A method for allocating RGV integrated storage area and storage capacity thereof

Abstract

The present invention discloses a method for allocating RGV integrated storage areas and their storage capacity. This method includes: arranging an RGV three-dimensional warehouse, wherein the storage area of ​​the RGV three-dimensional warehouse includes at least one type of storage area, including a first type storage area, a second type storage area, and a third type storage area, wherein the storage bits of the multiple types of storage areas are shared, and the storage bits of the second type storage area and the third type storage area are shared; obtaining the storage area number, storage area cycle time, emptying process line number, and emptying capacity requirement corresponding to each type of storage area; allocating the storage area capacity in the initial state; obtaining the optimized allocation for a regular production plan; and dynamically adjusting the storage area allocation for special production plans. This method solves the problem in related technologies where storage areas of different types cannot share storage bits after storage area construction.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile manufacturing, and in particular to a method for allocating an RGV integrated storage area and its storage capacity. Background Art

[0002] The automotive paint shop is a key component of the automotive manufacturing process, primarily responsible for surface treatment and coating of vehicle bodies to ensure both aesthetic appeal and durability. The automotive painting process involves multiple steps, including pretreatment, electrophoresis, primer, midcoat, basecoat, and clearcoat, each requiring specialized equipment.

[0003] Paint shops require several large-capacity storage areas for car bodies to meet the emptying, sorting, and buffering needs of the production process. Storage types are differentiated based on the stage of the painting process. Currently, mainstream painting processes require storage areas for electrophoretic vehicles, adhesive drying vehicles, mid-coat vehicles, color marshaling vehicles, topcoat vehicles, pre-coloring vehicles, post-coloring vehicles, pre-repair vehicles, and post-repair vehicles.

[0004] Car body storage areas can be either flat or high-bay. The use of high-bay storage has increased in recent years to better meet the efficiency and customization requirements of modern automotive manufacturing. High-bay storage, also known as high-bay storage or automated storage and retrieval systems, generally refers to warehouses that utilize multi-layered shelving to store unitized goods and utilize appropriate material handling equipment for warehousing and retrieval.

[0005] In the existing technology, storage areas of various storage types are scattered in different locations, and the storage areas are not connected to each other. The transportation path and storage capacity cannot be adjusted after construction is completed, and resource sharing of various types of storage areas cannot be achieved, which restricts the flexibility of the coating production system.

[0006] Currently, no effective solution has been proposed to the above-mentioned problems existing in the related technologies. Summary of the Invention

[0007] The main purpose of this application is to provide a method for allocating RGV integrated storage areas and their storage capacity, so as to at least solve the problem in the related art that storage areas of various types cannot realize storage bit sharing after the storage areas are constructed.

[0008] To achieve the above-mentioned objectives, according to one aspect of the present application, a method for allocating RGV integrated storage areas and their storage capacities is provided. The method comprises: arranging an RGV three-dimensional warehouse, wherein the storage areas of the RGV three-dimensional warehouse include at least one type of storage area, including a first type storage area, a second type storage area, and a third type storage area, wherein the storage bits of the multiple types of storage areas are shared, and the storage bits of the second type storage area and the third type storage area are shared; obtaining the storage area number, storage area beat, emptying process line number, and emptying capacity requirement corresponding to each type of storage area; allocating the storage area capacity in the initial state; obtaining the optimal allocation of the regular production plan; and dynamically adjusting the storage area allocation for special production plans.

[0009] Optionally, the emptying capacity requirement is calculated, where the emptying capacity requirement is the maximum value of the sum of the number of in-process car bodies that need to be emptied in the process line, and the calculation formula is: ,in, For storage area The maximum storage quantity, For storage area Number of storage bodies, For process lines The number of car bodies under production, Empty to storage area if necessary The set of emptying process line numbers, For time, is the storage area number, Number the emptying process line. The sum of the number of car bodies under production.

[0010] Optionally, the total amount of the three types of storage areas is obtained; and the optimal expression is calculated based on the total amount of the three types of storage areas.

