A smart beam yard manufacturing organization optimization method considering storage and transportation conditions

Abstract

The present invention discloses a method for optimizing the manufacturing organization of a smart beam yard that takes storage and transportation conditions into consideration, comprising: first, determining the date on which each beam is transported away from the beam yard based on the maximum daily transportation volume of the beam yard; arranging the production of the beams using the reverse insertion method, and formulating different production plans based on the number of different production lines. After calculating the production plan for each plan, continue to calculate the number of beams in the beam yard every day, and use this as a parameter to verify whether the production plan occupies too much storage space. If the storage quantity is greater than the maximum quantity that the storage area can bear, the plan is judged to be unqualified. Calculate the costs of the remaining qualified plans respectively, and select the plan with the lowest cost as the final production arrangement plan. Compared with traditional empirical estimation, this method can effectively prevent the problem of excessive backlog of beams in the beam yard and inability to transport them in time, and can also prevent beams from being stored in the beam yard for too long, resulting in excessive deflection and thus being unqualified, while also optimizing production costs.

Description

Technical Field

[0001] The present invention belongs to the field of prefabricated beam production for highway bridges, and specifically relates to a smart beam yard manufacturing organization optimization method that takes storage and transportation conditions into consideration. Background Art

[0002] Prefabricated bridge assembly boasts fast construction speed, a simple construction process, and minimal impact on the surrounding construction environment, making it widely used in bridge construction. The precast concrete beam components used in this technology are prefabricated in advance at a beam yard and, after passing inspection, transported to the construction site for assembly. Traditional precast concrete beam production plans are often based on experience, with full production lines operating at full capacity. This often results in problems such as inability to meet production needs, premature production, and overproduction. Due to the presence of prestressed tendons within precast beams, prematurely produced beams often exhibit camber, resulting in substandard installation; overproduction delays construction progress. Furthermore, if there are too many production lines, while production can be completed on time, production resources may not be fully utilized, resulting in wasted resources and increased production costs. Therefore, a method is needed to calculate production plans within precast beam yards and design the production time for each beam, ensuring that precast concrete beams are produced on time and with guaranteed quality and quantity. Summary of the Invention

[0003] Technical problem: In response to the above problems, the present invention proposes a smart beam yard manufacturing organization optimization method that takes into account storage and transportation conditions. This method can consider the impact of transportation efficiency and storage conditions under given production requirements, and plan and design the production scale and production time.

[0004] Technical Solution: To address the above issues, the present invention proposes a production planning design method for precast concrete bridge components that takes into account transportation efficiency and storage conditions. The method specifically includes the following steps:

[0005] Step 1: Determine the traffic conditions at the precast beam yard and construction site, as well as the project transportation capacity, and determine the maximum daily transportation volume q;

[0006] Step 2: According to the stage requirements M k and the maximum daily transport volume q, determine the number of beams transported from the beam yard per day m k , m k ≤q, and ∑M k =∑m k , the stage demand M corresponding to the beam k Converted into the corresponding daily transport volume m k , remember the date each beam was shipped out of the beam yard i ;

[0007] Step 3: Arrange the beams in reverse order according to the order in which they were transported from the beam yard. iEach beam has an independent production sequence number i. The later the beam is shipped from the beam yard, the smaller the number i is.

[0008] Step 4: Based on experience and rough production capacity calculations, set the possible range of production line quantities, and use the minimum number of production lines in the possible range as the initial number of production lines n0.

[0009] Step 5: According to the specifications and actual project needs, determine the production time t0, minimum storage time t, and maximum storage time T of the beam in the beam yard, determine the average storage area S0 required for each beam, and the maximum optional total area S of the beam yard storage area;

[0010] Step 6: The initial number of production lines is n0. Start with the precast beam with the smallest production sequence number i that has not been scheduled for production, and arrange production. First check d i -t-t0 to d i -t days are all occupied. If all are occupied, consider starting production one day in advance and check whether there are idle production lines that can produce. If all are occupied, continue to consider starting production one day in advance. In this way, we can finally find the production line scheduled on d′ i Production started on

[0011] Step 7: Check d′ i Daily production time d′ i Is +t0 less than d? i -T, if d′ i +t0 is less than d i -T means that this precast beam l i If the prefabrication is completed ahead of schedule and the beams are stored in the beam yard for an extended period, the result is unqualified. Add a production line, n0=n0+1, and restart from step 6 after adding the production line.

