具有条带约束和简化排样方式功能的排样系统分析

在板材分割中应用优化排样算法,能够提高材料利用率,从而降低生产成本。本文对基本的动态规划算法加以改造,使之能够处理最小和最大条带长度约束,能够生成切割工艺最简单的排样方式。在C＋＋环境下,在已有原型的基础上,开发出同尺寸矩形毛坯排样系统UR。利用这个软件,进行了大量的例题测试,得出对生产实践具有指导意义的结论。     

二维多阶段矩形剪切排样算法

讨论有需求约束的二维剪切矩形排样问题:将一张板材剪切成一组已知尺寸的毛坯,使排样价值(板材中包含的毛坯总价值)最大,约束条件是排样方式中包含每种毛坯数量都不能超过其需求量。采用普通条带多阶段排样方式,每次剪切都从板材上产生一根水平或者竖直的普通条带,条带中可以包含不同尺寸毛坯。引入分支限界与贪婪策略,以提高算法效率。实验结果表明,该算法可以有效提高排样价值。     

生成匀质块排样方式的递推算法

讨论矩形毛坯有约束二维剪切排样问题:将一张板材剪切成已知尺寸的一组毛坯,使排样方式的价值(板材中所含毛坯的总价值)最大;排样方式中每种毛坯的数量不能超过需求量.采用匀质块排样方式,每刀都从当前板材上切下一根水平或竖直的同质条带,其中仅含相同尺寸的毛坯.采用动态递推算法生成匀质块排样方式,在保证解的质量的前提下,有效地缩短计算时间,达到节约材料的目的.     

冲裁条带最优多段排样方式的动态规划算法

讨论冲裁件无约束剪冲排样问题,用动态规划算法生成冲裁条带多段排样方式。采用一组相互平行的分割线将板材分成多个段,每段含一组方向和长度都相同的条带。通过动态规划算法确定所有可能尺寸段的最优价值以及板材中段的最优组合,使整张板材价值达到最大。实验结果表明该算法能够提高材料利用率,计算时间能满足实际应用的需要。     

单一尺寸矩形毛坯排样时长板的最优分割

讨论了存在剪刃长度约束时单一尺寸矩形毛坯的优化排样问题,将板材分割成多张子板,通过优化确定子板张数、各子板长度和毛坯在各子板上的排列,使事 板材中所含毛坯数达到最大;并对Agrawal提出的单一尺寸矩形毛了优化排样方法进行扩展,构造出一种分支定界方法,用于解决长板最优分割问题,实验计算结果表明,所述算法非常有效;最后给出了例题数据的排样结果,与企业的通常做法相比较,说明了采用本方法的节材潜力。     

简化同尺寸矩形毛坯排样方式的动态规划算法

同尺寸矩形毛坯排样方式的最优性包括毛坯数量最优性和切割工艺最优性。前者是指排样方式中所含毛坯数最大;后者是指在所有实现毛坯数量最优性的排样方式中,切割工艺最为简单。采用条带数衡量排样方式的复杂性,用动态规划算法生成条带数最少的最优排样方式。实验计算结果表明,所述算法能够明显简化下料工艺,对指导生产实践具有较重要的意义。     

矩形毛坯最优层排样方式的动态规划算法*

讨论矩形毛坯无约束二维剪切排样问题,提出层排样方式的动态规划算法,使板材所含毛坯总价值最大。排样时使用一组平行的剪切线将板材分割为多个层,层的长度等于板材的长度或宽度,宽度等于最左边主毛坯的高度。通过动态规划算法确定所有可能尺寸层的最大价值和板材中层的最优组合。实验结果表明,该算法在满足实际应用要求的同时,板材利用率和计算时间两方面都较有效。     

