Logistics Simulator Device, Operating Plan Creation Method, Program, and Operating Method of Steelworks

Abstract

The logistics simulator device includes an input information acquisition module (301), a controller module (309) that executes simulation, a route module (310) that searches for a transportable route, and a simulation result output module (311) that outputs the inventory trend and job performance acquired for each discrete time. As an option with on-off control prepared, it includes an incoming goods width module (302), an incoming goods lot inventory management module (303), a processing material inventory yard module (304), an in-yard inventory management module for the processing material inventory yard (305), a processing equipment inventory yard module (306), a processing equipment tank-type inventory yard module (307), and a processing equipment module (308).

Description

Technical Field

[0001] The present disclosure relates to a logistics simulator device, an operation plan creation method, a program, and an operation method for a steelworks.

Background Art

[0002] In conveyance operations such as for workpieces, technologies have been developed to improve efficiency by inputting operation plans, equipment capabilities, etc., and reflecting the results of simulations in operations.

[0003] For example, Patent Document 1 discloses a simulation program generation device that reduces the burden on designers when creating a simulation program for simulating the operation of each device, the movement of workpieces, and process phenomena in a manufacturing plant. Further, Patent Document 2 describes that the logistics of raw materials sent to the next process can be reproduced and visualized by a logistics simulator device, inventory trends, etc. can be displayed, and the plan can be improved and operations can be improved by determining the feasibility of operations.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] Here, the method of Patent Document 1 targets the simulation of a processing process with specific physical phenomena, and lacks the logistics perspective of considering the conveyance and movement of workpieces between processes. The method of Patent Document 2 targets the logistics of workpieces, but when dealing with various layouts and preconditions, modifications are required for each.

[0006] An object of the present disclosure made to solve the above problems is to provide a logistics simulator device, an operation plan creation method, a program, and an operation method of a steelworks capable of realizing efficiency improvement that can cope with various layouts and preconditions.

Means for Solving the Problems

[0007] (1) A logistics simulator device according to an embodiment of the present disclosure is a logistics simulator device that simulates the logistics of transporting materials to the next process, an input information acquisition module that acquires a facility list, a receiving plan, inventory information, a material processing plan, facility capabilities, the start date and time and end date and time of the simulation, and the unit time; a controller module that executes a simulation according to the start date and time and end date and time of the simulation and the unit time; a route module that connects each of the facility elements in the simulation based on the facility list and the facility capabilities and searches for a transportable route; a simulation result output module that outputs the inventory trend and job performance acquired for each discrete time, and includes As an option with on-off control, it includes a receiving interval module, a receiving lot inventory management module, a processed material inventory yard module, an in-yard inventory management module for the processed material inventory yard, a processed equipment inventory yard module, a processed equipment tank-type inventory yard module, and a processing equipment module. The receiving interval module generates one or more receiving intervals and receiving lots of processed materials according to the facility list and the receiving plan. The receiving lot inventory management module generates receiving jobs for one or more types of processed materials to the processed material inventory yard. The processed material inventory yard module generates one or more of the processed material inventory yards according to the facility list. The in-yard inventory management module for the processed material inventory yard generates one or more processed material inventory yard tanks for each brand for each of the processed material inventory yards based on the inventory information, and increases or decreases the inventory of the processed material inventory yard tanks. The processing equipment storage site module generates two or more processing equipment storage sites based on the equipment list, and increases or decreases the inventory of the processing equipment storage site based on the material processing plan. The processing equipment tank-type inventory site module generates one or more processing equipment tank-type warehouses that are aggregates of a plurality of tanks based on the equipment list, and consumes or increases the inventory of the processing equipment tank-type warehouse. The processing equipment module generates processing equipment based on the equipment list, and processes materials with the processing equipment in simulation according to the material processing plan.

[0008] (2) As one embodiment of the present disclosure, in (1), The on-off control is set based on the input data acquired by the input information acquisition module, enabling automatic setting of the equipment elements.

[0009] (3) As one embodiment of the present disclosure, in (1) or (2), When the incoming lot inventory management module is not given the incoming plan, it generates incoming lots based on predefined rules.

[0010] (4) As one embodiment of the present disclosure, in any one of (1) to (3), The two or more processing equipment storage sites are a set of beds. When the other bed is removed, cutting is performed from the stacked beds, and stacking starts with the empty bed.

[0011] (5) As one embodiment of the present disclosure, in any one of (1) to (4), When the inventory in the processing material storage site tank becomes full or insufficient during job execution, the processing material storage site internal inventory management module interrupts the job and selects another processing material storage site tank according to predefined rules to resume the job.

[0012] (6) As one embodiment of the present disclosure, in any one of (1) to (5), The input information acquisition module acquires a facility shutdown plan, Based on the facility shutdown plan, the controller module stops the corresponding facility when the simulator discrete time reaches the facility shutdown time.

[0013] (7) As one embodiment of the present disclosure, in (3), The incoming lot inventory management module selects a receiving location according to a predetermined rule.

[0014] (8) As one embodiment of the present disclosure, in any one of (1) to (7), The granularity of the stock symbol classification is set based on the input data acquired by the input information acquisition module.