[0012] If d′ i +t0 is greater than or equal to d i -T, then this root beam l i If production can proceed normally, continue with the production plan of the next beam and repeat steps 6 and 7. If all beams can be produced normally, the number of production lines is valid. The number of production lines is recorded as n, forming a production plan f. n ;

[0013] If the number of production lines n does not exceed the maximum possible number, try a new number of production lines, increase the number of production lines to n = n + 1, repeat steps 6 and 7, and generate a new solution f n If n exceeds the maximum possible number, stop adding new production lines, otherwise continue with n=n+1, repeat steps 6 and 7, and generate a new solution f n , until n exceeds the maximum possible number and stops adding new production lines;

[0014] Step 8: Calculate the number of beams stored in the beam yard per day for each scheme c k , calculate the daily storage beam occupied area S k , S k =c k *S0. If S k If ≤S, the plan is considered valid and counted as a valid plan.

[0015] In addition, the present invention further comprises the steps of:

[0016] Step 9: Compare options: For each option f n , calculate the production line usage cost r n =n*(r0+d*r1), where d is the total use time of the production line, r0 is the fixed production cost of the production line, r1 is the daily use cost of a single production line (including labor and maintenance costs), and the selection cost r n The lowest option is taken as the final production plan.

[0017] Beneficial effects: Compared with the prior art, the technical solution of the present invention has the following beneficial technical effects:

[0018] 1. Ensure beams are produced on time through calculations, which can prevent beams from being unqualified due to excessive pre-camber caused by production too far in advance, and also avoid beams from being unable to be produced on time due to insufficient productivity;

[0019] 2. Help select lower-cost production plans through cost calculations to improve the economic benefits of the project. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Flowchart of the method proposed in the present invention. DETAILED DESCRIPTION

[0021] The technical solution of the present invention is further described below with reference to the accompanying drawings and examples:

[0022] The present invention provides a smart beam yard manufacturing organization optimization method that takes storage and transportation conditions into consideration. Taking actual production at a beam yard as an example, the method specifically includes the following steps:

[0023] Step 1: Obtain the traffic conditions around the beam yard (i.e., the construction site) and learn that the maximum daily output capacity of the beam yard is 8 beams per day.

[0024] Step 2: Obtain construction requirements, as shown in Appendix 1, and then calculate the number of beams that need to be output per day based on the maximum output capacity of the beam yard (m). k , as shown in Schedule 2;

[0025] Step 3: The 1600 beams are numbered from 1 to 1600 according to the time of their removal;

[0026] Step 4: If all four production lines are running at full capacity, 1,600 beams can be produced in approximately 480 days, so at least four production lines are required. As the daily production quantity does not exceed the maximum transportation capacity, the estimated number of production lines is between 4 and 8, starting with a minimum of 4.

[0027] Step 5: The beam yard adopts a cyclic construction method. Each production line can handle two groups of processes simultaneously. Each group of processes has one beam. Each beam requires a total of two days to produce. For ease of calculation, the production time t0 of the beam can be set to 1 day. The minimum storage time t is increased by one day on the basis of the original maintenance and inspection time of 7 days, that is, 8 days. The maximum storage days are set to 90 days based on construction requirements and industry standards.

[0028] Step 6: Arrange the production plan, starting from the beam with the smallest production sequence number i that has not been scheduled for production, and make production arrangements. First check d i - Check if all production lines are occupied on the 9th. If so, consider starting production one day in advance to check if there are any idle production lines that can be used for production. And so on. The final schedule is on d i ′ Production is carried out on a daily basis;

[0029] Step 7: Check d i ′ Daily production time i ′ Is +2 less than d? i -92: If it is less than, it means that this beam l i The prefabrication is completed in advance, and the beam is stored in the beam yard for an extended period. The result is unqualified, and it is necessary to add a production line. After adding a production line, start again from step 5 until the number of possible production lines is exceeded; if it is greater than or equal to, it means that this beam l i Production can proceed normally, and the production plan for the next beam is arranged. Repeat step 5. If all beams can be produced normally, the number of production lines n is valid and included in the preliminary feasible plan. The number of production lines is increased and the calculation is continued until the maximum estimated number of possible production lines is 8. The final calculation result shows that production can be carried out when there are 6-8 production lines.

