Production scheduling methods, systems, and storage media for large-volume heavy components of prefabricated bridges

Abstract

This invention provides a method, system, and storage medium for scheduling the production of large-volume heavy components for prefabricated bridges. The method includes: establishing a planning data foundation; aggregating and grouping dimensions based on the planning data; determining the sequence of template stages; allocating storage areas for beam groups; calculating target stacking levels; deriving the reverse production sequence based on stacking targets; and generating component-level production and stacking plans. This invention considers construction sequence, component size aggregation, stacking levels, and storage areas in a unified manner under complex scenarios, achieving coordinated optimization of production sequence, stacking sequence, and hoisting sequence. This reduces material handling, improves overall efficiency, and makes yard management more standardized and highly information-based. It facilitates the linkage of multiple systems such as WMS, MES, and BIM, and enables traceable management of the entire lifecycle of components from design and production to installation.

Description

Technical Field

[0001] This invention belongs to the field of information technology for engineering construction and production scheduling optimization, and in particular relates to a method, system and storage medium for scheduling large-volume heavy components of prefabricated bridges based on reverse production and partitioned stacking collaborative optimization. Background Technology

[0002] In prefabricated bridge construction, large-volume, heavy components such as precast T-beams and box girders are extensively used. Current engineering practices reveal the following main problems in beam yard production scheduling and storage management:

[0003] 1. The production sequence is disconnected from the construction sequence;

[0004] Although the accurate component information of the Building Information Modeling (BIM) system can be transmitted to the production end, construction units usually rely on manual or incomplete information based on resources such as equipment, personnel, and formwork to organize the production of large-volume heavy components, such as beams. The production sequence is often inconsistent with the on-site hoisting construction sequence, resulting in a mismatch between the beam stacking sequence and the hoisting sequence.

[0005] 2. Frequent relocation and low efficiency;

[0006] Beams are typically stacked in multiple layers in the yard. During hoisting, the upper layers must be lifted off before the lower layers can be removed. When beams installed earlier are pressed down by beams installed later, the only solution is to temporarily reposition or move them, resulting in multiple hoisting operations and on-site transportation, increasing costs and safety risks.

[0007] 3. Beams of different sizes are stacked together, making unified management difficult;

[0008] Components with different spans and cross-sectional dimensions are often mixed and stacked in the same area, and the stacking rules are not uniform, which makes it difficult to manage the yard numbering, and to link the Warehouse Management System (WMS) and the Manufacturing Execution System (MES).

[0009] 4. Lack of a unified method for production scheduling and stacking coordination;

[0010] Existing MES or WMS management systems mostly remain at the level of component lists and simple sorting, lacking a unified optimization method that comprehensively incorporates factors such as "construction sequence, component size, stacking physical constraints, and storage areas." This results in production scheduling results relying on manual experience, making it difficult to achieve standardization and automation.

[0011] Therefore, there is an urgent need for a scheduling method and system that can take into account the construction sequence, component size aggregation, stacking layers and storage areas in complex scenarios, so as to achieve coordinated optimization of production sequence, stacking sequence and hoisting sequence, thereby reducing relocation and improving overall efficiency. Summary of the Invention

[0012] To address the shortcomings of existing technologies, this invention provides a method, system, and storage medium for scheduling the production of large-volume heavy components for prefabricated bridges. It can unify the consideration of construction sequence, component size aggregation, stacking layers, and storage areas in complex scenarios, achieving coordinated optimization of production sequence, stacking sequence, and hoisting sequence, reducing relocation, and improving overall efficiency.

[0013] The present invention achieves the above-mentioned technical objectives through the following technical means.

[0014] A method for scheduling the production of large-volume heavy components for prefabricated bridges includes the following process:

[0015] Step 1: Collect component information from different sources and convert it into a standardized data model that can be used for calculation;

[0016] Step 2: Based on the standardized data model, aggregate and group component sizes according to the planning package to obtain a set of beam type groups;

[0017] Step 3: Determine the sequence of formwork stages for the beam group;

[0018] Step 4: Allocate storage areas for beam groups;

[0019] Step 5: Calculate the target stacking layer for each span within the beam group;

[0020] Step 6: Perform reverse production sequence derivation based on stacking targets;

[0021] Step 7: Generate component-level production and stacking plans.

