Physical distribution simulator device, method for creating operation plan, program, and method for operating iron mill

Abstract

This physical distribution simulator device comprises: an input information acquisition module (301); a controller module (309) for executing a simulation; a route module (310) for searching for a transportable route; and a simulation result output module (311) for outputting an inventory trend and a job result acquired for each discrete time. The physical distribution simulator device includes, as options for which on / off control is prepared, an arrival frontage module (302), an arrival lot inventory management module (303), a processing material storage module (304), a processing material storage inventory management module (305), a processing facility storage module (306), a processing facility tank-type storage module (307), and a processing facility module (308).

Description

Logistics simulator device, operation plan creation method, program, and steelworks operation method

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

[0002] In the transportation operations of processed materials, etc., technology is being developed to improve efficiency by inputting operation plans, equipment capacity, etc., conducting simulations, and reflecting the results in operations.

[0003] For example, Patent Document 1 discloses a simulation program generation device that reduces the burden on designers when creating simulation programs that simulate the operation of each device in a manufacturing plant, the movement of workpieces, and process phenomena. Patent Document 2 also describes how a logistics simulator device can be used to reproduce and visualize the logistics of sending raw materials to the next process, display inventory trends, and determine whether or not operations can be performed, thereby enabling refinement of plans and improvement of operations.

[0004] Japanese Patent No. 6468000 Japanese Patent Application Laid-Open No. 2023-118069

[0005] The method of Patent Document 1 is targeted at simulating a processing process that involves specific physical phenomena, and lacks a perspective of logistics that considers the transportation and movement of processing materials between processes. The method of Patent Document 2 is targeted at the logistics of processing materials, but when dealing with a wide variety of layouts and prerequisites, it needs to be modified to suit each of them.

[0006] The purpose of the present disclosure, which has been made to solve the above problems, is to provide a logistics simulator device that can accommodate a wide variety of layouts and prerequisites, an operation plan creation method, a program, and a steelworks operation method that can achieve efficiency.

[0007] (1) A logistics simulator device according to an embodiment of the present disclosure is a logistics simulator device that simulates logistics for transporting materials to a next process, comprising: an input information acquisition module that acquires an equipment list, an arrival plan, inventory information, a material processing plan, equipment capacity, a start date and time, an end date and time, and a unit time for the simulation; a controller module that executes the simulation according to the start date and time, an end date and time, and the unit time for the simulation; a route module that connects each of the equipment elements in the simulation based on the equipment list and the equipment capacity, and searches for a transportable route; and a simulation result output module that outputs inventory trends and job results acquired at each discrete time; and the following are options with on / off control: an arrival frontage module, an arrival lot inventory management module, a processed material inventory yard module, an inventory management module in the processed material inventory yard, a processing equipment inventory yard module, a processing equipment tank-type inventory yard module, and a processing equipment module; the arrival frontage module generates one or more arrival frontages and arrival lots for processed materials according to the equipment list and the arrival plan; the arrival lot inventory management module generates receiving jobs for one or more types of processed materials to the processed material inventory yard; The processing material inventory storage module generates one or more processing material inventory storage areas according to the equipment list; the processing material inventory storage area inventory management module generates one or more processing material inventory storage tanks for each brand of processing material for each processing material inventory storage area based on the inventory information, and increases or decreases the inventory in the processing material inventory storage tanks; the processing equipment inventory storage module generates two or more processing equipment inventory areas based on the equipment list, and increases or decreases the inventory in the processing equipment inventory storage areas 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 multiple tanks, based on the equipment list, and consumes or increases the inventory in the processing equipment tank-type warehouses; and the processing equipment module generates processing equipment based on the equipment list, and processes materials in the processing equipment in a 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 input data acquired by the input information acquisition module, making it possible to automatically set the equipment element.

[0009] (3) As an embodiment of the present disclosure, in (1) or (2), the incoming lot inventory management module generates an incoming lot based on a predetermined rule when the incoming plan is not given.

[0010] (4) As an embodiment of the present disclosure, in any of (1) to (3), the two or more processing equipment inventory areas are a set of beds, and when the other bed is cleared, the stacked bed is unloaded and stacking begins on the vacant bed.

[0011] (5) As an embodiment of the present disclosure, in any of (1) to (4), when the inventory in the processing material inventory storage tank becomes full or insufficient during execution of a job, the inventory management module in the processing material inventory storage tank suspends the job, selects another processing material inventory storage tank according to a predetermined rule, and resumes the job.