[0015] (9) As one embodiment of the present disclosure, in any one of (1) to (8), The in-stock management module for the processing material storage yard treats the processing material storage yard as having a pseudo-tank for each stock symbol, cuts out the inventory according to the dispensing job sent from the controller module, and replenishes and manages the inventory according to the receiving job.

[0016] (10) As one embodiment of the present disclosure, in any one of (1) to (9), If the controller module can execute the waiting job simultaneously by stopping the running job and switching it to another route, the controller module executes the process of switching the running job to the other route.

[0017] (11) The operation plan creation method according to one embodiment of the present disclosure includes obtaining a simulation result from any one of the logistics simulator devices of (1) to (10), and when it is determined from the simulation result that the simulation has ended abnormally, causing the logistics simulator device to obtain an operation plan corrected based on the simulation result and execute the simulation again.

[0018] (12) A program according to an embodiment of the present disclosure is a program that causes a computer to function as a logistics simulator device that simulates the logistics of transporting materials to the next process, and causes the computer to an input information acquisition module that acquires a facility list, a receiving plan, inventory information, a material processing plan, facility capabilities, a start date and time and an end date and time of the simulation, and a unit time; a controller module that executes a simulation according to the start date and time and the end date and time of the simulation and the unit time; a route module that connects each of the facility elements in the simulation based on the facility list and the facility capabilities, and searches for a transportable route; a simulation result output module that outputs an inventory trend and job results acquired for each discrete time; As an option with on-off control, function as a receiving interval module, a receiving lot inventory management module, a processed material inventory yard module, an in-yard inventory management module for the processed material inventory yard, a processed equipment inventory yard module, a processed equipment tank-type inventory yard module, and a processing equipment module, the receiving interval module generates one or more receiving intervals and receiving lots of processed materials according to the facility list and the receiving plan; the receiving lot inventory management module generates a receiving job for the processed material inventory yard for one or more types of processed materials; the processed material inventory yard module generates one or more of the processed material inventory yards according to the facility list; the in-yard inventory management module for the processed material inventory yard generates one or more processed material inventory yard tanks for each brand for one of the processed material inventory yards based on the inventory information, and increases or decreases the inventory of the processed material inventory yard tanks; the processed equipment inventory yard module generates two or more processed equipment inventory yards based on the facility list, and increases or decreases the inventory of the processed equipment inventory yards based on the material processing plan; the processed equipment tank-type inventory yard module generates one or more processed equipment tank-type inventory yards based on the facility list, and increases or decreases the inventory of the processed equipment tank-type inventory yards based on the material processing plan; The processing equipment tank type inventory storage module generates one or more processing equipment tank type warehouses that are aggregates of a plurality of tanks based on the equipment list, consumes or increases the inventory of the processing equipment tank type warehouses, The processing equipment module generates processing equipment based on the equipment list, and processes materials with the processing equipment in simulation according to the material processing plan.

[0019] (13) The operation method of a steelworks according to an embodiment of the present disclosure is The next process is a process of blending raw materials charged into the blast furnace, (11) In the operation plan making method, obtaining the optimized operation plan that is the operation plan when it is determined from the simulation result that the simulation has ended normally, and transporting the raw materials based on the optimized operation plan.

Advantages of the Invention

[0020] According to the present disclosure, it is possible to provide a logistics simulator device, an operation plan making method, a program, and an operation method of a steelworks capable of realizing efficiency that can cope with various layouts and preconditions.

Brief Description of the Drawings

[0021]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0022] Hereinafter, a logistics simulator device, an operation plan creation method, a program, and an operation method of a steelworks according to an embodiment of the present disclosure will be described with reference to the drawings.

[0023] The logistics simulator device according to this embodiment simulates the logistics of transporting materials (processed materials) to the next process. Although the logistics targeted by the logistics simulator device is not limited, in this embodiment, an example of the logistics of iron ore and raw coal in the raw material yard 102 (see FIG. 1), which is part of the operation of a steelworks, will be described. In the steel industry, iron ore, which is iron oxide, is charged into the blast furnace 107 (see FIG. 1) together with coke and reduced, and then refined to produce steel. In order to promote a smooth reduction reaction and avoid troubles in the blast furnace 107, the sintered ore and coke to be produced need to have a certain strength and quality, and it is necessary to blend a number of different iron ores and raw coals. FIG. 1 shows the logistics flow of iron ore and raw coal.

