钢铁企业板卷匹配与倒垛集成问题的研究

东北大学硕士学位论文 摘要- I -钢铁企业板卷匹配与倒垛集成问题的研究摘 要本文以国内某大型钢铁企业的板卷材料匹配为背景，分别研究了考虑板卷倒垛的无委托板卷匹配问题和全委托板卷匹配与倒垛集成问题。该研究对于该研究对于提高板卷资源利用率，降低库区存储与物流费用，优化板卷合同的匹配关系，从而提高企业利润与竞争力具有重要意义。主要工作概述如下：（1） 以钢铁企业无委托板卷匹配过程为背景，提炼出考虑板卷倒垛操作的无委托板卷匹配问题。该问题与已有研究相比，考虑了无委托板卷匹配关系对于库区物流及供料效率的影响。针对该问题，以提高板卷与合同的匹配质量、降低无委托库存、降低板卷倒垛费用为优化目标，建立了 0-1 整数规划线性模型。（2） 针对考虑板卷倒垛操作的无委托板卷匹配问题，设计了改进的差分进化算法，克服了常规商业求解软件无法求解大规模算例的难题。在算法中，设计了一种整数编码方式，保证了板卷合同多对一的匹配模式。提出了多种启发式算法，并将其与随机策略结合生成高质量的初始种群。同时，提出了一种新型变异方式，通过增加扰动策略和带有求余运算的变异操作，有效提升了算法的寻优能力。最后，通过对多组实际数据的测试，并与 CPLEX 商业求解软件进行比较，验证了模型和算法的有效性。（3） 以钢铁企业全委托板卷匹配调整过程为背景，提炼出全委托板卷匹配与倒垛集成问题。与已有全委托板卷匹配问题不同，该问题在决策板卷与合同匹配关系的同时还需要决策板卷在提取过程中的倒垛位置。针对该问题建立了 0-1 整数规划线性模型。（4） 为有效求解全委托板卷匹配与倒垛集成问题，大规模实际问题，本文设计了改进的差分进化算法。将设计的启发式算法与随机策略产生的初始解作为初始种群，提出了一种具有随机和小概率扰动的变异操作，能够有效降低算法陷入局部最优的概率。通过数值实验，将所提出算法与 CPLEX 商业软件进行比较，可以有效验证了模型、算法、及改进策略的有效性。（5） 基于钢厂实际板卷匹配过程的业务流程与需求分析，将提出的模型及算法与人机交互的方式相结合，设计并开发了板卷匹配与倒垛优化决策支持子系统，该系统能够有效提高了计划人员的工作效率，增加了板卷匹配的柔性与灵活性。关键词：无委托板卷；全委托板卷；板卷匹配；板卷倒垛；钢铁企业；差分进化算法东北大学硕士学位论文 摘要- II -东北大学硕士学位论文 Abstract- III -Research on the Integration of Coil-order Matching and Coil Shuffling in the Steel IndustryAbstractTaking the practical coil-order matching process of a domestic steel enterprise as background, this thesis studies an open-order coil matching problem with the consideration of coil shuffling as well as an integration problem of customer-order coil matching and coil shuffling, respectively. This research can effectively improve the coil utilization, reduce the logistics and inventory costs, optimal coil-order matching relationship, and hence improve the profits and competitiveness of steel enterprises. The main contents of this thesis are summarized as follows:(1) Taking the open-order coil matching process as background, an open-order coil matching problem with the consideration of coil shuffling is proposed. Different from the existing relevant researches, the problem in this thesis considers the actual relationship between the coil-order matching and the logistics of coil yard as well as the feed efficiency of production line. By considering the matching constraint and order capacity constraints, the problem is formulated as a 0-1 linear integer programming model with the objective of improving the matching quality, reducing the inventory cost and reducing the shuffling operations.Since the large scale instances cannot be solved by using the commercial solver, an improved differential evolution algorithm is proposed for the open-order coil matching problem with the consideration of coil shuffling to solve the large scale instances. In this algorithm, a kind of integer encoding method is designed to guarantee the several-for-one coil-order matching pattern. Several tailored heuristics and a random method are designed to obtain the initial population with good performance. In addition, a new mutation operation is proposed to improve the global search ability of the algorithm by introducing the disturbance strategy and remainder operator into the algorithm. Finally, the performance of the proposed improved differential evolution algorithm is evaluated by comparing it with CPLEX directly applied to the proposed model using practical problem instances. The computational results 东北大学硕士学位论文 Abstract- IV -show that the proposed improved differential evolution is effective for solving the open-order coil matching problem with the consideration of coil shuffling.Taking the customer-coil matching process as background, an integration problem of customer-coil matching and coil shuffling is proposed. Different from the existing relevant researches, there are two set of decisions should to make in the problem. The first is to decide the matching relationship between customer-order coil and order, while the second is to allocate a slot for each shuffled coil during the process of retrieving all target coils. For this problem, a 0-1 linear integer programming model is formulated.