Method for rapidly optimizing panel furniture typesetting waste division

Abstract

The invention relates to the technical field of furniture processing, in particular to a method for quickly optimizing panel furniture typesetting waste division, which comprises the following steps: acquiring a standard-size panel; the method comprises the steps that idle units in a standard-size plate are obtained, space division is conducted on the idle units according to boundaries of workpieces, an idle subunit set is obtained, a typesetting matrix is constructed, the positions of the idle subunits in the typesetting matrix are marked as 1, and the positions of the workpieces are marked as 0. According to the method, an intelligent optimization mechanism based on a genetic algorithm is introduced, under the condition that advantages and disadvantages of a plurality of sorting schemes cannot be distinguished or recyclable excess materials do not exist, evolution search can be carried out on sorting of idle subunits from the global perspective, a multi-target fitness function combining the total area of the excess materials and the length of a cutting path is constructed, and the sorting efficiency is improved. The optimal balance of a sorting scheme between material utilization and processing efficiency is realized, and an efficient, quantifiable and intelligent residual and waste material identification and typesetting optimization method is provided.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of furniture processing. More particularly, the present application relates to a method for quickly optimizing the division of leftover materials in the layout of panel furniture. BACKGROUND

[0002] In the manufacturing process of panel furniture, standard-sized boards are used as the main raw materials, and the layout and cutting strategy directly affect the material utilization rate, production efficiency, and cost control level. Traditional layout methods rely on manual experience or simple heuristic algorithms, which often fail to achieve optimal division when faced with complex and diverse workpiece sizes and board combinations, resulting in a large amount of unused space that is not effectively identified and managed, leading to resource waste. Especially in the processing process, the non-workpiece area left after cutting often exists in irregular shapes and cannot be directly used in subsequent production. If these areas can be identified and effectively classified as reusable leftovers or non-reusable waste, it will have a significant value for material recycling, inventory management, and cost control of the enterprise. With the increasing diversity of panel furniture design styles and customer customization needs, the combination of workpiece sizes presents a high degree of uncertainty and dispersion, further increasing the complexity of layout and cutting optimization. Therefore, relying solely on traditional methods cannot meet the requirements of modern manufacturing for efficient material utilization and rapid response.

[0003] Currently, although there are many basic leftover material management functions in the prior art, most of them still use the area size of the leftover material as the only basis for judgment, lack in-depth analysis of the spatial structure of the leftover material, and cannot accurately determine whether the area has reprocessing value. At the same time, the optimization of the division method still relies on fixed rules, lacks global search and intelligent optimization capabilities. In addition, in actual production, standard boards often need to carry the layout requirements of multiple heterogeneous size workpieces, and the remaining space after layout has different shapes. If it cannot be reasonably divided and evaluated, it is easy to lead to potential available areas being incorrectly classified as waste, increasing material waste. SUMMARY

[0004] The present application provides a method for quickly optimizing the division of leftover materials in the layout of panel furniture, which aims to solve the problem of different shapes of remaining space after layout in related technologies, which cannot be reasonably divided and evaluated, easily leading to potential available areas being incorrectly classified as waste, increasing material waste.

[0005] The application provides a method for quickly optimizing waste material division in plate furniture layout, comprising the following steps: obtaining standard size plates; obtaining idle units in the standard size plates, the idle units being areas on the standard size plates except workpieces, performing spatial division on the idle units according to the boundaries of the workpieces to obtain an idle sub-unit set, and constructing a layout matrix, wherein the positions of the idle sub-units in the layout matrix are marked as 1, and the positions of the workpieces are marked as 0; for any idle sub-unit, obtaining the total number of idle sub-units and continuously adjacent idle sub-units on the right side of the idle sub-unit in the layout matrix; performing serial number marking on each idle sub-unit, performing matrix division on the layout matrix according to the serial number order of each idle sub-unit to obtain a full 1 matrix in the layout matrix, and determining the full 1 matrix as a layout rectangular combination; and determining the type of the layout rectangular combination to be waste material or scrap material according to the area size of the layout rectangular combination. Through the construction of the layout matrix and the combination of the maximum order number of the idle sub-units and the serial number order, efficient identification and division of the idle area in the plate furniture layout are realized, the rectangular combination area that can be reused can be quickly extracted, and the waste material and the scrap material can be accurately distinguished according to the area threshold, so that the waste material recycling rate is improved, material waste is reduced, the layout efficiency is optimized, and the beneficial effects of rapid calculation, accurate identification and strong adaptability are achieved.