[0024] Iron ore and raw coal are received from the berth 101 into the raw material yard 102 and stored in piles for each brand. The raw material yard 102 is an example of an inventory yard. The received iron ore and raw coal are discharged to the bedding yard 103 and the blending tank 104, which are the next processes, and blended to have a predetermined quality. The blending tank 104 includes a ore storage tank provided in the sintering machine 105 for storing iron ore, a coal storage tank provided in the coke oven 106 for storing raw coal, and a blast furnace tank provided in the blast furnace 107. In the bedding yard 103, blending is performed by stacking brands in piles called beds in pairs. When one of the beds is being stacked, the other is being cut out towards the sintering machine 105 or the coke oven 106. Before the cutting out is completed, the bed being stacked is completed and switched, thereby realizing continuous cutting out to the sintering machine 105 or the coke oven 106. The blending tank 104 has a capacity of 140 m 3It is equipped with a number of silo-shaped tanks capable of storing iron ore or raw coal to a certain extent. A variety of brands can be replenished in the multiple tanks and can be blended on the belt conveyor on the output side while being cut out. The sintering machine 105 hardens the powdered iron ore after blending to produce sintered ore. The coke oven 106 manufactures coke from raw coal. The blast furnace 107 reduces the lump ore sent from the bedding yard 103, the sintered ore sent from the sintering machine 105, the processed ore and auxiliary raw materials sent from the raw material yard 102 with the coke sent from the coke oven 106 to produce pig iron. In the logistics operation of iron ore and raw coal, since it is of the highest priority not to stop the production of the downstream sintering machine 105, coke oven 106 and blast furnace 107, the receiving operation from the berth 101 to the raw material yard 102 is carried out at any time during the discharging operation from the raw material yard 102 to the next process. The logistics simulator device according to the present embodiment targets the logistics of iron ore and raw coal from being received from the berth 101 into the raw material yard 102 and discharged to the bedding yard 103 and the blending tank 104 until reaching the blast furnace 107 via the sintering machine 105 or the coke oven 106. Here, in the present embodiment, the logistics line of iron ore and raw coal in which the bedding yard 103 and the blending tank 104 are mixed is targeted, but it may be a logistics line including only the bedding yard 103 or the blending tank 104.

[0025] FIG. 2 is a diagram showing a schematic configuration of a logistics simulator device including its relationship with a higher-level system. The logistics simulator device includes an initial setting unit 201, a simulation execution unit 202, and a simulation end unit 203. The higher-level system includes a data output unit 204 for each process, a process computer 205, and a business computer 206. The initial setting unit 201 of the logistics simulator device prepares data necessary for simulation, initial parameters, etc. The simulation execution unit 202 executes the simulation. The simulation end unit 203 transmits the simulation results to the process computer 205. The data necessary for simulation is acquired from the business computer 206 and the data output unit 204 for each process, and sent to the initial setting unit 201 via the process computer 205. Here, the data necessary for simulation may be editable by the user of the logistics simulator device.

[0026] FIG. 3 is a diagram showing a configuration example of the simulation execution unit 202 of the logistics simulator device. Also, the arrows and lines in FIG. 3 indicate the flow and transmission / reception of data. The simulation execution unit 202 includes an input information acquisition module 301, a controller module 309, a route module 310, and a simulation result output module 311. Further, the simulation execution unit 202 may include at least one of a receiving bay module 302, a receiving lot inventory management module 303, a processing material inventory yard module 304, an in-yard inventory management module 305 for the processing material inventory yard, a processing equipment inventory yard module 306, a processing equipment tank-type inventory yard module 307, and a processing equipment module 308. That is, the simulation execution unit 202 includes, as an option with on-off control described later, the receiving bay module 302, the receiving lot inventory management module 303, the processing material inventory yard module 304, the in-yard inventory management module 305 for the processing material inventory yard, the processing equipment inventory yard module 306, the processing equipment tank-type inventory yard module 307, and the processing equipment module 308. Here, a module is a component having the function of a device or equipment that the logistics simulator device simulates, configured to be easily added or replaced. In the present embodiment, the module is a program module, and the input variables, output variables, and processing of the functions of the device or equipment to be simulated are defined.

[0027] The input information acquisition module 301 acquires a facility list necessary for the simulation, a receiving plan, inventory information, a material processing plan, facility capabilities, the start date and time and end date and time of the simulation, and the unit time. The unit time is the step time in the simulation. The simulation execution unit 202 starts the simulation at the start date and time of the simulation. Further, the input information acquisition module 301 may acquire a facility stop plan.

[0028] The incoming dock module 302 generates one or more incoming docks (i.e., berths 101) and incoming lots (i.e., raw material ships) of the processing materials according to the facility list and the incoming plan acquired by the input information acquisition module 301. When there is space in the berth 101, the incoming dock module 302 allows a waiting raw material ship to enter and occupy the berth, and releases the occupied berth 101 when the processing materials in the raw material ship are exhausted.

[0029] The incoming lot inventory management module 303 generates receiving jobs for one or more types of processing materials loaded on the raw material ships generated by the incoming dock module 302 to the raw material yard 102. The incoming lot inventory management module 303 outputs the generated receiving jobs to the controller module 309. Also, the incoming lot inventory management module 303 manages the loading capacity of the raw material ship for the processing materials during which the receiving jobs are being carried out. Here, a job means an operation in the operation, and it can also be paraphrased as a task. A job includes a receiving job, a dispensing job, and an emergency job.

[0030] The processing material inventory yard module 304 generates one or more processing material inventory yards (i.e., raw material yards 102) according to the facility list acquired by the input information acquisition module 301. Also, the processing material inventory yard module 304 sets the initial inventory and the maximum inventory quantity of the processing material inventory yard based on the inventory information acquired by the input information acquisition module 301.