[0022] Furthermore, in step 1, the standardized data model is cross-set. , , , , They represent the 1st span, the 2nd span, and the 3rd span, respectively. Span; and for any span ,1≤ ≤ It has the following attributes:

[0023] Span Used to distinguish beam types of different sizes;

[0024] On-site construction sequence ,and , Represents the set of positive integers;

[0025] Number of beam segments ;

[0026] Optional attributes include: bridge site zoning, direction, and traffic organization priority.

[0027] Furthermore, the specific process of size aggregation and grouping in step 2 is as follows:

[0028] Clustering the span sets based on span length forms beam-type groups. :

[0029]

[0030] in, This refers to the span length.

[0031] The beam group set obtained by aggregation for:

[0032]

[0033] in, , , These represent the various beam groups formed under different span lengths.

[0034] Furthermore, the specific process of step 3 is as follows:

[0035] Define a mapping function from beam span to formwork stage number. : , , , These represent the first span dimension, the second span dimension, and the third span dimension, respectively. Each span length dimension;

[0036] In cross sets In the middle, the cross will be carried out in accordance with the construction sequence. Sort in ascending order and construct the following sequence:

[0037] ,in

[0038] Scan the sequence sequentially, when a certain span length When it appears for the first time, a new stage number is assigned to it, thus obtaining the template stage sequence:

[0039] =Phase Number

[0040] in, , , These represent the first span, second span, and third span respectively, arranged in the construction sequence. Span; , , These represent the construction sequence numbers for the first, second, and last construction phases within the corresponding span. Indicates cross Corresponding span The template production stage number to which it is mapped; This indicates the sequence number of each span in the construction sequence, with a value range of [value missing]. .

[0041] Furthermore, the specific process of step 4 is as follows:

[0042] Set up storage area set for:

[0043]

[0044] Set the region allocation function :

[0045]

[0046] Each beam group When assigned to one or more storage areas, groups of beams with the same span are preferentially stacked in the same area:

[0047]

[0048] in, , , These represent the 1st, 2nd, and 3rd available in the storage yard, respectively. One storage area; Indicates the span length dimension category The corresponding memory allocation function; Indicates belonging to a cross-length category cross Storage areas allocated to the yard .

[0049] Furthermore, the specific process of step 5 is as follows:

[0050] For any beam type group Arrange its internal components in ascending order according to the construction sequence:

[0051]

[0052] in:

[0053]

[0054] in, Indicates beam type group The cross-sequence is arranged in ascending order of construction sequence; , , These represent the 1st, 2nd, and 3rd construction sequences within the beam group, arranged from earliest to latest. One span; , , They represent , , Construction sequence number;

[0055] Set target stacking level function , here This indicates the sequence number within the construction sequence of the beam group. The range of values ​​is ;

[0056] This is the highest level in this beam group;

[0057] This is the lowest level in this beam group;

[0058] The earlier the construction sequence, the higher the target stacking layer, which can be formalized as follows:

[0059]

[0060] in, , They represent the first One span, the first Construction sequence numbering for each span; , They represent and The target stacking layer number.

[0061] Furthermore, the specific process of step 6 is as follows:

[0062] In the same beam group Inside, the sorted sequence from step 5 Perform a reverse traversal to obtain the production sequence. :

[0063]

[0064] according to Production proceeds in the order specified, forming a production sequence function. ;

[0065] When stacking components, they should be arranged according to their completion time, which can be formalized as follows:

[0066]

[0067] in, , They represent cross and across Production sequence number; Indicates cross The actual stacking level in the stockyard; Indicates cross The actual stacking level in the stockyard;

[0068] Because the production sequence and the construction sequence are strictly in reverse order within the group, therefore:

[0069]

[0070] The target stacking level is achieved through reverse production; This represents the actual stacking layer bit function.

[0071] Furthermore, in step 7, each span is expanded to the component level, that is, from the beam group to each individual beam; for the first... beam Record the following fields:

[0072] Production sequence number Belonging to , span Beam type group Template stage number Storage area Stacked layers Construction sequence ;

[0073] Automatically generate component-level production and stacking plans to drive prefabrication production and yard operations.