[0006] Further, determining the type of the layout rectangular combination to be waste material or scrap material comprises: if the area of the layout rectangular combination is greater than or equal to a preset area threshold, it is considered that the area can be used for subsequent processing or reuse, and the layout rectangular combination is divided into waste material; otherwise, the layout rectangular combination is divided into scrap material. The area threshold can be connected with actual process parameters of an enterprise (such as the minimum processable size and the minimum inventory specification), so that the rectangular combination determined as waste material can be truly used for reuse or inventory management, and resource waste is prevented.

[0007] Further, if the area of the layout rectangular combination is less than the preset area threshold, it is considered that the area cannot be used for subsequent processing or reuse, and the layout rectangular combination is divided into scrap material.

[0008] Further, the optimal division scheme of the standard size plates is determined according to a genetic algorithm, comprising the following steps: randomly generating a plurality of chromosomes, wherein one chromosome is a group of idle sub-unit orders; constructing an adaptability function to obtain the adaptability function value of each chromosome, selecting the chromosomes with adaptability function values meeting a preset condition to enter the next generation, and then performing iteration through crossing, mutation and population updating until a set number of generations or adaptability convergence is reached, and then outputting an optimal chromosome, wherein the idle sub-unit order corresponding to the optimal chromosome is the optimal division scheme. The genetic algorithm has strong adaptability to fluctuations in input data and changes in constraint conditions, can process various conditions such as heterogeneous plate types, different arrangement rules and process constraints, and is suitable for actual engineering environments.

[0009] Furthermore, a fitness function is constructed, which is positively correlated with the total area of ​​the scrap material and negatively correlated with the travel distance of the scrap cutting path.

[0010] Furthermore, the fitness function is constructed using the following formula: In the formula, Indicates the first The fitness function value of each chromosome. Indicates the first The total area of ​​residual material for each chromosome. Indicates the first The distance of the waste cutting path in a chromosome is the sum of the adjacent common side lengths of the waste between the rectangular combinations of waste after utilizing the chromosome. The remaining area reflects the degree of material utilization; the larger the area, the higher the material utilization rate. The cutting path reflects the cutting complexity and cost in the processing; the smaller the path, the shorter the cutting distance and the higher the processing efficiency. Combining the two helps to find the optimal balance between high material utilization and low cutting cost.

[0011] Furthermore, chromosomes whose fitness function values ​​meet preset conditions are selected for the next generation, including using a roulette wheel selection method. The roulette wheel method assigns the probability of selection to each chromosome based on its fitness value; the higher the fitness, the greater the probability of selection. This aligns with the evolutionary logic of natural selection and is beneficial for the preservation and dissemination of superior genes.

[0012] Furthermore, chromosomes whose fitness function values ​​meet preset conditions are selected to enter the next generation, including: using a tournament method to select chromosomes to enter the next generation.

[0013] Furthermore, the idle units are spatially divided according to the boundaries of the workpieces, including: extending the boundary lines of each workpiece to the boundary lines of the standard-sized sheet metal; and using the extended lines of the workpiece boundary lines to spatially divide the idle units. Furthermore, each idle sub-unit is marked with a serial number, which can be a number or a letter. This serial number marking transforms scrap materials into addressable and schedulable digital material units, facilitating subsequent intelligent layout and resource scheduling.

[0014] Beneficial effects (I) By constructing a layout matrix to model the spatial structure of standard size plates, and based on the maximum order, adjacency relationship and serial number sorting, etc. information, the idle area is quickly positioned and divided. This scheme effectively improves the automation and precision level of idle area division, and can convert complex and fragmented idle areas into structured rectangular combinations. By setting an area threshold, the layout rectangular combination is classified and managed as waste and scrap, making the material utilization more clear and controllable, improving the efficiency of plate use from the source, reducing resource waste, and optimizing the plate utilization and scrap management process.