[0012] (6) As an embodiment of the present disclosure, in any one of (1) to (5), the input information acquisition module acquires an equipment shutdown plan, and the controller module shuts down the relevant equipment when the simulator discrete time reaches the equipment shutdown time based on the equipment shutdown plan.

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

[0015] (9) As an embodiment of the present disclosure, in any of (1) to (8), the inventory management module in the processing material inventory storage area treats the processing material inventory storage area as having virtual tanks for each brand, and cuts out inventory according to a dispensing job sent from the controller module, and replenishes and manages inventory according to a receiving job.

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

[0017] (11) An operation plan creation method according to one embodiment of the present disclosure includes: acquiring simulation results from a logistics simulator device according to any one of (1) to (10); and, when it is determined from the simulation results that the simulation has terminated abnormally, causing the logistics simulator device to acquire an operation plan modified based on the simulation results 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 logistics for transporting materials to a next process, and causes the computer to function as: an input information acquisition module that acquires an equipment list, an arrival plan, inventory information, a material processing plan, equipment capacity, a start date and time, an end date and time, and a unit time for the simulation; a controller module that executes the simulation according to the start date and time, an end date and time, and the unit time for the simulation; a route module that connects each of the equipment elements in the simulation based on the equipment list and the equipment capacity, and searches for a transportable route; a simulation result output module that outputs inventory trends and job results acquired at each discrete time; and an arrival frontage module, an arrival lot inventory management module, a processed material inventory yard module, a processed material inventory yard inventory management module, a processing equipment inventory yard module, a processing equipment tank-type inventory yard module, and a processing equipment module as options with on / off control, wherein the arrival frontage module generates one or more arrival frontages and arrival lots for processed materials according to the equipment list and the arrival plan, The incoming lot inventory management module generates receiving jobs for one or more types of processing materials to a processing material inventory storage area; the processing material inventory storage area module generates one or more processing material inventory areas according to the equipment list; the processing material inventory storage area inventory management module generates one or more processing material inventory storage tanks for each brand within the processing material inventory storage area based on the inventory information, and increases or decreases inventory in the processing material inventory storage tanks; the processing equipment inventory storage area module generates two or more processing equipment inventory areas based on the equipment list, and increases or decreases inventory in the processing equipment inventory areas based on the material processing plan; the processing equipment tank-type inventory storage area module generates one or more processing equipment tank-type warehouses, which are collections of multiple tanks, based on the equipment list, and consumes or increases inventory in the processing equipment tank-type warehouses; and the processing equipment module generates processing equipment based on the equipment list, and processes materials in the processing equipment in a simulation according to the material processing plan.

[0019] (13) In an embodiment of the present disclosure, a method for operating a steelworks includes the following steps: (1) obtaining an optimized operation plan, which is the operation plan when it is determined from the simulation results that the simulation has ended normally, in the method for creating an operation plan of (11), wherein the next step is a step of blending raw materials to be charged into a blast furnace; and (2) transporting the raw materials based on the optimized operation plan.

[0020] According to the present disclosure, it is possible to provide a logistics simulator device that can accommodate a wide variety of layouts and preconditions, an operation plan creation method, a program, and a steelworks operation method that can achieve efficiency.

[0021] Fig. 1 is a schematic diagram showing the logistics flow of iron ore and coking coal charged into a blast furnace. Fig. 2 is a diagram showing a schematic configuration of a logistics simulator device including its relationship with a host system. Fig. 3 is a diagram showing an example configuration of a simulation execution unit of the logistics simulator device. Fig. 4 is a schematic diagram of a layout of a logistics simulation target of an embodiment.

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

[0023] The logistics simulator according to this embodiment simulates the transport of materials (processed materials) to the next process. While the logistics that the logistics simulator can handle are not limited, this embodiment describes an example of the logistics of iron ore and coking coal in a raw material yard 102 (see FIG. 1 ) that is carried out as part of the operation of a steelworks. In the steel industry, iron ore, which is iron oxide, is charged into a blast furnace 107 (see FIG. 1 ) together with coke, reduced, and then refined to produce steel. To promote a smooth reduction reaction in the blast furnace 107 and avoid problems, the sintered ore and coke produced must have a certain level of strength and quality, and a large number of different iron ores and coking coals must be blended. FIG. 1 shows the logistics flow of iron ore and coking coal.