[0030] Step 8: Calculate the storage area required for each beam, which is 75m 2 The maximum number of beams stored in 6 production lines is 60, 7 production lines is 30, and 8 production lines is 10, which can meet the storage conditions;

[0031] Step 9: It takes 314 days from the start to the end of 6 production lines, 312 days for 7 production lines, and 311 days for 8 production lines. The total cost of 6 production lines is obviously the lowest, so the 6 production line solution is selected.

[0032] Table 1 Stage requirements table

[0033]

[0034]

[0035] Table 2 Daily Transport Scale

[0036]

[0037]

[0038]

Claims

1. A method for designing a production plan for precast concrete bridge components taking into account transportation efficiency and storage conditions, characterized in that: The method comprises the following steps: Step 1: Determine the traffic conditions at the precast beam yard and construction site, as well as the project transportation capacity, and determine the maximum daily transportation volume q; Step 2: According to the stage requirements M k and the maximum daily transport volume q, arrange the daily demand m k , m k ≤q, and ∑M k =∑m k , the stage demand M corresponding to the beam k Converted into the corresponding daily transport volume m k , the date each beam is shipped out of the beam yard is d i ; Step 3: Arrange the precast beams in reverse order according to the order in which they were transported from the beam yard; Step 4: Set the possible range of production line quantities, and use the minimum number of production lines in the possible range as the initial number of production lines n0; Step 5: According to the specifications and actual project needs, determine the production time t0, minimum storage time t, and maximum storage time T of the precast beams in the beam yard, determine the average storage area S0 required for each precast beam, and the maximum optional total area S of the beam yard storage area; Step 6: The initial number of production lines is n0. Start with the precast beam with the smallest production sequence number i that has not been scheduled for production, and arrange production. First check d i -t-t0 to d i -t days are all occupied. If all are occupied, consider starting production one day in advance to check whether there are idle production lines that can be produced. If all are occupied, continue to consider starting production one day in advance. In this way, we can finally find the production line scheduled on d i ′ Production started on Step 7: Check d i ′ Daily production time i ′ Is +t0 less than d? i -T, if d i ′ +t0 is less than d i -T, it means that this precast beam l i If the prefabrication is completed ahead of schedule and the beams are stored in the beam yard for an extended period, the result is unqualified. Add a production line, n0=n0+1, and restart from step 6 after adding the production line. If d i ′ +t0 is greater than or equal to d i -T, then this root beam l i If production can proceed normally, continue with the production plan of the next beam and repeat steps 6 and 7. If all beams can be produced normally, the number of production lines is valid. The number of production lines is recorded as n, forming a production plan f. n ; If the number of production lines n does not exceed the maximum possible number, try a new number of production lines, increase the number of production lines to n = n + 1, repeat steps 6 and 7, and generate a new solution f n If n exceeds the maximum possible number, stop adding new production lines, otherwise continue with n=n+1, repeat steps 6 and 7, and generate a new solution f n , until n exceeds the maximum possible number and stops adding new production lines; Step 8: Determine whether each solution meets the requirements, and count the solutions that meet the requirements as valid solutions.

2. A method for designing a production plan for precast concrete bridge components taking into account transportation efficiency and storage conditions according to claim 1, characterized in that: In step 3, the beams are arranged in reverse order according to the order in which they are transported from the beam yard. i Each beam has an independent production sequence number i, and the later the beam is transported away from the beam yard, the smaller the number i.

3. The method for designing a production plan for precast concrete bridge components taking into account transportation efficiency and storage conditions according to claim 1, characterized in that: The specific method of step 8 is as follows: Calculate the number of beams stored in the beam yard per day for each scheme c k , calculate the daily storage beam occupied area S k , S k =c k *S0, if S k If ≤S, the solution is determined to be effective and counted as effective solution.

4. The method for designing a production plan for precast concrete bridge components taking into account transportation efficiency and storage conditions according to claim 1, characterized in that: The method further comprises the following steps: Step 9: Compare options: For each option f n , calculate the production line usage cost r n =n*(r0+d*r1), where d is the total use time of the production line, r0 is the fixed production cost of the production line, and r1 is the daily use cost of a single production line. The use cost includes labor and maintenance costs. The selection cost r n The lowest option is taken as the final production plan.

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