[0074] A system for implementing the above-mentioned method for scheduling the production of large-volume heavy components for prefabricated bridges includes:

[0075] The data modeling module collects and stores basic information including span number, span length, construction sequence, number of beam segments, and storage area, and processes it into a standardized data model that can be used for calculation.

[0076] The size aggregation and grouping module clusters components based on span length to generate a set of beam-type groups.

[0077] The template stage decision module determines the sequence of template production stages for beam groups based on the construction sequence and project requirements.

[0078] The storage area allocation module allocates storage areas to each beam group, enabling centralized stacking of beams of the same size.

[0079] The stacking layer decision module calculates the target stacking layer based on the construction sequence within each beam group;

[0080] The reverse production scheduling module generates a reverse production sequence within the group based on the target stacking target layer, and forms a production sequence function;

[0081] The plan generation and release module generates production and stacking plans, driving prefabrication production and yard operations.

[0082] A computer-readable storage medium having a computer program stored thereon, which, when run on a processor, executes the steps of the above-described method for scheduling the production of large-volume heavy components for prefabricated bridges.

[0083] The present invention has the following beneficial effects:

[0084] (1) The production sequence and construction sequence are coordinated and matched;

[0085] By introducing a chain-like reasoning of "construction sequence → target layer → reverse production", it is ensured that once the components in the storage yard are stacked, they are consistent with the subsequent hoisting sequence, thus avoiding the problem of "first-built components being pressed down on lower layers" that is common in traditional schemes.

[0086] (2) Significantly reduces transshipment and repeated hoisting;

[0087] Since the stacking layers are pre-planned through reverse production, there is little or no need for temporary handling during component hoisting, which greatly reduces the amount of secondary handling work and the time spent by the crane.

[0088] (3) Reduce template switching and improve production efficiency;

[0089] By combining span-length dimension aggregation and formwork stage sequence decision-making, beam-type components are concentrated in the same production stage, reducing the frequency of formwork adjustments and thus improving the prefabrication production cycle.

[0090] (4) The yard management is highly standardized and information-based;

[0091] The components are stacked in zones according to beam type and a unified data model and schedule are formed in the system, which facilitates the linkage of multiple systems such as WMS, MES, and BIM, and realizes traceable management of the entire life cycle of components from design, production to installation.

[0092] (5) Based on the relationships of sets, sorting, mapping and inversion, this invention can be adapted to different component types, different storage area quantities and different construction organization strategies, and has good versatility and scalability.

[0093] (6) The present invention can take into account the construction sequence, component size aggregation, stacking layer and storage area in a unified manner in complex scenarios, realize the coordinated optimization of production sequence, stacking sequence and hoisting sequence, reduce handling and improve overall efficiency. Attached Figure Description

[0094] Figure 1 This is a flowchart of the prefabricated bridge large-volume heavy component scheduling method described in this invention; Detailed Implementation

[0095] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but the scope of protection of the present invention is not limited thereto.

[0096] Based on the above-mentioned prefabricated bridge large-volume heavy component scheduling system, the prefabricated bridge large-volume heavy component scheduling method is as follows: Figure 1 As shown, the specific process includes the following:

[0097] Step 1: Establish the planning data foundation, which involves using a BIM system to transform component information from different sources (such as BIM models, construction organization designs, yard systems, etc.) into a standardized data model that can be used for calculations. Specifically:

[0098] Building across collections:

[0099]

[0100] in, Denotes the set of spans consisting of all spans. , , They represent the 1st span, the 2nd span, and the 3rd span, respectively. Span;

[0101] For any cross (1≤ ≤ Define the following properties:

[0102] Span Used to distinguish beam types of different sizes;

[0103] On-site construction sequence The smaller the value, the earlier the construction began, and , Represents the set of positive integers;

[0104] Number of beam segments , is usually a constant, but can also be any integer;

[0105] Optional attributes include: bridge site zoning, direction, traffic organization priority, etc.

[0106] The BIM system is used to store the above information (i.e., a cross set containing several attribute information) into the component data table, and more component attributes are extracted based on the unified identifier GUID provided by the BIM system, including geometric attributes and semantic attributes (such as construction section, material type, etc.). The component geometric attributes (length, width, height, section, span number, beam number) are automatically associated with the production scheduling system as the basic data for subsequent production scheduling and stacking calculations.