[0024] Iron ore and coking coal are received from the berth 101 into the raw material yard 102 and stored in piles by brand. The raw material yard 102 is an example of an inventory storage area. The received iron ore and coking coal are discharged to the next process, the bedding yard 103 and blending tank 104, where they are blended to a predetermined quality. The blending tank 104 includes a storage tank for iron ore provided in the sintering machine 105, a coal storage tank for coking coal provided in the coke oven 106, and a blast furnace tank provided in the blast furnace 107. In the bedding yard 103, brands are blended by stacking them in piles, called pairs of beds. While one bed is being loaded, the other is being unloaded toward the sintering machine 105 or the coke oven 106. By completing the loading of the bed and switching it over before the unloading is completed, continuous unloading to the sintering machine 105 or the coke oven 106 is realized. Each blending tank 104 has a capacity of 140 m ３ The facility is equipped with multiple silo-like tanks capable of storing iron ore or coking coal of about 100 liters each. Various brands of iron ore or coking coal can be replenished into the multiple tanks and blended on an outlet belt conveyor while being cut out. The sintering machine 105 bakes the blended powdered iron ore to produce sintered ore. The coke oven 106 produces coke from the coking coal. The blast furnace 107 reduces lump ore delivered from the bedding yard 103, sintered ore delivered from the sintering machine 105, and processed ore and auxiliary materials delivered from the raw material yard 102 with coke delivered from the coke oven 106 to produce pig iron. In the logistics operations for iron ore and coking coal, the highest priority is to maintain production in the downstream processes of the sintering machine 105, coke oven 106, and blast furnace 107. Therefore, receiving operations from the berth 101 to the raw material yard 102 are carried out as needed between discharge operations from the raw material yard 102 to the next process. The logistics simulator device according to this embodiment targets the logistics of iron ore and coking coal from being received by a raw material yard 102 from a berth 101, being discharged to a bedding yard 103 and a blending tank 104, passing through a sinter machine 105 or a coke oven 106, and reaching a blast furnace 107. Here, in this embodiment, a logistics line for iron ore and coking coal that includes a bedding yard 103 and a blending tank 104 is targeted, but the logistics line may include only the bedding yard 103 or the blending tank 104.

[0025] 2 is a diagram showing a schematic configuration of a logistics simulator device, including its relationship with a host system. The logistics simulator device includes an initial setting unit 201, a simulation execution unit 202, and a simulation termination unit 203. The host 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, initial parameters, and the like required for the simulation. The simulation execution unit 202 executes the simulation. The simulation termination unit 203 transmits the simulation results to the process computer 205. The data required for the 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 required for the simulation may be editable by a user of the logistics simulator device.

[0026] 3 is a diagram showing an example of the configuration of the simulation execution unit 202 of the logistics simulator device. Arrows and lines in FIG. 3 indicate the flow of data and the transmission and 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. The simulation execution unit 202 may also include at least one of an incoming entry module 302, an incoming lot inventory management module 303, a processing material inventory yard module 304, a processing material inventory yard inventory management module 305, 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 an incoming port module 302, an incoming lot inventory management module 303, a processing material inventory storage module 304, a processing material inventory storage yard inventory management module 305, a processing equipment inventory storage module 306, a processing equipment tank-type inventory storage module 307, and a processing equipment module 308 as options with on / off control, which will be described later. Here, a module is a component that has the function of a device or facility to be simulated by the logistics simulator device, and is configured to be easily added or replaced. In this embodiment, a module is a program module in which input variables, output variables, and processing of the function of the device or facility to be simulated are defined.

[0027] The input information acquisition module 301 acquires a list of equipment required for the simulation, a delivery plan, inventory information, material processing plan, equipment capacity, the start date and time, end date and time, and unit time of the simulation. 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. The input information acquisition module 301 may also acquire an equipment shutdown plan.

[0028] The arrival frontage module 302 generates one or more arrival frontages (i.e., berths 101) and arrival lots (i.e., raw material ships) for processed materials according to the equipment list and arrival plan acquired by the input information acquisition module 301. When there is a vacant berth 101, the arrival frontage module 302 allows a waiting raw material ship to enter the port and occupy it, and when the raw material ship runs out of processed materials, it releases the occupied berth 101.