[0031] The in-yard inventory management module 305 of the processing material inventory yard pseudo-generates one or more processing material inventory yard bins for each brand for each of the raw material yards 102 based on the inventory information acquired by the input information acquisition module 301. That is, the processing material inventory yard bin is a pseudo-bin of the processing material inventory yard and is generated for each brand. Also, the in-yard inventory management module 305 of the processing material inventory yard receives the receiving jobs to the raw material yard 102 and the dispensing jobs to the next process sent from the controller module 309, and manages the inventory of the processing material inventory yard bins by increasing or decreasing it.

[0032] The processing equipment inventory yard module 306 generates two or more processing equipment inventory yards (i.e., bedding yards 103) based on the equipment list obtained by the input information acquisition module 301. Further, the processing equipment inventory yard module 306 sets the initial inventory of two or more bedding yards 103 according to the inventory information obtained by the input information acquisition module 301. At least one of the two or more bedding yards 103 is in the process of stacking. The processing equipment inventory yard module 306 generates a dispensing job according to the material processing plan obtained by the input information acquisition module 301 and outputs the generated dispensing job to the controller module 309. During the execution of the dispensing job to the bedding yard 103, the processing equipment inventory yard module 306 increases the inventory of the bedding yard 103. Also, at least one of the other bedding yards 103 is in the process of cutting. The processing equipment inventory yard module 306 increases or decreases the inventory of the bedding yard 103 according to the material processing plan obtained by the input information acquisition module 301 or the material processing plan of the processing equipment generated by the processing equipment module 308.

[0033] The processing equipment tank type inventory placement module 307 generates one or more processing equipment tank type warehouses (i.e., compounding tanks 104), which are aggregates of a plurality of tanks, based on the equipment list obtained by the input information acquisition module 301. The processing equipment tank type inventory placement module 307 sets the maximum inventory and initial inventory of all compounding tanks 104 according to the inventory information obtained by the input information acquisition module 301. Also, the processing equipment tank type inventory placement module 307 consumes the inventory of the compounding tank 104 according to the material processing plan obtained by the input information acquisition module 301 or the material processing plan of the processing equipment generated by the processing equipment module 308. Here, when the inventory of the compounding tank 104 falls below a predetermined threshold, the processing equipment tank type inventory placement module 307 generates an appropriate amount of payout job from the raw material yard 102 to the compounding tank 104. The processing equipment tank type inventory placement module 307 outputs the generated payout job to the controller module 309. During the execution of the payout job to the compounding tank 104, the processing equipment tank type inventory placement module 307 increases the inventory of the compounding tank 104.

[0034] The processing equipment module 308 generates processing equipment (i.e., at least one or more of the sintering machine 105, coke oven 106, blast furnace 107) based on the equipment list obtained by the input information acquisition module 301. The processing equipment module 308 processes materials with the processing equipment in the simulation according to the material processing plan obtained by the input information acquisition module 301 to generate sintered ore, coke or pig iron. The attributes of the processing equipment are specified in the equipment list.

[0035] The controller module 309 executes the simulation according to the start date and time, end date and time, and unit time of the simulation acquired by the input information acquisition module 301. Specifically, the controller module 309 acquires the receiving job generated by the incoming lot inventory management module 303 and the dispensing jobs generated by the processing equipment inventory yard module 306 and the processing equipment tank type inventory yard module 307. The controller module 309 manages the receiving job and the dispensing job for each discrete time when they occur, and searches for a route on which each job can be executed from the connection relationship generated by the route module 310. That is, the controller module 309 searches for a route along which materials can be transported using the route module 310. The controller module 309 selects a route based on a preset logic from the plurality of searched route candidates, and executes the simulation using the selected route. Here, the route selection logic may be, for example, random selection according to a random number, a method of using the oldest pile among the raw material yards 102, or a method of using the processing material inventory yard tank with less inventory.

[0036] The route module 310 connects each of the equipment elements in the simulation based on the equipment list and equipment capabilities acquired by the input information acquisition module 301, searches for a transportable route, and further sets the moving capabilities of each of the equipment elements. The equipment elements include the birthplace 101, the raw material yard 102, the bedding yard 103, the blending tank 104, the sintering machine 105, the coke oven 106, the blast furnace 107, the belt conveyor, the transfer machine, and the heavy machine dump.

[0037] The simulation result output module 311 outputs the inventory trend and job performance acquired for each discrete time. Here, the discrete time is determined based on the start date and time, end date and time, and unit time of the simulation acquired by the input information acquisition module 301. The job performance means a job that can be completed by the deadline date and time.

[0038] Here, the simulation end unit 203 checks whether the predefined simulation end condition is satisfied. When the end condition is satisfied, the simulation in the updated acceptance plan and disbursement plan is terminated. If the simulation end unit 203 does not satisfy the end condition, it advances the unit time by 1 and returns to the process of the simulation execution unit 202 to continue the simulation.