[0011] Optionally, obtain the number of in-process vehicle bodies of each process line corresponding to each type of storage area; calculate the number of planned storage vehicle bodies and the number of unplanned storage vehicle bodies corresponding to each type of storage area; and calculate the total number of the three types of storage areas.

[0012] Optionally, the number of vehicles stored in the plan is calculated using the following formula: ,in, The number of car bodies to be stored in the plan, is the number of storage areas of a type in the initial state, is the number of the second-class storage areas in the initial state, For process lines The number of car bodies under production, Empty to storage area if necessary The process line number set, is the time; calculate the number of unplanned storage vehicles, the calculation formula is: , For unplanned storage of car bodies, For storage area The number of storage bodies.

[0013] Optionally, the total amount of the three types of storage areas is calculated according to the formula: , is the total amount of three types of storage areas, For storage area The total amount of the three types of storage areas in the initial state, To store the number of car bodies for unplanned purposes.

[0014] Optionally, the storage area is calculated based on the failure rate of the upstream process line, the repair rate of the upstream process line, the failure rate of the downstream process line, and the repair rate of the downstream process line corresponding to each type of storage area. The availability of the local production system composed of its upstream and downstream process lines; all available three types of storage areas are reasonably allocated to each storage type, and the optimization objective expression is ,in, is the availability rate, For the optimization goal, The number of the storage area.

[0015] Optionally, calculate the storage area The availability of the local production system consisting of its upstream and downstream process lines is calculated as follows: ,in, For storage area and the availability of the local production system consisting of its upstream and downstream process lines, For storage area Failure rate of upstream process lines, For storage area Repair rate of upstream process lines, For storage area Failure rate of downstream process lines, For storage area Repair rate of downstream process lines, It is the total amount of three types of storage areas.

[0016] Optionally, reallocate the second-class storage area based on the difference in emptying demand and calculate the storage area under the special production plan The emptying demand difference is calculated as follows: ,in, Plan storage areas for special production The difference in emptying demand, For process lines The number of car bodies in production under a special production plan, For process lines Product input rhythm under special production plan, is the product output rhythm of process line j under a special production plan, The time when the special production plan starts to be implemented. The calculation deadline is For process lines The product input cycle under the regular production plan, is the product output rhythm of process line j under the conventional production plan;

[0017] Optionally, the total capacity constraint relationship between the second-class storage area and the third-class storage area is obtained as follows: ,in, Plan storage areas for special production The difference in emptying demand, For storage area The number of secondary storage areas in For storage area The total amount of the three types of storage areas in the initial state, To store the number of car bodies for unplanned purposes.

[0018] Through this application, the following steps are adopted: arranging an RGV three-dimensional warehouse, wherein the storage area of ​​the RGV three-dimensional warehouse includes at least one type of storage area, the storage area includes a type I storage area, a type II storage area and a type III storage area, the storage bits of multiple types of storage areas are shared, and the storage bits of the type II storage area and the type III storage area are shared; obtaining the storage area number, storage area rhythm, emptying process line number and emptying capacity requirement corresponding to each type of storage area; allocating the storage area capacity in the initial state; obtaining the optimal allocation of the conventional production plan; dynamically adjusting the storage area allocation of the special production plan, which solves the problem in the related technology that the storage areas of various types cannot share storage bits after the storage area is built, thereby achieving the optimal utilization of storage resources according to real-time needs and improving the flexibility of the coating production system. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 This is a flowchart of a method for allocating an RGV integrated storage area and its storage capacity according to an embodiment of the present application. DETAILED DESCRIPTION

[0021] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0022] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0023] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0024] As introduced in the background technology, in the prior art, storage areas of various storage types are dispersed in different locations, and the storage areas are not interconnected. The conveying path and storage capacity cannot be adjusted after construction is completed, and resource sharing of various types of storage areas cannot be achieved, which restricts the flexibility of the coating production system. In order to solve the problem that storage areas of various types cannot share storage bits after storage area construction, an embodiment of the present application provides a method for allocating RGV integrated storage areas and their storage capacity.