[0029] The incoming lot inventory management module 303 generates receiving jobs for the raw material yard 102 for one or more types of processing materials loaded on the raw material ship generated by the receiving frontage module 302. The incoming lot inventory management module 303 outputs the generated receiving jobs to the controller module 309. The incoming lot inventory management module 303 also manages the amount of processing materials loaded on the raw material ship for which a receiving job is being carried out. Here, a job means work in an operation, and can also be referred to as a task. Jobs include receiving jobs, delivery jobs, and urgent jobs.

[0030] The processing material inventory storage module 304 generates one or more processing material inventory storage areas (i.e., raw material yards 102) according to the equipment list acquired by the input information acquisition module 301. In addition, the processing material inventory storage module 304 sets the initial inventory and maximum inventory amount of the processing material inventory storage area based on the inventory information acquired by the input information acquisition module 301.

[0031] The processing material inventory storage yard inventory management module 305 generates one or more virtual processing material inventory storage yard tanks for each brand of processing material for each raw material yard 102 based on the inventory information acquired by the input information acquisition module 301. In other words, the processing material inventory storage yard tanks are virtual tanks of the processing material inventory yard, and are generated for each brand of processing material. The processing material inventory storage yard inventory management module 305 also receives receiving jobs for the raw material yard 102 and delivery jobs to downstream processes sent from the controller module 309, and manages the inventory of the processing material inventory storage yard tanks by increasing or decreasing them.

[0032] The processing equipment inventory yard module 306 generates two or more processing equipment inventory yard locations (i.e., bedding yards 103) based on the equipment list acquired by the input information acquisition module 301. The processing equipment inventory yard module 306 also sets initial inventory for the two or more bedding yards 103 according to the inventory information acquired by the input information acquisition module 301. At least one of the two or more bedding yards 103 is currently being loaded. The processing equipment inventory yard module 306 generates a removal job according to the material processing plan acquired by the input information acquisition module 301, and outputs the generated removal job to the controller module 309. While the removal job for the bedding yard 103 is being executed, the processing equipment inventory yard module 306 increases the inventory of the bedding yard 103. At least one of the other bedding yards 103 is currently being cut out. The processing equipment inventory storage module 306 increases or decreases the inventory in the bedding yard 103 according to the material processing plan acquired 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 storage module 307 generates one or more processing equipment tank-type warehouses (i.e., blending tanks 104), which are collections of multiple tanks, based on the equipment list acquired by the input information acquisition module 301. The processing equipment tank-type inventory storage module 307 sets maximum inventory and initial inventory for all blending tanks 104 according to the inventory information acquired by the input information acquisition module 301. The processing equipment tank-type inventory storage module 307 also consumes inventory in the blending tanks 104 according to the material processing plan acquired by the input information acquisition module 301 or the material processing plan for the processing equipment generated by the processing equipment module 308. Here, the processing equipment tank-type inventory storage module 307 generates a transfer job for an appropriate amount from the raw material yard 102 to the blending tank 104 when the inventory in the blending tank 104 falls below a predetermined threshold. The processing equipment tank-type inventory storage module 307 outputs the generated transfer job to the controller module 309. During execution of a dispense job to the blending tank 104, the processing facility tank-type inventory storage module 307 increases the inventory of the blending tank 104.

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

[0035] The controller module 309 executes a simulation according to the start date / time, end date / time, and unit time of the simulation acquired by the input information acquisition module 301. Specifically, the controller module 309 acquires receiving jobs generated by the incoming lot inventory management module 303 and unloading jobs generated by the processing equipment inventory storage module 306 and the processing equipment tank-type inventory storage module 307. The controller module 309 manages the receiving jobs and unloading jobs at each discrete time they occur, and searches for routes on which each job can be executed based on the connection relationships generated by the route module 310. In other words, the controller module 309 searches for a route on which materials can be transported using the route module 310. The controller module 309 selects a route from the searched multiple route candidates based on preset logic and executes a simulation using the selected route. Here, the route selection logic may be, for example, random selection based on random numbers, a method of using older piles in the raw material yard 102, or a method of using processed material inventory storage tanks with less inventory.

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

[0037] The simulation result output module 311 outputs inventory trends, job results, etc. acquired at 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. Job results refer to jobs that were completed by the deadline date and time.

[0038] Here, the simulation termination unit 203 checks whether a predetermined termination condition of the simulation is met, and if the termination condition is met, terminates the simulation with the updated receiving plan and delivery plan. If the termination condition is not met, the simulation termination unit 203 advances the unit time by 1 and returns to the processing of the simulation execution unit 202 to continue the simulation.