[0015] (II) By introducing an intelligent optimization mechanism based on genetic algorithm, in the case where multiple sorting schemes cannot be distinguished between good and bad or there is no recyclable scrap, the idle sub-unit sorting can be evolved and searched from a global perspective. A multi-objective fitness function combining the total area of scrap and the length of cutting path is constructed to achieve the optimal balance between material utilization and processing efficiency, providing an efficient, quantifiable and intelligent scrap and waste material identification and layout optimization method. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 is a schematic diagram illustrating a standard size plate according to an embodiment of the present application; Figure 2 is a schematic diagram illustrating a first sorting scheme according to an embodiment of the present application; Figure 3 is a schematic diagram illustrating a second sorting scheme according to an embodiment of the present application; Figure 4 is a schematic diagram illustrating a third sorting scheme according to an embodiment of the present application; Figure 5 is a schematic diagram illustrating the cutting stroke of the third sorting scheme according to an embodiment of the present application; Figure 6 is a flowchart illustrating the division of scrap according to an embodiment of the present application. DETAILED DESCRIPTION

[0017] The specific embodiments of the present application will be described in detail below with reference to the accompanying drawings.

[0018] As shown in Figure 6 S101: Obtain a standard size plate.

[0019] As shown in Figure 1 In one embodiment, the standard size plate is the basic carrier for layout and cutting, and usually contains several workpieces to be cut (e.g. furniture panels, cabinets, etc.) inside. Figure 1These workpieces are rectangular structures of preset sizes, representing the structural members or functional components to be cut out in the actual furniture production process, such as door panels, side panels, drawer panels, etc. Each workpiece has been determined in terms of specific size and type according to the finished product drawings in the design stage, and usually exists in the form of a rectangle or an approximate rectangle, facilitating efficient and compact arrangement and cutting on the board. In actual operation, these workpieces to be cut need to be arranged on one or more standard-sized boards, and the arrangement process not only needs to meet the basic geometric constraints of non-overlapping and non-exceeding the board edge, but also needs to improve the board utilization rate as much as possible and reduce the generation of invalid excess material or waste. Therefore, the spatial organization structure of the standard board directly determines the complexity and benefit level of subsequent cutting optimization and excess material management. For example: Figure 1 The outer contour rectangle in FIG. 1 represents a standard-sized board, the size of which can be randomly selected according to actual conditions. For example, the size of the standard-sized board is , etc.

[0020] S102: Obtain the arrangement matrix in the standard-sized board.

[0021] In one embodiment, the idle unit in the standard-sized board is obtained, and the idle unit is the idle area remaining in the standard-sized board except the workpieces to be cut (the workpieces to be cut are and ). Then, the idle unit is spatially divided according to the boundaries of the workpieces, to obtain a set of idle sub-units, as an idle sub-unit set. Specifically, the horizontal boundary lines and the vertical boundary lines of all workpieces are extended outward until they extend to the upper and lower boundaries and the left and right boundaries of the standard-sized board, thereby constructing a series of longitudinal and transverse spatial division lines, which construct a plurality of small rectangular areas inside the idle unit. The above extension operation divides the originally irregular idle unit into a plurality of regular rectangular areas, referred to as idle sub-units. Each idle sub-unit is the smallest rectangular unit enclosed by adjacent boundary lines, and all the divided idle sub-units collectively constitute a set, referred to as an idle sub-unit set. Finally, it is necessary to judge whether the area of the idle sub-unit constitutes available excess material or useless waste material.