[0025] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0026] In this embodiment, a method for allocating an RGV integrated storage area and its storage capacity running on a mobile terminal, a computer terminal or a similar computing device is provided. It should be noted that the steps shown in the flowchart of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and although a logical order is shown in the flowchart, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0027] Figure 1 FIG. 1 is a flow chart of a method for allocating an RGV integrated storage area and its storage capacity according to an embodiment of the present application. Figure 1 As shown, the method includes the following steps:

[0028] Step S101, arranging an RGV stereoscopic warehouse, wherein the storage area of ​​the RGV stereoscopic warehouse includes at least one type of storage area, the storage area includes a first type storage area, a second type storage area, and a third type storage area, the storage bits of the multiple types of storage areas are shared, and the storage bits of the second type storage area and the third type storage area are shared;

[0029] Specifically, the storage area of ​​the RGV three-dimensional warehouse is an integrated storage area. (1) The integrated storage area contains more than one type of storage area function. For example, it is represented by storage type A, storage type B, storage type C, etc. For automobile paint shops, the integrated storage area contains multiple or even all functions of various types of storage areas (electrophoretic storage area, midcoat / sealant storage area, color grouping area, topcoat storage area and repair storage area). (2) The integrated storage area can have multiple entrances and exits. Goods of different storage types can have independent entrances and exits, or they can share entrances and exits. (3) There are shared storage locations within the integrated storage area. The definition of a shared storage location is: if the goods can enter the storage area from the entrance of storage type A, be stored in a certain storage location after a feasible transportation process, and then leave the storage area from the exit of storage type A after a feasible transportation process; and if the goods can enter the storage area from the entrance of storage type B, be stored in the same storage location after a feasible transportation process, and then leave the storage area from the exit of storage type B after a feasible transportation process, then the storage location is a shared storage location. (4) The determination of the shared storage location is based on the physical feasibility provided by the storage area structure and the conveying equipment. Whether the current equipment control logic realizes or allows the objective existence without affecting the physical feasibility.

[0030] Functional requirements of integrated storage areas: (1) The integrated storage area should ensure the accuracy of the type of goods. That is, after the goods have completed the warehousing and storage process, they must be correctly sent to the corresponding type of exit. (2) The integrated storage area should meet the rhythm of goods in and out of the warehouse. (3) The integrated storage area should meet the emptying requirements of goods. Emptying means that some process lines in the paint shop are not allowed to stay in the product for a long time. At the end of production, all work-in-progress in these process lines must be stored in the storage area after production is completed. (4) The integrated storage area should provide a production system buffer function. Production system buffer means that when the downstream process line of the storage area cannot produce normally, the upstream process line of the storage area can continue to produce and store the output products in the storage area; when the upstream process line of the storage area cannot produce normally, the downstream process line of the storage area can obtain input products from the storage area and continue production.

[0031] Step S102, obtaining the storage area number, storage area beat, emptying process line number and emptying capacity requirement corresponding to each type of storage area;

[0032] Specifically, to meet the functional requirements of integrated storage areas and take into account the difficulty of implementing storage area scheduling, integrated storage areas are typically divided into zones to store different types of goods. Storage areas are categorized by their nature into Class I, Class II, and Class III. Class I storage areas are constant storage areas; Class II storage areas are limited storage areas, where changes to them affect the area's emptying function; and Class III storage areas are free storage areas, where changes to them do not affect the area's emptying function. Class II and Class III storage areas must contain shared storage locations.

[0033] Storage capacity expression and related constraints. Summarize the process lines and storage areas in the production system into and define the number according to the upstream and downstream production order , where the number of storage areas is indivual.

[0034]

[0035] in: For storage area The maximum storage quantity, For storage area The number of storage areas of a type in For storage area The number of secondary storage areas in For storage area The number of three types of storage areas in .