[0039] In this embodiment, the logistics simulator is configured with a computer, and the computer's processor functions as each module according to a program. Some of the modules constituting the logistics simulator are optional, with their use or non-use selected based on an equipment list included in the input data acquired by the input information acquisition module 301. This configuration allows for a wide variety of layouts and preconditions to be accommodated. Specifically, the following are optional: an incoming entry module 302, an incoming lot inventory management module 303, a processing material inventory storage module 304, an inventory management module within the processing material inventory storage module 305, a processing equipment inventory storage module 306, a processing equipment tank-type inventory storage module 307, and a processing equipment module 308. Each of these modules has an on / off control; for example, if "1" is set to on, the module is used; if "0" is set to off, the module 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, allowing for automatic configuration of the equipment elements. For example, when the receiving frontage module 302, receiving lot inventory management module 303, processing material inventory storage module 304, and processing material inventory storage yard inventory management module 305 are turned off, the inventory in the raw material yard 102 is treated as infinite, enabling a simulation focused on the dispensing operations from the raw material yard 102 onward. Furthermore, for example, by turning off the coke oven 106 in the processing equipment module 308 and adding only the sinter machine 105 and blast furnace 107 that are turned on to the logistics flow, a simulation focused on the logistics of iron ore is possible. Furthermore, simply by specifying the presence or absence of the bedding yard 103 and the presence or absence of the blending tank 104 in the equipment list, it is possible to set up the system to match the configuration of the target steelworks. Furthermore, module on / off control has the effect of eliminating the need for software modification (coding) when the equipment list is changed.

[0040] The details of the processing performed by the logistics simulator will be explained below using the logistics flow of iron ore and coking coal shown in Figure 1 as an example. The incoming raw material vessel is given by the data shown in Table 1.

[0041]

[0042] The row direction is defined as a receiving job, and the controller module 309 sets an executable trigger (e.g., "1") for receiving jobs for the same ship at the port arrival date and time. Furthermore, if the incoming raw material ship is not given as data like Table 1 (i.e., an incoming plan), the processing material stockyard inventory management module 305 generates an incoming lot based on a predetermined rule. The predetermined rule may, for example, randomly generate a raw material ship loaded with a certain brand when the inventory of that brand falls below a threshold. The receiving location is selected by the incoming lot inventory management module 303 according to a predetermined rule. For example, if there are storage areas for the incoming brand in multiple raw material yards 102, the raw material may be divided and received according to the ratio of the maximum capacity of the raw material yards 102. Furthermore, the receiving location may be randomly selected from candidate receiving locations. The handling volume of one lot of a receiving job is preferably determined based on the size of the raw material ship's hatch. In addition, if the inventory in the processing material inventory storage tank becomes full or insufficient during the execution of a job, the processing material inventory storage tank inventory management module 305 may interrupt the job, select another processing material inventory storage tank according to predetermined rules, and resume the job.

[0043] The processing equipment tank-type inventory storage module 307 is defined by input data relating to the equipment as shown in Table 2.

[0044]

[0045] The blending tanks 104 associated with multiple pieces of equipment can be set using input data, eliminating the need for the user to code the relative positions of the equipment. The blending tanks 104 are connected to multiple pieces of downstream equipment according to the equipment layout and equipment information, and inventory is extracted according to the product of their processing efficiency and the blending ratio of the brands. The processing equipment tank-type inventory storage module 307 may employ logic that, when the extracted inventory falls below the replenishment threshold set in the input data, generates a job to eject the product from that tank and sends it to the controller module 309.

[0046] In the bedding yard 103, multiple brands are stacked in layers and blended. If the generation of a delivery job to the bedding yard 103 is specified for multiple lots using input data, detailed specifications are required, making the input data complicated, and omitting detailed specifications may result in multiple brands not being stacked as intended by the user. When generating the bedding yard 103, the processing equipment inventory storage module 306 defines virtual tanks according to the input data in Table 3.