[0039] In this embodiment, the logistics simulator device is configured by a computer, and the processor of the computer functions as each module by a program. A part of the modules constituting the logistics simulator device is an option in which use or non-use is selected according to the facility list included in the input data acquired by the input information acquisition module 301. With such a configuration, it is possible to cope with various layouts and preconditions. Specifically, the incoming width module 302, the incoming lot inventory management module 303, the processing material inventory yard module 304, the in-yard inventory management module 305 for the processing material inventory yard, the processing equipment inventory yard module 306, the processing equipment tank-type inventory yard module 307, and the processing equipment module 308 are options. For each of these modules, on / off control is provided. For example, if "1" is set and it is on, it is used, and if "0" is set and it is off, it is not used (see Table 9). The on / off control is set based on the input data acquired by the input information acquisition module 301, enabling automatic setting of facility elements. For example, when the incoming width module 302, the incoming lot inventory management module 303, the processing material inventory yard module 304, and the in-yard inventory management module 305 for the processing material inventory yard are off, the inventory of the raw material yard 102 is treated as infinite, and simulation concentrated on the payout operation after the raw material yard 102 becomes possible. Also, for example, when the coke oven 106 is turned off in the processing equipment module 308 and only the sintering machine 105 and the blast furnace 107 that are turned on are added to the logistics flow, simulation focused on the logistics of iron ore becomes possible. Also, for example, simply specifying the presence or absence of the bedding yard 103, the presence or absence of the blending tank 104, etc. in the facility list enables setting according to the configuration of the target steelworks. Also, the on / off control of the module has the effect of eliminating the labor of software modification (coding) when the facility list is changed.

[0040] Hereinafter, the details of the processing performed by the logistics simulator device will be described using the logistics flow of iron ore and raw coal in FIG. 1 as an example. The incoming raw material ship is given data as shown in Table 1.

[0041]

Table 1

[0042] The row direction is defined as the receiving job, and when the receiving job of the same ship reaches the arrival date and time, a trigger (e.g., "1") that can be executed is set by the controller module 309. Also, when the incoming raw material ship is not given as data (i.e., the incoming plan) as shown in Table 1, the incoming lot is generated by the in-stock management module 305 of the processing material in-stock yard according to a predefined rule. The predefined rule may be, for example, when the inventory of a certain brand falls below the threshold, randomly generate a raw material ship loaded with that brand. For the receiving location, it is selected by the in-stock management module 303 of the incoming lot according to a predefined rule. For example, when there are storage locations for the received brands in multiple raw material yards 102, it may be received by dividing according to the ratio of the maximum capacity of the raw material yard 102. Also, the receiving location may be randomly selected from among the candidates of the locations where receiving is possible. It is preferable to determine the handling quantity of one lot of the receiving job according to the size of the hatch of the raw material ship. Also, when the inventory in the processing material in-stock yard tank becomes full or insufficient during the execution of the job, the in-stock management module 305 of the processing material in-stock yard may interrupt the job and select another processing material in-stock yard tank according to a predefined rule to resume the job.

[0043] The processing equipment tank type in-stock yard module 307 is defined by the input data regarding the equipment as shown in Table 2.

[0044]

Table 2

[0045] The blending tanks 104 associated with multiple facilities can be set with input data. For example, it is not necessary for the user to code the positional relationship of the facilities. The blending tanks 104 are connected to multiple downstream facilities according to the facility layout and facility information, and the inventory is cut out according to the product of their processing efficiency and the brand blending ratio. The processing equipment tank-type inventory yard module 307 may adopt a logic that generates a payout job to the tank and sends it to the controller module 309 when the inventory is cut out and falls below the replenishment threshold set with the input data.

[0046] In the bedding yard 103, multiple brands are stacked in layers and blended. Here, if the generation of the payout job to the bedding yard 103 is specified with input data for multiple lots, detailed specification is required and the input data becomes complicated. If the detailed specification is omitted, there is a possibility that multiple brands will not be stacked as expected by the user. The processing equipment inventory yard module 306 defines a pseudo-tank according to the input data in Table 3 in the generation of the bedding yard 103.

[0047]

Table 3

[0048] The processing equipment inventory yard module 306 cuts out inventory according to the product of the processing efficiency of the processing equipment designated as the destination and the blending ratio of the brands, similar to the processing equipment tank-type inventory yard module 307. When the processing equipment inventory yard module 306 falls below the replenishment threshold, it can use the logic to generate a payout job to a pseudo tank and can simulate the state where different brands are loaded in order as in the actual operation. Here, there is no limit to the setting of the maximum capacity of the pseudo tank, but since the bedding yard 103 is in a stacking blend, it is more than the payout to the actual blending tank 104, so it may be set more than the actual blending tank 104. Also, the initial inventory of the pseudo tank may be set to 0. By virtually treating the configuration of the bedding yard 103 as being replenished with various brands in a large number of tanks, it is possible to handle it in the same way as the blending tank 104. That is, the bedding yard 103 and the blending tank 104 can be treated as common equipment elements in the simulation. As a result, the processing equipment inventory yard module 306 can execute the management of inventory increase and decrease and the creation of a payout plan more efficiently.

[0049] Also, the bedding yard 103 is composed of bed sets. While one is being stacked and blended, the other is being cut out to the processing equipment in the next process. When the other bed is removed, cutting is performed from the stacked bed, and stacking starts with the empty bed. It is possible to change the blending ratio and the planned stacking amount every time such a bed is switched. For example, like the data indicated by the same bed number in Table 4, the stacking amount, brand, blending ratio, etc. may be changed. Here, if the next bed is not completed by the time the bed being cut out is removed, the simulation may be terminated as an abnormal end.