[0036] For any process line and storage area, the number of car bodies and the input and output cycle times have the following balance constraints:

[0037] , ,in, For process lines The number of car bodies under production, For storage area Number of storage bodies, For process lines or storage areas The product input beat, For process lines or storage areas product output rhythm. 、 、 、 All time function.

[0038] Step S103, allocating storage area capacity in the initial state;

[0039] Specifically, the initial capacity of the storage area is allocated according to the type of the storage area and the configuration of the storage bits. When the storage area and the storage capacity are allocated subsequently, the allocation starts with the storage area capacity in the initial state.

[0040] Step S104, obtaining the optimal allocation of the conventional production plan;

[0041] Specifically, the regular production plan of the production system means that the four indicators of the start time, stop time, work-in-process input rhythm, and work-in-process output rhythm of all process lines outside the storage area are in line with the regular production plan, that is, the production plan predetermined at the beginning of the production system design.

[0042] Step S105: Dynamically adjust the storage area allocation of the special production plan.

[0043] Specifically, a special production plan of a production system means that some indicators of at least some process lines do not conform to the regular production plan. For example, a process line is shut down or operates at a reduced pace outside the regular production plan. The reason may be that a special production plan is temporarily adopted due to flexible production needs, or it may be a long-term process line failure or storage area failure.

[0044] In an optional embodiment, the emptying capacity requirement is calculated, wherein the emptying capacity requirement is the maximum value of the sum of the number of in-process car bodies that need to be emptied in the process line, and the calculation formula is: ,in, For storage area The maximum storage quantity, For storage area Number of storage bodies, For process lines The number of car bodies under production, Empty to storage area if necessary The set of emptying process line numbers, For time, is the storage area number, Number the emptying process line. The sum of the number of car bodies under production.

[0045] Specifically, 、 For time This constraint needs to hold true at any time. is a fixed value, and the integrated storage area planning model proposed in this technical solution A variable value.

[0046] In an optional embodiment, when a vehicle body enters or leaves the warehouse, a dynamic allocation process is executed to obtain the total amount of the three types of storage areas; and an optimization expression is calculated based on the total amount of the three types of storage areas.

[0047] Specifically, when a vehicle body is put into or taken out of the warehouse, the storage area and storage capacity are allocated according to a dynamic allocation process, and the total amount of the three types of storage areas is obtained after allocation, and the optimal allocation is obtained based on the total amount of the three types of storage areas.

[0048] In an optional embodiment, the number of in-process vehicle bodies of each process line corresponding to each type of storage area is obtained; the number of planned storage vehicle bodies and the number of unplanned storage vehicle bodies corresponding to each type of storage area are calculated; and the total number of the three types of storage areas is calculated.

[0049] When the paint shop production system is operating under a regular production schedule, each storage type utilizes Class I and Class II storage areas to ensure that goods are cleared, and Class III storage areas are used to provide a buffer for the production system. If the buffering demand for a particular storage type, such as Type A, increases while other storage types operate normally, unoccupied Class III storage areas in the other storage types can be dynamically adjusted to become Class III storage areas for Type A, significantly increasing the production buffer capacity of Type A without affecting the clearing function of other storage areas. This process first divides the car bodies within the storage area into planned and unplanned areas. After excluding the storage space occupied by unplanned car bodies, the total amount of the three storage areas is constrained as follows.

[0050] Calculate the number of vehicle bodies stored in the plan using the following formula: ,in, The number of car bodies to be stored in the plan, is the number of storage areas of a type in the initial state, is the number of the second-class storage areas in the initial state, For process lines The number of car bodies under production, Empty to storage area if necessary The process line number set, is the time; calculate the number of unplanned storage vehicles, the calculation formula is: , For unplanned storage of car bodies, For storage area The total amount of the three types of storage areas is calculated according to the formula: , is the total amount of three types of storage areas, For storage area The total amount of the three types of storage areas in the initial state, To store the number of car bodies for unplanned purposes.