[0107] Step 2: Group by size based on the planned packaging;

[0108] In the BIM system and its corresponding Work Breakdown System (WBS) plugin, planning objects are extracted and packaged, and components are aggregated into construction sections (e.g., spans). Then, they are entered into the MES (Manufacturing Execution System) for parameter and coefficient extraction, specifically extracting production queue information and scheduling information to form the basis for production scheduling. The specific process of dimension aggregation and grouping is as follows:

[0109] Within the predetermined planning and packaging, components are assembled according to their dimensions;

[0110] According to the span cross set Clustering is performed to form several beam-shaped groups:

[0111]

[0112] in, This indicates a beam type group, i.e., a span of... All cross sets, For a certain span length, such as 20m, 25m, 30m, etc.

[0113] The beam group set obtained by aggregation for:

[0114]

[0115] in, , , These represent the various beam groups formed under different span lengths.

[0116] This step allows for the categorization of components with the same geometric dimensions and template requirements, which helps reduce the number of template changes and also enables the integration of BIM and WBS information into MES.

[0117] Step 3: Determine the template phase sequence in the WBS and import it into the MES;

[0118] Building upon step 2, the production phase sequence for each beam group needs to be determined. The construction sequence information for the spans is provided by the construction plan or WBS, serving as input data for the formwork phase sequencing. The MES does not regenerate the construction sequence; instead, it derives the phase sequence based on the construction sequence data provided by the WBS. The specific process is as follows:

[0119] Define function : , A mapping function representing the beam span to the formwork stage number. , , These represent the first span dimension, the second span dimension, and the third span dimension, respectively. Each span length dimension This indicates the total number of span dimensions (i.e., the number of beam groups).

[0120] In cross sets In the middle, the cross will be carried out in accordance with the construction sequence. Sort in ascending order and construct the following sequence:

[0121] ,in

[0122] Scan the sequence sequentially, when a certain span length When it appears for the first time, a new stage number is assigned to it, thus obtaining the template stage sequence:

[0123] =Phase Number

[0124] in, , , These represent the first span, second span, and third span respectively, arranged in the construction sequence. Span; , , These represent the construction sequence numbers for the first, second, and last construction phases within the corresponding span. Indicates cross Corresponding span The template production stage number to which it is mapped; This indicates the sequence number of each span in the construction sequence, with a value range of [value missing]. ;

[0125] The template stage refers to the stage of template adjustment during production. For example, the first stage is 25m beam template, the second stage is 30m beam template, and the third stage is adjusted back to 25m beam template. This step ensures that the production stage sequence of the beam group takes into account both the construction plan and the template utilization rate.

[0126] Step 4: Allocate a storage area for beam groups in WMS;

[0127] Set up storage area set for:

[0128]

[0129] Set the region allocation function :

[0130]

[0131] Each beam group They are assigned to one or more storage areas, preferably in a one-to-one relationship, meaning that groups of beams with the same span are preferentially stacked in the same area:

[0132]

[0133] in, , , These represent the 1st, 2nd, and 3rd available in the storage yard, respectively. One storage area; Indicates the span length dimension category The corresponding memory allocation function; Indicates belonging to a cross-length category cross Storage areas allocated to the yard ;

[0134] This step enables the stacking of items by size, facilitating unified management and hoisting organization.

[0135] Step 5: Calculate the target stacking level in WMS;

[0136] This step involves calculating the target stacking layer for each span within the beam group, based on the construction sequence, as detailed below:

[0137] For any beam type group Arrange its internal components in ascending order according to the construction sequence:

[0138]

[0139] in

[0140]

[0141] in, Indicates beam type group The cross-sequence is arranged in ascending order of construction sequence; , , These represent the 1st, 2nd, and 3rd construction sequences within the beam group, arranged from earliest to latest. One span; , , They represent , , Construction sequence number;

[0142] Define target stacking level function , where This indicates the sequence number within the construction sequence of the beam group (i.e., the first...). (a construction span), at this time The range of values ​​is :

[0143] This is the highest level (easiest to lift) in this beam group.