[0050]

Table 4

[0051] The controller module 309 arranges the received jobs and payout jobs sent from each module in the order of execution priority as shown in Table 5. The controller module 309 may create a list in which the jobs with high urgency are listed at the top as interrupts. Also, the executed jobs are deleted from the list.

[0052]

Table 5

[0053] The execution priority in Table 5 indicates the priority of the jobs with the highest priority being "1". The issue date and time indicates the date and time when the job was generated, and for received jobs, it is generated when the ship arrives at the port. In the list, the jobs are arranged in the order of execution priority. The execution priority is set regardless of the order of the issue date and time. That is, even if the issue date and time is earlier, the execution priority is not necessarily earlier. The source and destination of the job in the job are indicated in the From and To columns respectively. The execution item indicates that for the job indicated in the row, "Done" means completed, "On progress" means in progress, and "Wait" means waiting. Other descriptions of the execution item will be described later. The emergency item indicates that "1" is an emergency job. Here, since the workload is given by the input data for received jobs, specific numerical values are described. On the other hand, for payout jobs, the workload until the payout destination (for example, blending tank 104) is full will be entered. However, since cutting can be performed even during replenishment at the payout destination, the workload is not specified and no specific numerical value is described.

[0054] The controller module 309 executes simultaneously executable jobs in parallel. The controller module 309 executes emergency jobs with the highest priority and gives priority to payout jobs over acceptance jobs. Also, the controller module 309 waits for jobs that cannot be executed because they conflict with jobs that are already running. In the example of Table 5, the seventh job from the top has been interrupted by an emergency job (the fourth job from the top) and stopped, and the "Implementation" column indicates "Interrupted". Also, in the example of Table 5, the third job from the top has been deleted from the list before execution because an emergency job that pays out the same brand to the same location has occurred, and the "Implementation" column indicates "Delete". Here, if the controller module 309 can execute the waiting jobs simultaneously by stopping the running job and switching it to another route, the controller module 309 may execute the process of switching the running job to another route to achieve efficient operation.

[0055] Here, it is possible to set the granularity of brand classification in the input data. For example, specific brands such as Brand A and Brand B can be specified for the blending of raw materials. Also, for example, it is possible to set the blending at a higher brand classification such as South American Mine X (to which Brand A and Brand B apply) and Australian Mine Y (to which Brand a and Brand b apply). In the logistics operations of iron ore and raw coal, the brand name of the smallest classification unit is often changed. Therefore, although data editing was complicated in conventional simulations, according to the logistics simulator device of the present disclosure, it is possible to flexibly respond by setting the input data.

[0056] The initial inventory of the processing inventory yard is given for each yard and each brand as shown in Table 6. The in-stock management module 305 in the processing material inventory yard treats that there are pseudo-tanks for each brand in the raw material yard 102, cuts out the inventory according to the payout job sent from the controller module 309, and replenishes and manages the inventory according to the acceptance job.

[0057]

Table 6

[0058] When the equipment shutdown plan is given as input data as shown in Table 7, the controller module 309 stops the corresponding equipment based on the equipment shutdown plan when the simulator discrete time reaches the equipment shutdown time. When equipment related to conveyance or movement, such as a belt conveyor or a stack reclaimer (an example of a transfer machine), stops, the route module 310 may search for a conveyable route excluding the route passing through the stopped equipment. It becomes possible to search for a conveyable route excluding the route including the equipment element scheduled to be stopped due to maintenance or the like. When there is a brand that cannot be dispensed or received without using the equipment to be stopped, the controller module 309 may end the simulation as an abnormal end.

[0059] [Table 7]

[0060] In Table 7, "BC201" is one belt conveyor. "SR2" is one stack reclaimer. "UL1" is one ship.

[0061] Figure 4 is a schematic diagram of the layout of the logistics simulation target of the embodiment. In addition to the input data exemplified in Tables 1 to 7 above, the equipment list exemplified in Tables 8 to 10, the on / off control of the module by the master included in the input data, the equipment capacity, etc. are used.

[0062] [Table 8]

[0063] [Table 9]

[0064] [Table 10]

[0065] In Table 8, "UL1" is one ship. "BC101" is one belt conveyor. "SR1" is one stack reclaimer. As shown above in Table 9, for the on-off items, if "1" is set, it is used; if "0" is set, it is not used. For example, if "Coke Oven" is "0", in the simulation, coke oven 106 is set to "none". In this way, only by editing the input data, the birth 101, the number of handling equipment, the number of yards, the number of beds, the base numbers of sintering machine 105 and blast furnace 107, the presence or absence of coke oven 106, the correspondence between the beds and sintering machine 105 and blast furnace 107, the operating status and production capacity of each facility, etc. are set. Also, according to FIG. 4, it is possible to include the competition relationship of the equipment in the input data.