[0051] In an optional embodiment, the storage area is calculated based on the failure rate of the upstream process line, the repair rate of the upstream process line, the failure rate of the downstream process line, and the repair rate of the downstream process line corresponding to each type of storage area. The availability of the local production system composed of its upstream and downstream process lines; all available three types of storage areas are reasonably allocated to each storage type, and the optimization objective expression is ,in, is the availability rate, For the optimization goal, The number of the storage area.

[0052] Specifically, the storage area allocation principle of conventional production planning is to reasonably allocate all available three types of storage areas to each storage type to avoid bottlenecks with low availability in the overall production system. The optimization objective expression is: This constrained optimization problem can be solved using a variety of methods, including nonlinear programming, genetic algorithms, particle swarm optimization, and Lagrangian relaxation. During production, the optimal number of storage areas is determined based on the real-time status of the process lines and storage areas, and storage area allocation is dynamically adjusted to improve the overall availability of the production system.

[0053] In an optional embodiment, the computing storage area The availability of the local production system consisting of its upstream and downstream process lines is calculated as follows: ,in, For storage area and the availability of the local production system consisting of its upstream and downstream process lines, For storage area Failure rate of upstream process lines, For storage area Repair rate of upstream process lines, For storage area Failure rate of downstream process lines, For storage area Repair rate of downstream process lines, It is the total amount of three types of storage areas.

[0054] Specifically, the storage area allocation of the conventional production plan is optimized. The failure of the process line is a probabilistic event, usually described by exponential distribution or Weibull distribution. For a two-stage series process line with a buffer in the middle, the relationship between the local production system availability and the buffer capacity is obtained through state transition analysis as shown in the formula The buffer capacity is the storage area The part that provides buffering function corresponds to the number of three types of storage areas . 、 、 、 It is a fixed value and can be determined based on the probability statistical analysis of actual production conditions.

[0055] In an optional embodiment, the second type of storage area is reallocated according to the emptying demand difference, and the storage area under the special production plan is calculated. The emptying demand difference is calculated as follows: ,in, Plan storage areas for special production The difference in emptying demand, For process lines The number of car bodies in production under a special production plan, For process lines Product input rhythm under special production plan, For process lines Product output rhythm under special production plan, The time when the special production plan starts to be implemented. The calculation deadline is For process lines The product input cycle under the regular production plan, is the product output rhythm of process line j under the conventional production plan;

[0056] Specifically, the paint shop's use of special production plans aims to achieve energy conservation and emission reduction by optimizing production scheduling within various constraints. Constraints primarily include: paint shop output requirements, the pace and shift structure of the paint shop's input and output, storage area capacity limitations, and process line structure and installation capacity. The key to production scheduling is to shorten the operating time of high-energy-consuming process lines, thereby reducing energy consumption and pollutant emissions.

[0057] When a production system is operating under a special production plan, changes in process line production time and cycle time can cause changes in emptying requirements. Class II storage areas can be reallocated based on these changes. For example, if the emptying requirement for storage type A increases while the emptying requirement for storage type B decreases under a special production plan, the Class II storage area for storage type B can be dynamically adjusted to the Class II storage area for storage type A. This will meet the emptying requirement for storage type A under the special production plan while maintaining the emptying requirement for storage type B under the special production plan. Furthermore, unoccupied Class III storage areas within other storage types can also be dynamically adjusted to Class II storage areas for storage type A.

[0058] Theoretically, the difference in emptying requirements between a special production plan and a regular production plan can be calculated using the following formula. In practice, for complex production systems, the precise time-varying trend of emptying capacity requirements can be calculated using production system simulation software.

[0059] In an optional embodiment, the total capacity constraint relationship between the second-class storage area and the third-class storage area is obtained as follows: ,in, Plan storage areas for special production The difference in emptying demand, For storage area The number of secondary storage areas in For storage area The total amount of the three types of storage areas in the initial state, To store the number of car bodies for unplanned purposes.

[0060] If a special production plan is formulated at any time Constraint, then the special production plan is feasible; otherwise, the special production plan is not feasible. During the execution of the special production plan, the storage area allocation is continuously and dynamically adjusted so that each storage area satisfies the formula constraint.