[0047]

[0048] Like the processing equipment tank-type inventory module 307, the processing equipment inventory storage module 306 extracts inventory according to the product of the processing efficiency of the processing equipment designated as the destination and the blending ratio of the brands. The processing equipment inventory storage module 306 can use logic to generate a dispensing job to a virtual tank when the replenishment threshold is exceeded, allowing for simulation of a state in which different brands are loaded in sequence, similar to actual operations. While there are no restrictions on the maximum capacity of the virtual tank, since the bedding yard 103 is an open-air blending facility, the dispensing capacity to the actual blending tank 104 will be greater than that of the actual blending tank 104. The initial inventory of the virtual tank may be set to 0. By treating the configuration of the bedding yard 103 as a virtual system in which various brands are replenished in multiple tanks, it can be treated similarly to the blending tank 104. In other words, the bedding yard 103 and the blending tank 104 can be treated as common equipment elements in the simulation. This allows the processing equipment inventory module 306 to more efficiently manage inventory increases and decreases and create withdrawal plans.

[0049] The bedding yard 103 is composed of a set of beds, one of which is loaded and blended, while the other is being unloaded to downstream processing equipment. When the other bed is unloaded, unloading is performed from the loaded bed, and unloading begins on the vacant bed. The blending ratio and planned stacking amount can be changed each time the bed is switched. For example, the stacking amount, brand, blending ratio, etc. may be changed, as shown by the data indicated by the same bed number in Table 4. Here, if the next bed is not completed before the unloading bed is unloaded, the simulation may be terminated as an abnormal end.

[0050]

[0051] The controller module 309 sorts the incoming and outgoing jobs sent from each module in order of execution priority, as shown in Table 5. The controller module 309 may create a list in which urgent jobs are listed at the top by interruption. In addition, jobs that have been executed are deleted from the list.

[0052]

[0053] The execution priority in Table 5 indicates the priority of the job, with "1" representing the highest priority. The filing date and time indicates the date and time the job was created; for an acceptance job, it is created when the ship arrives at port. The list arranges jobs in execution priority order. The execution priority order is set regardless of the filing date and time. In other words, even if the filing date and time is earlier, it does not necessarily mean that the job will have the highest execution priority. The source and destination of a job are indicated in the From and To columns, respectively. Regarding the execution items, for the job indicated by the row, "Done" indicates that the job has been completed, "On progress" indicates that the job is being executed, and "Wait" indicates that the job is waiting. Other descriptions of the execution items will be described later. Regarding the urgent item, "1" indicates that the job is urgent. Here, for acceptance jobs, the amount of work is given in the input data, so a specific numerical value is listed. In contrast, for a dispensing job, the amount of work required to fill the destination tank (e.g., blending tank 104) is entered, but since dispensing can occur at the destination tank even while refilling is in progress, the amount of work is not specified and no specific numerical value is entered.

[0054] The controller module 309 executes jobs that can be executed simultaneously in parallel. The controller module 309 executes urgent jobs with the highest priority, and prioritizes delivery jobs over receipt jobs. The controller module 309 also places jobs that cannot be executed due to conflicts with jobs already in progress on hold. In the example of Table 5, the seventh job from the top is interrupted by an urgent job (the fourth job from the top) and is stopped, and the execution column is marked "Interrupted." In the example of Table 5, the third job from the top was deleted from the list before execution because an urgent job to deliver the same brand to the same location occurred, and the execution column is marked "Delete." Here, if stopping the running job and reassigning it to a different route would allow the waiting job to be executed simultaneously, the controller module 309 may execute a process to reassign the running job to a different route, thereby achieving efficient operation.

[0055] Here, the granularity of the brand classification can be set using input data. For example, specific brands such as brand A and brand B can be specified for the raw material blend. It is also possible to set blends using higher-level brand classifications such as South American ore X (applicable to brand A and brand B) and Australian ore Y (applicable to brand a and brand b). In logistics operations for iron ore and coking coal, the brand name of the smallest classification unit is often changed. For this reason, editing data in conventional simulations has been cumbersome, but the logistics simulator device disclosed herein allows for flexible response by setting input data.

[0056] The initial stock in the processing stockyard is given for each yard and each brand as shown in Table 6. The processing material stockyard inventory management module 305 treats the raw material yard 102 as being equipped with virtual tanks for each brand, and manages by cutting out stock according to a take-out job sent from the controller module 309 and replenishing stock according to a receiving job.