[0066] Referring to FIG. 2 again, the simulation end part 203 ends the simulation when it reaches a preset end condition. The end condition may include, for example, when the end date and time of the simulation obtained by the input information acquisition module 301 is reached, or when the inventory level is insufficient in the bedding yard 103 or the blending tank 104. When the simulation ends, the simulation result is output. The simulation result may include a flag indicating normal end or abnormal end, the receiving job performance, the discharging job performance, etc. Here, normal end means that the simulation ends after transporting the materials without causing a shortage in the inventory level. On the other hand, abnormal end means that the simulation ends with abnormalities such as the occurrence of a shortage in the inventory level or the existence of discharging jobs that did not end at the end date and time. Also, as the simulation result, trend information may be output. The trend information may include, for example, the change in the inventory level of the bedding yard 103 and the change in the inventory level of the blending tank 104.

[0067] Until the simulation is completed, information such as inventory trend information may be output. For example, even if the simulation ends abnormally, in the upper-level system, the content of the alert can be confirmed while looking at information such as inventory trend information, and the input data such as the operation plan and inventory location plan can be corrected. Here, the operation plan includes the material processing plan acquired by the input information acquisition module 301. The material processing plan includes, in the present embodiment, the production volume and blending plan of sintered ore, coke, or pig iron produced by the blast furnace 107. The material processing plan determines the iron source supply amount and its breakdown for realizing the steel product manufacturing plan in the steelworks. The operation plan may consider up to the steel product manufacturing plan. Further, the operation plan may include the incoming plan. It is expected that a good result will be obtained in the re-simulation using the corrected input data. Further, the logistics simulator device can also transmit the operation plan in the case where a good result is obtained (when the simulation ends normally) to the upper-level system through the process computer 205 together with the related simulation data.

[0068] An operation plan creation method may be executed, including obtaining simulation results from a logistics simulator device. When it is determined from the simulation results that the simulation ended abnormally, the operation plan creation method may include causing the logistics simulator device to obtain an operation plan modified based on the simulation results and execute the simulation again. For example, the operation plan creation method may be performed in a higher-level system. Further, in the operation plan creation method, an optimized operation plan, which is an operation plan when it is determined from the simulation results that the simulation ended normally, may be obtained, and raw materials may be conveyed based on the optimized operation plan. An operation method of a steelworks may be executed, including controlling a control device that controls the conveyance of each raw material to instruct and control the conveyance amount and the like via a process computer 205. Here, the raw materials to be conveyed are raw materials that are blended in the next process and charged into the blast furnace 107, and include the iron ore and raw coal of the present embodiment, but are not limited to the iron ore and raw coal. For example, the raw materials to be blended include auxiliary raw materials, and the concept of the present embodiment can also be applied to such auxiliary raw materials.

[0069] As described above, the logistics simulator device, operation plan creation method, and program according to the present embodiment can represent various simulations only by combining modules and editing input data, and thus can cope with a wide variety of layouts and preconditions. Further, compared with the prior art, the development period of the logistics simulator device or program can be significantly shortened. Further, by following the operation plan when such a simulation ends normally, an efficient operation method of a steelworks becomes possible. Further, by appropriately managing the inventory of each raw material brand, it is possible to always supply raw materials of a certain quality, which can contribute to the production of high-quality steel materials.

[0070] Although the embodiments according to the present disclosure have been described based on the drawings and examples, it should be noted that those skilled in the art can easily make various modifications or corrections based on the present disclosure. Therefore, it should be noted that these modifications or corrections are included in the scope of the present disclosure. For example, functions included in each component or each step can be rearranged so as not to be logically contradictory, and a plurality of components or steps can be combined into one or divided. The embodiments according to the present disclosure can also be realized as a storage medium (for example, a non-transitory computer-readable recording medium) that records a program executed by a processor included in the device. It should be understood that these are also included in the scope of the present disclosure.

Explanation of Signs

[0071] 101 Birth 102 Raw Material Yard 103 Bedding Yard 104 Blending Tank 105 Sintering Machine 106 Coke Oven 107 Blast Furnace 201 Initial Setting Unit 202 Simulation Execution Unit 203 Simulation End Unit 204 Data Output Unit for Each Process 205 Process Computer 206 Business Computer 301 Input Information Acquisition Module 302 Incoming Width Module 303 Incoming Lot Inventory Management Module 304 Processed Material Stockyard Module 305 In-Store Inventory Management Module for Processed Material Stockyard 306 Processed Equipment Stockyard Module 307 Processed Equipment Tank-Type Stockyard Module 308 Processed Equipment Module 309 Controller Module 310 Route Module 311 Simulation Result Output Module