[0061] In the existing technology, storage areas of various storage types are scattered in different locations, and the storage areas are not connected to each other. The transportation path and storage capacity cannot be adjusted after construction is completed, and resource sharing of various types of storage areas cannot be achieved, which restricts the flexibility of the coating production system.

[0062] The specific problems to be solved by the present invention include:

[0063] 1) Insufficient or wasted storage resources during process changes. For example, the proportion of car bodies that require color matching is originally planned to be 50%, but the actual color matching ratio may change according to production needs. If it exceeds 50%, the color matching storage area capacity is insufficient, and if it falls below 50%, the color matching storage area capacity is idle.

[0064] 2) It does not support differentiated production at different process lines or shifts. Typically, upstream and downstream process lines within a main coating production line operate at the same pace and shift. However, when implementing leaner production scheduling for energy conservation and emission reduction, different process lines may operate at inconsistent paces or shifts. This difference in upstream and downstream pace creates additional storage requirements, leading to insufficient capacity in some storage areas.

[0065] 3) Short buffering time for process line failures. The occurrence and duration of process line failures are probabilistic. Storage areas are configured with capacity redundancy for fault buffering, but this does not provide sufficient buffering capacity for long-lasting failures.

[0066] The technical effects achieved by the present invention are:

[0067] In the paint shop, integrated storage areas are used to store multiple types of car bodies (≥3 types). Different storage areas are interconnected, and a dynamic storage capacity allocation method is implemented on this basis: under conventional production plans, the free change storage areas that do not affect emptying are allocated to storage areas with higher buffering requirements based on the real-time status of the production system, thereby eliminating the low availability bottleneck of the production system; under unconventional production plans, the restricted change storage areas and free change storage areas are allocated to storage areas with higher emptying requirements based on the production plan and the real-time status of the production system, ensuring that the total capacity constraints and emptying constraints are met, thereby supporting special production plans.

[0068] Storage areas of different storage types are physically interconnected, and some conveying equipment and storage areas within the storage area can switch between different storage functions. In order to meet the beat and flexibility requirements, RGV three-dimensional warehouses are used as integrated storage areas.

[0069] Compared to existing technologies, the integrated storage area's storage capacity can be dynamically allocated to different storage functions, optimizing storage resource utilization based on real-time needs and improving the flexibility of the coating production system. This enhances the storage area's buffering capacity for probabilistic process line failures and repairs, improving production system stability. It also supports process changes and special production plans, including differentiated production schedules for different process lines or shifts, to achieve energy conservation and emission reduction.

[0070] Example

[0071] (1) A large-scale RGV three-dimensional warehouse is arranged in the center of the paint shop, integrating four types of storage: electrophoretic vehicle, glue drying vehicle, topcoat vehicle, and color matching vehicle.

[0072] (2) RGV stereoscopic warehouses are used as integrated storage areas to meet the requirements of pace and flexibility. The technical characteristics of RGV stereoscopic warehouses are that they are equipped with multiple lanes, with multi-layer stereoscopic shelves arranged on both sides of each lane to store car bodies. On each layer, several RGV trolleys that can run on horizontal tracks are set up to carry out horizontal transportation of car bodies, and several elevators are set up on both sides of the lanes to carry out vertical transportation of car bodies.

[0073] (3) The entire integrated storage area is divided into four storage areas, corresponding to four storage types. The RGV three-dimensional warehouse design fully considers interoperability. Various storage types can be transported to any storage location, that is, all storage locations are shared storage locations.

[0074] (4) The process lines and storage areas of the main production line of the painting workshop are numbered in sequence as follows: 1-pretreatment, 2-electrophoresis, 3-electrophoresis drying, 4-electrophoresis storage area, 5-glue coating, 6-glue drying, 7-glue drying storage area, 8-electrophoresis polishing, 9-color grouping, 10-topcoat spraying, 11-topcoat drying, 12-topcoat storage area, 13-color spraying, 14-color drying, 15-color storage area, 16-quality control.