[0144] This is the lowest level in this beam group;

[0145] The earlier the construction sequence, the higher the target stacking layer, which can be formalized as follows:

[0146]

[0147] The smaller the layer number, the higher the layer; , They represent the first One span, the first Construction sequence numbering for each span; , They represent and The target stacking layer number (the smaller the layer number, the higher it is).

[0148] Step 6: Perform reverse production sequence derivation based on stacking target in MES;

[0149] Within the same stack group, components produced earlier must be located on the lower layer, and components produced later must be located on the upper layer. To ensure that the actual stack layer position matches the target layer position, this invention introduces a reverse-order production principle:

[0150] In the same beam group Inside, the sorted sequence from step 5 Perform a reverse traversal to obtain the production sequence. :

[0151]

[0152] according to Production proceeds in the order specified, forming a production sequence function. ;

[0153] When stacking components, they should be arranged according to their completion time, which can be formalized as follows:

[0154]

[0155] in, , They represent cross and across Production sequence number; Indicates cross The actual stacking level in the stockyard; Indicates cross The actual stacking level in the stockyard;

[0156] Because the production sequence and the construction sequence are strictly in reverse order within the group, therefore:

[0157]

[0158] That is, the target stacking level is achieved through reverse production; This represents the actual stacking layer bit function.

[0159] Step 7: Generate component-level production and stacking plans in MES and WMS;

[0160] Based on the aforementioned steps, MES and WMS are used to process each cross-... Expanding to the component level, that is, from beam group to each individual beam; for the first beam , Record the following fields:

[0161] Production sequence number Inheritance across levels can be further subdivided into intra-level inheritance;

[0162] Belonging to , span ;

[0163] Beam type group ;

[0164] Template stage number ;

[0165] storage area ;

[0166] Stacked layers ;

[0167] Construction sequence .

[0168] The system automatically generates component-level production scheduling and stacking plans, and can output data in a format recognizable by MES and WMS to drive prefabrication production and yard operations.

[0169] This invention also provides a production scheduling system for large-volume heavy components of prefabricated bridges, comprising:

[0170] The data modeling module collects and stores basic information such as span number, span length, construction sequence, number of beam segments, and storage area, and processes it into a standardized data model that can be used for calculation.

[0171] The size aggregation and grouping module clusters components based on span length to generate a set of beam-type groups.

[0172] The template stage decision module determines the sequence of template production stages for beam groups based on the construction sequence and project requirements.

[0173] The storage area allocation module allocates storage areas to each beam group, enabling centralized stacking of beams of the same size.

[0174] The stacking layer decision module calculates the target stacking layer based on the construction sequence within each beam group;

[0175] The reverse production scheduling module generates a reverse production sequence within the group based on the target stacking target layer, and forms a production sequence function;

[0176] The planning generation and publishing module generates production and stacking plans and publishes them to MES and WMS to drive prefabrication production and yard operations.

[0177] The present invention also provides a computer-readable storage medium storing a computer program that, when run on a processor, executes the steps of the above-described method for scheduling the production of large-volume heavy components for prefabricated bridges, thereby realizing the reverse-order production and zoned stacking of prefabricated beam segments in a collaborative and optimized scheduling manner.