Claims

1. A logistics simulator device that simulates logistics for transporting materials to a next process, an input information acquisition module for acquiring equipment list, arrival schedule, inventory information, material processing schedule, equipment capacity, start date and time, end date and time, and unit time of a simulation; a controller module for executing a simulation in accordance with the start date and end date and time of the simulation and the unit time; a route module that connects each of the facility elements in the simulation based on the facility list and the facility capacity, and searches for a transportable route; a simulation result output module that outputs inventory trends and job results acquired at each discrete time, As options with on / off control, an incoming frontage module, an incoming lot inventory management module, a processing material inventory storage module, an inventory management module in the processing material inventory storage module, a processing equipment inventory storage module, a processing equipment tank-type inventory storage module, and a processing equipment module are provided. The receiving window module generates one or more receiving windows and receiving lots of processing materials according to the equipment list and the receiving plan; The incoming lot inventory management module generates a receiving job for one or more types of processing materials to a processing material inventory yard; The processing material stockpile module generates one or more processing material stockpile locations according to the equipment list; The processing material stock storage area inventory management module generates one or more processing material stock storage area tanks for each brand in each processing material stock storage area based on the inventory information, and increases or decreases the inventory of the processing material stock storage area tanks; The processing equipment stock yard module generates two or more processing equipment stock yard locations based on the equipment list, and increases or decreases inventory in the processing equipment stock yard locations based on the material processing plan; The processing equipment tank-type inventory storage module generates one or more processing equipment tank-type warehouses, which are collections of a plurality of tanks, based on the equipment list, and consumes or increases inventory in the processing equipment tank-type warehouses; The processing facility module generates processing facilities based on the facility list, and processes materials at the processing facilities in a simulation in accordance with the material processing plan, the logistics simulator device.

2. 2. The logistics simulator device according to claim 1, wherein the on / off control is set based on input data acquired by the input information acquisition module, thereby making it possible to automatically set the facility elements.

3. 3. The logistics simulator device according to claim 1, wherein said receiving lot inventory management module generates a receiving lot based on a predetermined rule when said receiving plan is not given.

4. 3. A logistics simulator device according to claim 1 or 2, wherein the two or more processing equipment inventory areas are a set of beds, and when the other bed is cleared, unloading is performed from the loaded bed and loading begins in the vacant bed.

5. 3. The logistics simulator device according to claim 1, wherein the processing material storage tank inventory management module interrupts the job when the processing material storage tank becomes full or insufficient during execution of a job, and selects another processing material storage tank according to a predetermined rule to resume the job.

6. The input information acquisition module acquires an equipment shutdown plan; 3. The logistics simulator device according to claim 1, wherein the controller module stops a piece of equipment when a simulator discrete time reaches a time for stopping the equipment based on the equipment stop plan.

7. 4. The logistics simulator device according to claim 3, wherein said incoming lot inventory management module selects a receiving location in accordance with a predetermined rule.

8. 3. The logistics simulator device according to claim 1, wherein the granularity of the brand classification is set based on the input data acquired by the input information acquisition module.

9. 3. A logistics simulator device according to claim 1, wherein the processing material storage area inventory management module treats the processing material storage area as equipped with virtual tanks for each brand, and manages by extracting inventory according to a take-out job sent from the controller module and replenishing inventory according to a receiving job.

10. 3. The logistics simulator device according to claim 1, wherein the controller module executes a process of reassigning an active job to another route when the active job can be stopped and reassigned to the other route so that the waiting job can be executed simultaneously.

11. acquiring a simulation result from the logistics simulator device according to claim 1 or 2; when it is determined from the simulation results that the simulation has ended abnormally, causing the logistics simulator device to obtain an operation plan corrected based on the simulation results and to execute the simulation again.

12. A program for causing a computer to function as a logistics simulator device that simulates logistics for transporting materials to a next process, the program comprising: an input information acquisition module for acquiring equipment list, arrival schedule, inventory information, material processing schedule, equipment capacity, start date and time, end date and time, and unit time of a simulation; a controller module for executing a simulation in accordance with the start date and end date and time of the simulation and the unit time; a route module that connects each of the facility elements in the simulation based on the facility list and the facility capacity, and searches for a transportable route; a simulation result output module that outputs inventory trends and job results obtained at each discrete time; As an option with on / off control, it can function as an incoming frontage module, incoming lot inventory management module, processing material inventory storage module, processing material inventory storage inventory management module, processing equipment inventory storage module, processing equipment tank-type inventory storage module, and processing equipment module. The receiving window module generates one or more receiving windows and receiving lots of processing materials according to the equipment list and the receiving plan; The incoming lot inventory management module generates a receiving job for one or more types of processing materials to a processing material inventory yard; The processing material stockpile module generates one or more processing material stockpile locations according to the equipment list; The processing material stock storage area inventory management module generates one or more processing material stock storage area tanks for each brand in each processing material stock storage area based on the inventory information, and increases or decreases the inventory of the processing material stock storage area tanks; The processing equipment stock yard module generates two or more processing equipment stock yard locations based on the equipment list, and increases or decreases inventory in the processing equipment stock yard locations based on the material processing plan; The processing equipment tank-type inventory storage module generates one or more processing equipment tank-type warehouses, which are collections of a plurality of tanks, based on the equipment list, and consumes or increases inventory in the processing equipment tank-type warehouses; The processing equipment module is a program that generates processing equipment based on the equipment list, and processes materials at the processing equipment in a simulation in accordance with the material processing plan.

13. The next step is a step of blending raw materials to be charged into a blast furnace, The method for creating an operation plan according to claim 11, further comprising the steps of: acquiring an optimized operation plan, which is the operation plan when it is determined from the simulation result that the simulation has been normally completed; and transporting the raw materials based on the optimized operation plan.

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