[0075] (5) The cycle time and emptying requirements of various storage types under conventional production planning are as follows, where the emptying capacity requirement is calculated based on the formula The calculated maximum value of the sum of the number of car bodies in process that need to be emptied from the process line.

[0076]

[0077] (6) Allocate the storage area capacity in the initial state. In this embodiment, the number of the first type of storage area is 0, ensuring that the second type of storage area meets the emptying capacity requirement, and then allocate the surplus capacity in the entire three-dimensional library to the third type of storage area.

[0078] .

[0079] (7) Every time a car body enters or leaves the warehouse, a dynamic allocation process is executed. First, the status of the process line and storage area is checked. For example, at a certain point in time, the status is as follows:

[0080] Electrophoresis storage area: =40, =30, =0, =55;

[0081] Glue drying storage area: =30, =30, =20;

[0082] Topcoat storage area: =50, =20, =20;

[0083] Color storage area: =30, =30, =5.

[0084] According to the formula as well as Calculate:

[0085] Electrophoresis storage area: =50, =5;

[0086] Glue drying storage area: =0, =20;

[0087] Topcoat storage area: =20, =0;

[0088] Color storage area: =0, =5.

[0089] According to the formula The total number of available storage areas of the three categories is calculated to be 70.

[0090] (8) Based on statistics, a set of failure rate and repair rate parameters of the upstream and downstream process lines of the storage area are given.

[0091] Electrophoresis storage area: =0.003, =0.03, =0.003, =0.05;

[0092] Glue drying storage area: =0.003, =0.03, =0.001, =0.10;

[0093] Topcoat storage area: =0.003, =0.03, =0.003, =0.05;

[0094] Color storage area: =0.003, =0.03, =0.001, =0.10.

[0095] Substitute into the formula as well as Solve the optimization problem. Taking into account the accuracy and timeliness of the solution, this embodiment uses the optimization module of the professional mathematical tool SciPy to solve the problem, and obtains the optimal capacity allocation of the three types of storage areas at the current time point as follows:

[0096] =20, =15, =20, =15.

[0097] Before the dynamic allocation of storage area capacity, the bottleneck availability of the entire production system was 90.0%. After the dynamic allocation, it increased to 99.4%. The dynamic allocation of storage area capacity significantly improved the stability of the production system.

[0098] The storage area capacity allocation results will be sent to the intelligent scheduling system of the RGV three-dimensional warehouse, and the scheduling system will implement the storage type change behavior of the storage area based on inventory status, path feasibility, transportation efficiency and other conditions.

[0099] It should also be noted that the terms "comprises," "includes," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, commodity, or apparatus that includes a series of elements includes not only those elements but also other elements not explicitly listed, or includes elements inherent to such process, method, commodity, or apparatus. In the absence of further limitations, an element defined by the phrase "comprises a ..." does not exclude the presence of other identical elements in the process, method, commodity, or apparatus that includes the element.

[0100] From the above description, it can be seen that the above embodiments of the present application achieve the following technical effects:

[0101] 1) The storage capacity of the integrated storage area can be dynamically allocated to different storage functions, enabling optimal utilization of storage resources based on real-time needs and improving the flexibility of the coating production system. This supports process changes and special production plans, including differentiated production for different process lines or shifts, to achieve energy conservation and emission reduction.

[0102] 2) For probabilistic process line failure and repair events, strengthen the buffering capacity of the storage area and improve the stability of the production system.

