a commitment period T 0 are generated.
5. The method for controlling a load balancing control system according to claim 4, wherein the order placement sequence is generated in a middle layer module by the following steps, Inputting an admission order set O ́ and a real-time manufacturing resource state as pre-conditions for order priority ordering; Calculating the delivery priority of each admission order set O ́ by adopting a three-dimensional evaluation matrix according to P=alpha- (1-L_util) +beta.R_mat+gamma.S_gold, wherein alpha, beta and gamma E [0,1] are adjustable weighted evaluation values, L_util is the load margin of equipment, R_mat is the nesting rate of materials, and S_gold is the readiness of a die; and adopting an FCP limited yield planning algorithm, aiming at a load peak value of a single operation device, solving the constraint of matching the order with the device, and generating an order release sequence and release time.
6. The method for controlling a load balancing control system according to claim 5, wherein the machine-level job instruction is generated in the bottom module by a method comprising, Inputting a process route of the placed order; Distributing order tasks by adopting a dynamic rule base engine, selecting EDD rules if a queue of the operation equipment is empty, and applying CPM critical path optimization or starting SPT rules if a bottleneck process exists; Generating machine-level operation instructions.
7. The method of claim 6, wherein when an order is required to be inserted, a disturbance response mechanism is adopted to start a variable neighborhood search algorithm to reorder the affected process, and a new order placement sequence of the inserted order and the subsequent non-placed order is generated.

Description

Balanced control system and control method for production load Technical Field The invention relates to the technical field of production scheduling, in particular to a calculation method of production load. Background The existing production scheduling system has obvious defects when dealing with an MTO mode (multi-variety small lot production on order (MTO) mode) in the pump valve industry: 1) Static scheduling defects that traditional ERP/MRP relies on infinite capacity assumption, and cannot handle dynamic constraints such as equipment conflict, mold exclusive matching and the like, so that plan executable is low; 2) The problem of load unbalance is that a single-level scheduling strategy (such as workshop dispatching or order delivery control only) lacks global coordination, causes equipment busy and idle non-uniformity (fluctuation rate > 30%) and average retention of an order pool for more than 48 hours; 3) The disturbance response is lagged, namely events such as bill insertion, equipment failure and the like trigger the full-plan rearrangement, and the adjustment time is more than 2 hours, so that the order delay rate is more than or equal to 25%; 4) The algorithm suitability is poor, and the general APS tool is not used for modeling the characteristics of 'long process chain and multiple resource constraint', so that the valve production core bottlenecks such as die switching, material alignment and the like can not be optimized. Disclosure of Invention In view of the problem of load unbalance in the production of the MTO mode, it is necessary to provide a balanced control system and a control method for production load, which solve the problem of load unbalance in the production of multiple varieties and small-batch products by integrating a hierarchical control theory, a constraint planning algorithm and a signal processing technology. A balanced control system of production load comprises a top layer module, a middle layer module and a bottom layer module, and the three modules can communicate information, so that the information circulation of the whole balanced control system is realized; the top layer module is used for inputting and analyzing orders, namely inputting customer orders into the top layer module, converting the orders into a frequency domain through a Fourier load smoothing algorithm, and achieving the purposes of low-pass filtering and high-frequency fluctuation suppression; The middle layer module is used for arranging the optimal order, and on the premise of ordering the ORR optimal rule, arranging the optimal order of the order by adopting a three-dimensional evaluation matrix method and generating an order release sequence which is also the release priority of the order; the bottom module is used for dispatching the operation workshop layer, and order tasks generated through the top module and the middle module are issued to each operation device. The technical scheme realizes the balanced production of multiple varieties and small batches of products, adopts a Fourier load smoothing algorithm to inhibit the problem of excessive production from the source, adopts a three-dimensional evaluation matrix method to determine the optimal production sequence of orders, improves the production efficiency, and realizes the balance of the full chain load of the orders received and delivered to the dispatching by a layered ladder control architecture. A control method of a production load balance control system comprises the following steps, Inputting a customer order set in a top-level module, generating an admission order set according to a Fourier load smoothing algorithm, and inhibiting the risk of overload of a production system from the source; Inputting the admitting order set in a middle layer module, and generating an order release sequence according to a three-dimensional evaluation matrix, namely, prioritizing the order arrangement production sequence in the admitting order set; And inputting a process route of the placed order in the bottom layer module according to the order placement sequence, and matching the order with the operation equipment according to a dynamic rule base engine to generate a machine-level operation instruction so as to realize balanced production of equipment load. By executing the control method, the idle rate of equipment, the actual queuing waiting and the like are reduced, the working efficiency is improved, and the production cost is reduced. Further, in order to smoothly realize the control method of the balance control system, cooperative logic of the control method is further arranged in the balance control system, and the cooperative logic comprises a forward condition transmission path and a reverse state feedback path; the forward condition transmission path comprises a top layer module, a middle layer module, a bottom layer module, a plurality of operation devices, a plurality of control modules and a plurality of control modules, wher