生成冲裁条带四块排样方式的最优算法

提出一个生成冲裁条带四块布局方式的最优算法,用于解决冲裁件无约束排样问题。该算法用三条剪切线把板材划分成四个块,每个块里面只包含方向和长度都相同的冲裁条带。首先生成所有可能长度的冲裁条带,然后求解背包问题生成冲裁条带在块里面的最优布局,最后通过枚举三条剪切线位置得到不同的四块组合,选择使排样价值最大的四块组合生成最优的四块排样方式。实验结果表明,该算法不仅可以提高材料利用率,而且计算时间合理。     

生成矩形毛坯最优T形排样方式的递归算法

讨论矩形毛坯无约束两维剪切排样问题．采用由条带组成的T形排样方式，切割工艺简单．排样时用一条分界线将板材分成2段，同一段中所有条带的方向和长度都相同．一段含水平条带．另一段含竖直条带．采用递归算法确定分界线的最优位置以及每段中条带的最优组合．以便使下料利用率达到最高．采用大量随机生成的例题进行实验，结果表明该算法在计算时间和提高材料利用率2方面都较有效．     

二维剪切排样的束搜索启发式算法

针对约束二维矩形剪切排样问题,提出了一种基于束搜索的三阶段剪切排样算法。其切割过程包括三个阶段：板材剪切成段,段剪切成条带,条带切割成准确尺寸毛坯。采用动态规划确定段的价值,复杂度低的拼接递推不同长度子板的初始价值和板材的初始可行解,束搜索优化板材的排样方式。束搜索的节点用矩形对表示,分别是段组合而成的局部方式和未填充的剩余子板。以局部方式价值与剩余子板的初始价值之和作为节点的估计值。按估计值选择精英节点继续分支,其他节点直接删除不再回溯。实验结果表明该算法可缩短三阶段同质排样的计算时间,且所获得的余料大,利于余料的回收管理和再利用。     

Strips minimization in two-dimensional cutting stock of circular items

Circular items are often produced from stock plates using the cutting and stamping process that consists of two stages. A guillotine machine divides the plate into strips at the cutting stage, and then a press punches out the items from the strips at the stamping stage. The cutting cost at the first stage often increases with the number of strips in the cutting plan. An approach is presented for the two-dimensional cutting stock problem of the strips at the cutting stage. The objective is to minimize the sum of the material and the cutting costs. The approach formulates the problem as an integer linear programming, and uses a column generation method for generating the cutting patterns. The cutting patterns have the feature that each cut on the plate produces just one strip. The computational results indicate that the approach can greatly reduce the number of strips in the cutting plan.     

A simple algorithm for generating optimal equal circle cutting patterns with minimum sections

The cutting and stamping process is often used to divide stock plates into circular items. A guillotine machine cuts the plates into strips at the cutting phase. A stamping press stamps out the items from strips at the stamping phase. Normal patterns have been proposed for the case of equal circles. They consist of sections that contain strips of the same direction. The cutting process can be simplified if the number of sections is reduced. This short communication presents a simple algorithm for selecting from the optimal patterns the one that has the minimum number of sections. It assumes that the pattern value equals the value of the produced items minus the cost of the sections. The expected solution can be obtained by using an adequate section cost. The algorithm is faster and much simpler to design than a recently published algorithm.     

Exact algorithms for the two-dimensional guillotine knapsack

The two-dimensional knapsack problem requires to pack a maximum profit subset of “small” rectangular items into a unique “large” rectangular sheet. Packing must be orthogonal without rotation, i.e., all the rectangle heights must be parallel in the packing, and parallel to the height of the sheet. In addition, we require that each item can be unloaded from the sheet in stages, i.e., by unloading simultaneously all items packed at the same either y or x coordinate. This corresponds to use guillotine cuts in the associated cutting problem.In this paper we present a recursive exact procedure that, given a set of items and a unique sheet, constructs the set of associated guillotine packings. Such a procedure is then embedded into two exact algorithms for solving the guillotine two-dimensional knapsack problem. The algorithms are computationally evaluated on well-known benchmark instances from the literature.The C++ source code of the recursive procedure is available upon request from the authors.     