[0022] As mentioned above, after completing the spatial division of the standard-sized board and obtaining the idle sub-unit set, it is necessary to construct an arrangement matrix with a spatial indication function based on the set. The arrangement matrix is used to uniformly represent the spatial use state in the standard board in the form of a two-dimensional discrete grid, including the area occupied by the workpieces to be cut and the geometric distribution of the idle sub-units. Specifically, the two-dimensional coordinate axes are constructed according to the horizontal and vertical coordinate boundaries divided by the extension lines of the standard-sized board (as shown in FIG. 2). Figure 1x1, x2, y1, y2) and establishes a two-dimensional matrix structure, referred to as a layout matrix, based thereon to record the spatial state information of each divided region. In the matrix: if a cell corresponds to a laid-out workpiece region, the value of the cell is set to 0, indicating that the region is occupied and cannot participate in the waste material division; if a cell corresponds to a divided idle sub-cell, the value of the cell is set to 1, indicating that the region is idle space and can participate in subsequent waste material judgment and rectangular combination operations. Through the above method, the entire standard plate space is digitally encoded and mapped into a layout matrix. As shown in FIG. 7, the layout matrix is Figure 1 . .

[0023] S103: Screen out the layout rectangular combination.

[0024] In one embodiment, the maximum order of the idle sub-cell in the layout matrix is extracted, the maximum order of any idle sub-cell and the maximum order of the adjacent idle sub-cell thereon are obtained, the full 1 matrix with the largest order is quickly combined by searching the relationship between the maximum order of the current idle sub-cell and the maximum order of the adjacent pixel, the full 1 matrix with the most 1 is quickly found, and the full 1 matrix is determined as the layout rectangular combination, wherein the maximum order refers to the total number of the idle sub-cell and the right continuous adjacent idle sub-cell in the layout matrix. Specifically, each idle sub-cell is marked with a serial number, which is a number or a letter, the layout matrix is divided by the serial number sorting of each idle sub-cell to obtain the full 1 matrix in the layout matrix, and the full 1 matrix is determined as the layout rectangular combination. One serial number sorting of each idle sub-cell corresponds to one sorting scheme.

[0025] To sum up, for any idle sub-unit (matrix unit with value 0) in the layout matrix, the maximum order number of the idle sub-unit is defined as the total number of the idle sub-units including itself and the idle sub-units adjacent to the right of the idle sub-unit. In other words, the index reflects the ability of the current unit to form a continuous idle rectangle in the X-axis direction in the layout matrix, and is a basic parameter for judging whether it can participate in forming a larger rectangular combination. In order to facilitate subsequent processing, first, all idle sub-units are uniquely marked, which can be numbered with numbers (such as 1, 2, 3,...) or letters (such as A, B, C,...), to ensure that the identity of each idle sub-unit in the matrix can be identified and tracked. According to these serial number identifiers, a sorting list is constructed, and the matrix is sequentially traversed and structured. The all-1 matrix obtained by the above search is taken as a layout rectangle combination under the current sorting scheme, and its position index, contained idle sub-unit number, actual physical area and other information are recorded as the input of the subsequent scrap / waste classification judgment and fitness function evaluation. For example, the serial numbers of the idle sub-units are marked, and then the serial numbers of the idle sub-units are sorted to obtain the first sorting scheme "6754321" (as shown in Figure 2 ), at this time, the idle space can be divided into a rectangle composed of "6754", a rectangle composed of "3" alone, and a rectangle composed of "21", so that three layout rectangle combinations can be obtained under the sorting scheme. The second sorting scheme "6457312" (as shown in Figure 3 ) is obtained by sorting again; the third sorting scheme "3421567" (as shown in Figure 4 ) is obtained by sorting again.

[0026] S104: Determine whether the type of the layout rectangle combination belongs to scrap or waste according to the area of the layout rectangle combination.

[0027] In one embodiment, in order to realize the classification management of the layout rectangle combination, the actual area of the layout rectangle combination needs to be evaluated, and the type is divided according to the preset area threshold. Specifically, for any layout rectangle combination, the actual area of the combination can be calculated by counting the physical size of the idle sub-units contained in the combination. Then, the area is compared with the preset area threshold (that is, the minimum recyclable area threshold). The preset area threshold can be set according to the actual production capacity of the enterprise, the processing process requirement or the material recycling standard, and usually represents the critical value of whether an idle plate has recycling value. For example, if the minimum cutting piece size of the subsequent processing process is , the preset area threshold can be set to ; below the value, the combination of rectangle is difficult to cut or utilize, and can be directly regarded as corner waste material processing. The specific division logic is as follows: if the area of the current layout rectangle combination is greater than or equal to the preset area threshold, it is considered that the rectangular region has the value of reusing, and can be included in the subsequent cutting plan or inventory management system, and is marked as a surplus material region; if the area of the current layout rectangle combination is less than the preset area threshold, it is considered that the area is too small to meet the subsequent processing requirements or the storage cost is higher than its utilization value, and it is divided into a waste region.

