基于数字孪生的定制化士兵装备装箱生产过程优化方法

doi:10.12382/bgxb.2024.0200

摘要/Abstract

摘要：

士兵装备与战士的身高、体重、任务分工等密切相关,具有高度定制化和大批量生产特征,而定制化和大批量生产给士兵装备生产交付带来了巨大挑战。装箱是士兵装备生产的最后环节,也是实现定制化和大批量生产最难环节,针对这一难题,提出一种基于数字孪生的士兵装备装箱生产过程优化方法。建立士兵装备装箱生产过程的数字孪生模型;通过仿真刻画士兵装备铺货补货、箱子运输、工人拣货、装箱等整个生产过程,并通过改进遗传算法对生产过程进行优化。将所提方法在某装备生产企业进行实际应用,通过迭代仿真实现了货位配置、工人数量和搬运设备数量的最佳设计和优化,有效解决士兵装备大规模个性化生产中动态性高,拥堵锁死频发,生产周期长,工位忙闲不均衡以及漏装错装问题发现不及时等难题,士兵装备的装箱生产效率提升了11.18%。

关键词: 装备拣选, 大规模定制化生产, 数字孪生, 改进遗传算法, 生产优化

Abstract:

Individual equipment is closely related to the user’ height and weight as well as the task division,and has the characteristics of high customization and mass production,which bring great challenges to the production and delivery of individual equipment.Packing is the last step of individual equipment production,and is also the most difficult step to achieve customization and mass production.To solve this problem,an optimization method of individual equipment packing production process based on digital twin is proposed.First,a digital twin model of individual equipment packing production process is established.Secondly,the whole production process of individual equipment,such as distribution and replenishment,transportation,workers’ picking and boxing,is described by simulation,and the production process is optimized by an improved genetic algorithm.Finally,the proposed method is actually applied in equipment production.The optimal design and optimization of the cargo location,the number of workers and the number of handling equipment are realized by iterative simulation,thus effectively solving the problems of highly dynamic,congestion and transportation conflicts,long production cycle,unbalanced busy and idle stations,and delayed detection of misloading in large-scale customized production of individual equipment.The production efficiency of soldier equipment packing is improved by 11.18%.

Key words: equipment selection, large-scale customized production, digital twin, improved genetic algorithm, production optimization

中图分类号:

TJ05

高丰, 赵宁, 庄存波, 于冬梅. 基于数字孪生的定制化士兵装备装箱生产过程优化方法[J]. 兵工学报, 2025, 46(4): 240200-.

GAO Feng, ZHAO Ning, ZHUANG Cunbo, YU Dongmei. Digital Twin-driven Customized Individual Equipment Packing Production Optimization[J]. Acta Armamentarii, 2025, 46(4): 240200-.

图/表 24

图1 装箱流水生产线示意图

Fig.1 Sketch map of packing flow production line

图2 基于数字孪生的装箱线设计优化

Fig.2 Production line optimization based on digital twin

图3 虚拟车间与物理车间链接方式

Fig.3 Connection method of virtual and physical workshops

表1 关键参数组成

Table 1 Key parameters

类别	参数
上线录入信息	箱子绑定的订单号,箱子拣货的清单,箱子上线的时间
补货任务单	货位(商品),数量/箱,数量/零散
下线统计信息	订单拣选完成时间,完成订单的数量,目前所有订单的总完成时间,订单的平均完成时间

图4 士兵装箱生产线补货仿真流程

Fig.4 Packing production line replenishment simulation flowchart

图5 士兵装箱生产线仿真流程

Fig.5 Simulation flowchart of packing production line

图6 仿真优化流程

Fig.6 Simulation optimization process

图7 遗传算法编码示意图

Fig.7 Encoding diagram of genetic algorithm

图8 自适应精英遗传算法流程图

Fig.8 Flowchart of adaptive elite genetic algorithm

图9 货位配置表示例

Fig.9 Location configuration table

图10 士兵装备装箱流程图

Fig.10 Packing flowchart of individual equipment

图11 工人工作流程

Fig.11 Working simulation flowchart

表2 验证案例

Table 2 Verification cases

案例	装箱工位	AGV数量	叉车数量	工人数量
1	8	8	8	23
2	8	6	6	18
3	12	12	12	30
4	12	10	10	26
5	16	14	14	32
6	16	12	12	30

表3 货位配置优化前后完工时间对比

Table 3 Completion times before ans after cargo location optimization

案例	完工时间/min		优化率/%
案例	优化前	优化后	优化率/%
1	62.86	55.68	11.42
2	94.17	85.52	9.74
3	122.72	105.08	11.17
4	115.00	100.36	11.46
5	176.53	152.57	11.88
6	150.12	128.00	11.42

表4 搬运设备优化前后数量对比

Table 4 Mean usage quantities of AGVs and forklifts before and after handing equipment optimization

案例	AGV使用数量		叉车使用数量
案例	优化前	优化后	优化前	优化后
1	8	3	8	2
2	6	2	6	2
3	12	7	12	6
4	10	6	10	6
5	14	10	14	11
6	12	10	12	8

图12 传统遗传算法的适应度趋势

Fig.12 Fitness trend chart of traditional genetic algorithm

图13 混合遗传算法的适应度趋势

Fig.13 Fitness trend chart of hybrid genetic algorithm

图14 自适应精英遗传算法的适应度趋势

Fig.14 Fitness trend chart of adaptive elite genetic algorithm

图15 工人数量和搬运设备数量输入界面

Fig.15 Input interface for the number of workers and handing equipment

图16 流利架铺货过程

Fig.16 Flow racking distribution process

图17 AGV搬运货物示例

Fig.17 AGV handing goods

图18 工人搬运货物示例

Fig.18 Worker handing goods

图19 订单箱拣选过程

Fig.19 Order box selection process

图20 统计图表示例

Fig.20 Example of statistical chart

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