Algorithms for 3D guillotine cutting problems: Unbounded knapsack, cutting stock and strip packing

We present algorithms for the following three-dimensional (3D) guillotine cutting problems: unbounded knapsack, cutting stock and strip packing. We consider the case where the items have fixed orientation and the case where orthogonal rotations around all axes are allowed. For the unbounded 3D knapsack problem, we extend the recurrence formula proposed by [1] for the rectangular knapsack problem and present a dynamic programming algorithm that uses reduced raster points. We also consider a variant of the unbounded knapsack problem in which the cuts must be staged. For the 3D cutting stock problem and its variants in which the bins have different sizes (and the cuts must be staged), we present column generation-based algorithms. Modified versions of the algorithms for the 3D cutting stock problems with stages are then used to build algorithms for the 3D strip packing problem and its variants. The computational tests performed with the algorithms described in this paper indicate that they are useful to solve instances of moderate size.     

双排多段排样方式及其生成算法

为解决大规模矩形毛坯无约束的二维剪切排样问题,提出双排多段排样方式及其 生成算法。排样时采用一条剪切线将板材切分为两段,用一组剪切线将每段切分成一系列的块, 每个块由一组水平方向的同质条带构成。采用枚举法确定两段分界线的最优位置,通过求解背 包模型确定所有可能尺寸的块的最大价值和块在段中的最优布局。利用文献中的2 组基准测题 对所述算法进行测试,实验结果表明,该算法能在合理的计算时间内取得较好的优化结果。     

矩形件无约束二维板材剪切的4块排样算法

针对矩形件无约束二维板材剪切排样问题,提出一种新的4块排样方式及其生成算法.该排样方式将板材划分成4个块,对每个块,按照递归方式进行排样.选择一行同种矩形件放置在块的左下角,沿着这行矩形件的上边界和右边界将该块剩余部分划分成两个更小的子块以待进一步递归考察.首先,构造动态规划算法一次性生成所有可能尺寸的块中矩形件的递归排样方式;然后,采用隐式枚举算法确定板材的最优4块划分,得到矩形件在板材上的最优4块排样方式.采用文献基准例题和符合实际情况的随机例题,将所提出算法与几种典型的文献算法进行对比,实验结果表明所提出算法时间复杂度在低于或等于文献算法的前提下,排样方式价值比文献算法高.     

Feedforward control of the transverse strip profile in hot-dip galvanizing lines

Hot-dip galvanizing is a standard technology to produce coated steel strips. The primary objective of the galvanizing process is to establish a homogeneous zinc layer with a defined thickness. One condition to achieve this objective is a uniform transverse distance between the strip and the gas wiping dies, which blow off excessive liquid zinc. Therefore, a flat strip profile at the gas wiping dies is required. However, strips processed in such plants often exhibit residual curvatures which entail unknown flatness defects of the strip. Such flatness defects cause non-uniform air gaps and hence an inhomogeneous zinc coating thickness. Modern hot-dip galvanizing lines often use electromagnets to control the transverse strip profile near the gas wiping dies. Typically, the control algorithms ensure a flat strip profile at the electromagnets because the sensors for the transverse strip displacement are also located at this position and it is unfeasible to mount displacement sensors directly at the gas wiping dies. This brings along that in general a flatness defect remains at the gas wiping dies, which in turn entails a suboptimal coating.In this paper, a model-based method for a feedforward control of the strip profile at the position of the gas wiping dies is developed. This method is based on a plate model of the axially moving strip that takes into account the flatness defects in the strip. First, an estimator of the flatness defects is developed and validated for various test strips and settings of the plant. Using the validated mathematical model, a simulation study is performed to compare the state-of-the-art control approach (flat strip profile at the electromagnets) with the optimization-based feedforward controller (flat strip profile at the gas wiping dies) proposed in this paper. Moreover, the influence of the distance between the gas wiping dies and the electromagnets is investigated in detail.