[0103] The foregoing description is merely a preferred embodiment of the present application and is not intended to limit the present application. Persons skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A method for allocating RGV integrated storage area and its storage capacity, characterized in that: include: Arrange an RGV three-dimensional warehouse, wherein the storage area of ​​the RGV three-dimensional warehouse includes at least one type of storage area, each type of storage area includes a first type storage area, a second type storage area and a third type storage area, storage bits of multiple types of storage areas are shared, and the second type storage area shares storage bits with the third type storage area; Get the storage area number corresponding to each type of storage area , storage area beat, emptying process line number and emptying capacity requirements; Allocate the storage capacity of the initial state; Obtaining the optimal allocation of regular production plans; Obtaining an optimal allocation of a conventional production plan, including: obtaining the total amount of three types of storage areas; calculating an optimal expression based on the total amount of the three types of storage areas; Obtaining the total amount of the three types of storage areas includes: obtaining the number of in-process vehicle bodies of each process line corresponding to each type of storage area; calculating the number of planned storage vehicles and the number of unplanned storage vehicles corresponding to each type of storage area; and calculating the total amount of the three types of storage areas; Calculating the number of planned storage vehicles and the number of unplanned storage vehicles corresponding to each storage area of ​​the type includes: calculating the number of planned storage vehicles, and the calculation formula is: ,in, The number of car bodies to be stored in the plan, is the number of storage areas of a type in the initial state, is the number of the second-class storage areas in the initial state, For process lines The number of car bodies under production, Empty to storage area if necessary The process line number set, is the time; calculate the number of unplanned storage vehicles, the calculation formula is: , For unplanned storage of car bodies, For storage area Number of stored car bodies; Calculating the total amount of the three types of storage areas in all types of storage areas, including: calculating the total amount of the three types of storage areas according to a formula, the calculation formula is , For the The number of three types of storage areas in each type of storage area, In the initial state The number of three types of storage areas in each type of storage area, To store the number of car bodies for unplanned purposes; The optimization expression is obtained based on the total amount of the three types of storage areas, including: the storage area is obtained based on the failure rate of the upstream process line, the repair rate of the upstream process line, the failure rate of the downstream process line, and the repair rate of the downstream process line corresponding to each type of storage area. The availability of the local production system composed of its upstream and downstream process lines; all available three types of storage areas are reasonably allocated to each storage type, and the optimization objective expression is ,in, For the optimization goal, is the availability rate, is the number of the storage area; The storage area is calculated based on the failure rate of the upstream process line, the repair rate of the upstream process line, the failure rate of the downstream process line, and the repair rate of the downstream process line corresponding to each type of storage area. The availability of the local production system consisting of its upstream and downstream process lines, including: computing storage area The availability of the local production system consisting of its upstream and downstream process lines is calculated as follows: ,in, For the storage area and the availability of the local production system consisting of its upstream and downstream process lines, For storage area Failure rate of upstream process lines, For storage area Repair rate of upstream process lines, For storage area Failure rate of downstream process lines, For storage area Repair rate of downstream process lines, The total amount of three types of storage areas; Dynamically adjust storage area allocation for special production plans; Dynamically adjust the storage area allocation for special production plans, including: reallocating the second-class storage area based on the difference in emptying demand, and calculating the storage area under the special production plan The emptying demand difference is calculated as follows: ,in, Plan storage areas for special production The difference in emptying demand, For process lines The number of car bodies in production under a special production plan, For process lines Product input rhythm under special production plan, is the product output rhythm of process line j under a special production plan, The time when the special production plan starts to be implemented. The calculation deadline is For process lines The product input cycle under the regular production plan, is the product output rhythm of process line j under the conventional production plan; Dynamically adjust the storage area allocation of the special production plan, including: obtaining the total capacity constraint relationship between the second type storage area and the third type storage area as follows: ,in, Plan storage areas for special production The difference in emptying demand, For storage area The number of the second type of storage area, In the initial state The number of three types of storage areas in each type of storage area, To store the number of car bodies for unplanned purposes.

2. The method according to claim 1, characterized in that Obtain the storage area number, storage area beat, emptying process line number, and emptying capacity requirements corresponding to each type of storage area, including: Calculate the emptying capacity requirement, where the emptying capacity requirement is the maximum value of the sum of the number of in-process car bodies that need to be emptied in the process line. The calculation formula is: ,in, For storage area The maximum storage quantity, For storage area Number of storage bodies, For process lines The number of car bodies under production, Empty to storage area if necessary The set of emptying process line numbers, For time, is the storage area number, Number the emptying process line, The sum of the number of car bodies under production.

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