(4) To effectively solve the practical problems with a large, an improved differential evolution algorithm is proposed. Several customized heuristics and random method are designed to obtain initial population with good performance. In addition, a new mutation operation is proposed to avoid the solution process being trapped into local optima by introducing the random and small probability disturbance strategies into the algorithm. Finally, the performance of the proposed improved differential evolution algorithm is evaluated by comparing it with CPLEX directly applied to the proposed model. The computational results show that the proposed model, algorithm, and the improve strategy are effective for solving the integration problem of customer-coil matching and coil shuffling.Based on the practical operations and requirements of the coil-order matching process, a decision support system that embeds all proposed models and algorithms is designed and developed. The application of this system can effectively improve the work efficiency of planners and make the coil-order matching decisions more flexible.Keywords: open-order coil; customer-order coil; coil-order matching; coil shuffling; steel plants; differential evolution algorithm东北大学硕士学位论文 目录- V -目 录独创性声明 .I摘 要 .IIIABSTRACT .V目 录 .VII第 1 章 绪论 .11.1 问题研究背景 .11.2 问题的研究意义 .21.3 国内外研究现状 .41.4 本文主要工作和研究路线 .61.4.1 本文主要工作.61.4.2 本文研究路线.71.5 本章小结 .8第 2 章 考虑板卷倒垛操作的无委托板卷匹配问题的建模与求解 .92.1 问题描述.92.2 问题建模.132.2.1 符号定义.132.2.2 数学模型.152.3 差分进化算法求解 .172.3.1 编码与解码操作.182.3.2 初始种群的产生.192.3.3 基于扰动的改进变异操作.202.3.4 交叉操作.222.3.5 可行性修复.232.3.6 选择操作.232.4 数值实验 .24东北大学硕士学位论文 目录- VI -2.4.1 基于经验的手工求解方法.242.4.2 实验结果.242.5 本章小结 .27第 3 章 全委托板卷匹配与倒垛集成问题的建模与求解 .283.1 问题描述.283.2 问题建模 .303.2.1 符号定义.303.2.2 数学模型.323.3 差分进化算法求解 .353.3.1 编码与解码操作.363.3.2 初始种群的产生.373.3.3 基于随机和扰动的改进变异操作.373.3.4 交叉操作.383.3.5 解的修复.383.3.6 邻域搜索改进算法.383.4 数值实验 .393.4.1 基于经验的手工求解方法.393.4.2 实验结果.393.5 本章小结 .41第 4 章 板卷匹配与倒垛决策支持子系统设计与开发 .424.1 系统分析 .424.1.1 系统需求分析.424.1.2 业务流程分析.434.2 系统设计 .434.2.1 系统目标.434.2.2 系统运行环境.444.2.3 系统结构设计.444.2.4 子系统模块操作流程.454.2.5 子系统模块设计.46东北大学硕士学位论文 目录- VII -4.3 子系统模块功能实现 .474.3.1 用户登录模块.484.3.2 数据下载模块.484.3.3 参数设置.494.3.4 算法运行界面.534.3.5 结果显示.534.4 本章小节 .54第 5 章 结束语 .56参考文献 .58致 谢 .64东北大学硕士学位论文 目录- VIII -东北大学硕士学位论文 第 1 章 绪论- 1 -第 1 章 绪论本文以钢铁企业板卷匹配过程为背景，研究了综合考虑板卷倒垛量与板卷-合同匹配质量的板卷匹配问题。本章介绍了问题的研究背景及意义，综述了钢铁企业板卷匹配与倒垛问题的研究现状，分析了板卷匹配与倒垛问题的特点及其影响因素，最后总结了本文的主要框架和研究路线。1.1 问题研究背景钢铁行业是国民经济中必不可少的一部分，为许多其他行业提供了生产原材料 1 。然而，由于钢铁生产过程复杂，生产与合同波动频繁，常常导致大量余材板卷的存在。此外，在生产过程中也经常会出现材料规格改变或合同加急等情况，使得板卷的规格与合同不符合，或紧急合同无法按时完成。上述情况都严重影响钢铁企业材料的利用率和客户的满意度。热轧板卷热轧轧机 冷轧轧机冷轧板卷彩涂板卷. . .镀锌板卷图 1. 1 钢铁企业板卷生产工艺流程图Fig. 1. 1 The procedure chart of the steel enterprise of coil钢铁生产是一个复杂的多阶段的过程，如 图 1. 1 所示，各工序间是串行顺序加工的，前后工序衔接紧密。板卷是钢铁企业生产过程中的重要中间品，板卷分热轧板卷和冷轧板卷，是附加值较高的一类产品。在实际生产过程中，企业在生产过程中由于东北大学硕士学位论文 第 1 章 绪论- 2 -板卷规格不符合需求、订单取消、人工脱合同等原因会产生大量的余材板卷，企业将其称之为无委托板卷。为了降低余材库存、提高资源利用率，将余材板卷匹配给有欠量且规格要求相似的合同的过程，称为无委托板卷匹配。此外，钢铁企业多采取以销定产模式，即板卷生产规模与合同直接挂勾，但实际生产过程的复杂性、生产扰动随机性致使产出的板卷不符合合同需求。为了提高板卷资源的利用率和客户的满意度，在板卷进行下一步加