[0178] The embodiments described above are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments. Any obvious improvements, substitutions or modifications that can be made by those skilled in the art without departing from the essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for scheduling the production of large-volume heavy components for prefabricated bridges, characterized in that, The process includes the following: Step 1: Collect component information from different sources and convert it into a standardized data model that can be used for calculation; Step 2: Based on the standardized data model, aggregate and group component sizes according to the planning package to obtain a set of beam type groups; Step 3: Determine the sequence of formwork stages for the beam group; Step 4: Allocate storage areas for beam groups; Step 5: Calculate the target stacking layer for each span within the beam group; Step 6: Perform reverse production sequence derivation based on stacking targets; Step 7: Generate component-level production and stacking plans; The specific process of size aggregation and grouping in step 2 is as follows: Clustering of span sets based on span length forms beam-type groups. : ； in, This refers to the span length. Indicates the span length; Indicates span; The beam group set obtained by aggregation for: ； in, , , These represent the various beam groups formed under different span lengths; The specific process of step 3 is as follows: Define a mapping function from beam span to formwork stage number. : , , , These represent the first span dimension, the second span dimension, and the third span dimension, respectively. Each span length dimension; In cross sets In the middle, the cross will be carried out in accordance with the construction sequence. Sort in ascending order and construct the following sequence: ,in ; Scan the sequence sequentially, when a certain span length When it appears for the first time, a new stage number is assigned to it, thus obtaining the template stage sequence: =Phase number; in, , , These represent the first span, second span, and third span respectively, arranged in the construction sequence. Span; , , These represent the construction sequence numbers for the first, second, and last construction phases within the corresponding span. Indicates cross Corresponding span The template production stage number to which it is mapped; This indicates the sequence number of each span in the construction sequence, with a value range of [value missing]. ; The specific process of step 4 is as follows: Set up storage area set for: ； Set the region allocation function : ； Each beam group When assigned to one or more storage areas, groups of beams with the same span are preferentially stacked in the same area: ； in, , , These represent the 1st, 2nd, and 3rd available in the storage yard, respectively. One storage area; Indicates the span length dimension category The corresponding storage area allocation function; Indicates belonging to a cross-length category cross Storage areas allocated to the yard; The specific process of step 5 is as follows: For any beam type group Arrange its internal components in ascending order according to the construction sequence: ； in: ； in, Indicates beam type group The cross-sequence is arranged in ascending order of construction sequence; , , These represent the 1st, 2nd, and 3rd construction sequences within the beam group, arranged from earliest to latest. One span; , , They represent , , Construction sequence number; Set target stacking level function , here This indicates the sequence number within the construction sequence of the beam group. The range of values ​​is ; This is the highest level in this beam group; This is the lowest level in this beam group; The earlier the construction sequence, the higher the target stacking layer, which can be formalized as follows: ； in, , They represent the first One span, the first Construction sequence numbering for each span; , They represent and The target stacking layer number; The specific process of step 6 is as follows: In the same beam group Inside, the sorted sequence from step 5 Perform a reverse traversal to obtain the production sequence. : ； according to Production proceeds in the order specified, forming a production sequence function. ; When stacking components, they should be arranged according to their completion time, which can be formalized as follows: ； in, , They represent cross and across Production sequence number; Indicates cross The actual stacking level in the stockyard; Indicates cross The actual stacking level in the stockyard; Because the production sequence and the construction sequence are strictly in reverse order within the group, therefore: ； The target stacking level is achieved through reverse production; This represents the actual stacking layer bit function.

2. The method for scheduling the production of large-volume heavy components for prefabricated bridges according to claim 1, characterized in that, In step 1, the standardized data model is cross-set. , , , , They represent the 1st span, the 2nd span, and the 3rd span, respectively. Span; and for any span ,1≤ ≤ It has the following attributes: Span Used to distinguish beam types of different sizes; On-site construction sequence ,and , Represents the set of positive integers; Number of beam segments ; Optional attributes include: bridge site zoning, direction, and traffic organization priority.

3. The method for scheduling the production of large-volume heavy components for prefabricated bridges according to claim 1, characterized in that, In step 7, each span is expanded to the component level, that is, from the beam group to each individual beam; for the first... beam Record the following fields: Production sequence number ; Belonging to , span ; Beam type group Template stage number Storage area Stacked layers Construction sequence ; Automatically generate component-level production and stacking plans to drive prefabrication production and yard operations.

4. A system for implementing the production scheduling method for large-volume heavy components of prefabricated bridges as described in claim 1, characterized in that, include: The data modeling module collects and stores basic information including span number, span length, construction sequence, number of beam segments, and storage area, and processes it into a standardized data model that can be used for calculation. The size aggregation and grouping module clusters components based on span length to generate a set of beam-type groups. The template stage decision module determines the sequence of template production stages for beam groups based on the construction sequence and project requirements. The storage area allocation module allocates storage areas to each beam group, enabling centralized stacking of beams of the same size. The stacking layer decision module calculates the target stacking layer based on the construction sequence within each beam group; The reverse production scheduling module generates a reverse production sequence within the group based on the target stacking target layer, and forms a production sequence function; The plan generation and release module generates production and stacking plans, driving prefabrication production and yard operations.

5. A computer-readable storage medium, characterized in that, It stores a computer program that, when run on a processor, executes the steps of the prefabricated bridge large-volume heavy component scheduling method as described in claim 1.

Images