[0028] It should be noted that if the areas of all layout rectangle combinations are less than the preset area threshold, it means that the standard size board cannot obtain surplus material meeting the area limit, or the areas of the layout rectangle combinations in multiple sorting schemes are equal, at this time, the optimal division scheme is determined according to the genetic algorithm. In other words, if there is no rectangular region meeting the minimum reuse requirement in the current division result, all divided rectangular combinations do not meet the minimum area requirement that can be defined as surplus material, and cannot be used as raw materials for subsequent processing and production, at this time, the whole standard size board will be completely converted into waste material under the current division method. Or, in another case, although multiple sorting schemes can divide several surplus material regions meeting the area threshold, the areas of the surplus materials in these schemes are equal, that is, it is difficult to distinguish between the advantages and disadvantages in the main target dimension (material recycling rate). At this time, simply relying on the area of the surplus material is not enough to determine the optimal division strategy. In this case, the optimal waste division strategy based on the genetic algorithm is introduced to minimize the cutting cost as the optimization target, and the optimal division scheme is selected from the global perspective. Specifically, through the global search and fitness driving mechanism of the genetic algorithm, all possible pixel sorting combinations are iteratively optimized, and the optimal division result in terms of waste processing efficiency is selected. If no effective surplus material can be generated under a certain sorting scheme, or the advantages and disadvantages cannot be distinguished by the area of the surplus material under multiple sorting schemes, the genetic algorithm optimization process with the target of minimizing the cutting cost is started.

[0029] In one embodiment, determining the optimal partitioning scheme using a genetic algorithm includes: randomly generating several chromosomes, where each chromosome represents a group of free subunits; constructing a fitness function, where the fitness function is positively correlated with the total area of ​​surplus material and negatively correlated with the length of the waste cutting path, thereby obtaining the fitness function value of each chromosome; selecting chromosomes whose fitness function values ​​meet preset conditions to enter the next generation, where meeting the preset conditions means using classic strategies such as roulette wheel selection, tournament selection, or ranking selection to ensure the priority retention of individuals with high fitness. After iterating through crossover, mutation, and population updates until a set number of generations or fitness convergence is reached, the optimal chromosome is output, and the free subunit sorting corresponding to the optimal chromosome is the optimal partitioning scheme. This optimal partitioning scheme has the optimal structural characteristics of maximizing surplus material area, minimizing cutting path, or both, and can be used to guide actual sheet metal cutting scheduling and processing execution.

[0030] In one embodiment, if there is excess material in the layout scheme, its fitness function is constructed, and the formula is as follows: In the formula, Indicates the first The fitness function value of each chromosome. Indicates the first The total area of ​​residual material for each chromosome. Indicates the first The stroke of the waste cutting path in a chromosome, wherein the stroke of the waste cutting path is the sum of the adjacent common side lengths of the waste between the rectangular combinations of the chromosome after layout, that is, in the th Under the sorting and partitioning scheme corresponding to each chromosome, analyze all the partitioned layout rectangle combinations and extract the adjacent and shared edge relationships between their waste materials (e.g., Figure 5 The black part shown is Figure 3 The cutting path travel of the layout scheme is calculated as the sum of the lengths of adjacent shared edges of the scrap materials. The total length of the boundaries between these contacting rectangles is then summed to obtain the cutting path travel. A larger fitness function value indicates a better sorting scheme while achieving the combined goals of high material utilization (large surplus area) and short scrap cutting paths; conversely, a smaller value indicates a poorer sorting effect. In another embodiment, if there is no surplus material in the layout scheme (i.e., the layout scheme consists entirely of scrap materials), a fitness function is constructed. This fitness function is negatively correlated only with the scrap cutting path travel, which is the travel of the scrap cutting path using the first... The sum of the side lengths of adjacent waste materials in the rectangular combination of chromosomes after their arrangement.

[0031] Finally, based on the optimal chromosome obtained by the iterative optimization process of the genetic algorithm, the corresponding idle sub-unit order is determined as the optimal division scheme of the current standard size board under the specific layout condition. This division scheme not only realizes the reasonable division and effective organization of the idle area in structure, but also takes into account the material utilization efficiency and processing path cost in quantitative indicators at the same time. After determining the optimal division scheme, the system will cut the standard size board according to the scheme. Specifically, according to the combination of the layout rectangles in the division result, the processing path is generated in turn, and the partition cutting is carried out according to the corresponding surplus and waste material area. For the area judged as surplus material, it can be further managed according to its position, shape and area, and put into the subsequent cutting plan or recycling plan; while the area judged as waste material can be arranged for centralized recovery or processed according to the specified process flow.

[0032] The above-described embodiments only express several embodiments of the present application, and the description is more specific and detailed, but it cannot be understood as limiting the scope of the application. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are within the scope of protection of the present application.

Claims

1. A method for fast optimization of board furniture layout waste division, characterized by, The method comprises the following steps: Obtaining a standard size plate; Obtaining an idle unit in the standard size plate, the idle unit being an area on the standard size plate other than the workpiece, spatially dividing the idle unit according to the boundary of the workpiece to obtain a set of idle sub-units, and constructing a layout matrix, wherein the position of the idle sub-unit in the layout matrix is marked as 1, and the position of the workpiece is marked as 0; For any idle sub-unit, obtaining the total number of idle sub-units and their right-continuous adjacent idle sub-units in the layout matrix; Marking the serial numbers of each idle sub-unit, and performing matrix division on the layout matrix according to the serial number order of each idle sub-unit to obtain a full 1 matrix in the layout matrix, and determining the full 1 matrix as a layout rectangle combination; Determining whether the type belongs to the excess material or the waste material according to the area size of the layout rectangle combination.

2. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 1, wherein, Determining whether the type belongs to the excess material or the waste material comprises: If the area of the layout rectangle combination is greater than or equal to a preset area threshold, it is considered that the area can be used for subsequent processing or recycling, and the layout rectangle combination is divided into excess material, otherwise it is divided into waste material.

3. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 2, wherein, Determining the optimal division scheme of the standard size plate according to the genetic algorithm.

4. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 3, wherein, Determining the optimal division scheme of the standard size plate according to the genetic algorithm comprises: Randomly generating a plurality of chromosomes, wherein one chromosome is a set of idle sub-unit orders; Constructing a fitness function to obtain the fitness function value of each chromosome, selecting chromosomes with fitness function values meeting preset conditions to enter the next generation, and then performing iteration through crossover, mutation and population updating until a set number of generations or fitness convergence is reached, and outputting the optimal chromosome, wherein the idle sub-unit order corresponding to the optimal chromosome is the optimal division scheme.

5. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 1, wherein, Constructing a fitness function comprises: The fitness function is positively correlated with the total area of the excess material and negatively correlated with the travel of the waste material cutting path.

6. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout of claim 1, wherein, The fitness function is constructed by the following formula: ； In the formula, a fitness function value of the i-th chromosome, a fitness function value of the i-th chromosome, a total area of the waste material of the i-th chromosome, a total area of the waste material of the i-th chromosome, a total area of the waste material of the i-th chromosome, a total area of the waste material of the i-th chromosome, 7. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 1, wherein, Selecting chromosomes with fitness function values meeting preset conditions to enter the next generation comprises: Using roulette selection to select chromosomes to enter the next generation.

8. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout of claim 1, wherein, Selecting chromosomes with fitness function values meeting preset conditions to enter the next generation comprises: Using tournament selection to select chromosomes to enter the next generation.

9. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 1, wherein, Spatially dividing the idle unit according to the boundary of the workpiece comprises: Extending the boundary line of each workpiece to the boundary line of the standard size plate; Using the extended boundary line of the workpiece to spatially divide the idle unit.

10. The method of quickly optimizing scrap and yield breaks for panel-based furniture layout according to claim 1, wherein, Marking the serial numbers of each idle sub-unit comprises: The serial number is a number or a letter.

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