[0057]

[0058] When an equipment shutdown plan is given as input data as shown in Table 7, the controller module 309 shuts down the relevant equipment based on the equipment shutdown plan when the simulator discrete time reaches the equipment shutdown time. When equipment related to transport or movement, such as a belt conveyor or a stack reclaimer (an example of a moving machine), is stopped, the route module 310 may search for a possible transport route excluding routes that pass through the stopped equipment. This makes it possible to search for a possible transport route excluding routes that include equipment elements that are scheduled to be stopped for maintenance or the like. When there is a brand that cannot be delivered or received without using the stopped equipment, the controller module 309 may terminate the simulation as an abnormal end.

[0059]

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

[0061] 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 modules by masters included in the input data, the equipment capacity, etc. are used.

[0062]

[0063]

[0064]

[0065] In Table 8, "UL1" represents one ship. "BC101" represents one belt conveyor. "SR1" represents one stack reclaimer. As shown above, Table 9 indicates that an on / off item is used when "1" is set, and not used when "0" is set. For example, if "Coke Oven" is set to "0," the coke oven 106 is set to "not present" in the simulation. In this way, simply by editing the input data, the berth 101, the number of loading / unloading equipment, the number of yards, the number of beds, the number of sintering machines 105 and blast furnaces 107, the presence or absence of a coke oven 106, the correspondence between the beds and the sintering machines 105 and blast furnaces 107, the operating status and production capacity of each facility, and the like can be set. Furthermore, it is possible to include equipment competition in the input data, as shown in Figure 4.

[0066] Referring back to FIG. 2 , the simulation termination unit 203 terminates the simulation when a preset termination condition is met. The termination condition may include, for example, when the end date and time of the simulation acquired by the input information acquisition module 301 is reached, or when inventory is insufficient in the bedding yard 103 or the blending tank 104. When the simulation is terminated, the simulation results are output. The simulation results may include a flag indicating normal or abnormal termination, receiving job results, dispensing job results, etc. A normal termination here refers to the end of the simulation with material transport without any inventory shortages. On the other hand, an abnormal termination refers to the end of the simulation with an abnormality, such as an inventory shortage or a dispensing job that was not completed by the end date. Trend information may also be output as a simulation result. The trend information may include, for example, changes in inventory in the bedding yard 103 and changes in inventory in the blending tank 104.

[0067] Information on inventory trends, etc. may be output until the simulation is completed. For example, even if the simulation terminates abnormally, the host system can confirm the contents of the alert while viewing information on inventory trends, etc., and modify input data such as the operation plan and inventory storage plan. Here, the operation plan includes a material processing plan acquired by the input information acquisition module 301. In this embodiment, the material processing plan includes plans for the production volume and composition of sintered ore, coke, or pig iron produced by the blast furnace 107. The material processing plan determines the amount of iron source supply and its breakdown to realize the steel product manufacturing plan at the steelworks. The operation plan may also take into account the steel product manufacturing plan. The operation plan may also include a receiving plan. A second simulation using the modified input data is expected to produce good results. Furthermore, if good results are obtained (if the simulation terminates normally), the logistics simulator device can transmit the operation plan, along with related simulation data, to the host system via the process computer 205.

[0068] For example, an operation plan creation method may be executed, including acquiring simulation results from a logistics simulator device. The operation plan creation method may include, when it is determined from the simulation results that the simulation has abnormally ended, having the logistics simulator device acquire an operation plan modified based on the simulation results and execute the simulation again. For example, the operation plan creation method may be executed by a host system. Furthermore, the operation plan creation method may be executed, including acquiring an optimized operation plan, which is an operation plan when it is determined from the simulation results that the simulation has normally ended, and transporting raw materials based on the optimized operation plan. Specifically, the operation method may include controlling a control device that controls the transport of each raw material by issuing instructions, such as transport amounts, via the process computer 205. Here, the transported raw materials are raw materials to be blended in the next process and charged into the blast furnace 107, including, but not limited to, the iron ore and coking coal of this embodiment. For example, the blended raw materials may also include auxiliary raw materials, and the concept of this 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 express various simulations simply by combining modules and editing input data, and therefore can accommodate a wide variety of layouts and preconditions. Furthermore, compared to conventional techniques, the development period for the logistics simulator device or program can be significantly shortened. Furthermore, by following the operation plan resulting from the successful completion of such a simulation, an efficient steelworks operation method becomes possible. Furthermore, by properly managing the inventory of each raw material grade, it becomes possible to constantly supply raw materials of consistent quality, contributing to the production of high-quality steel materials.

[0070] Although the embodiments of the present disclosure have been described based on the drawings and examples, it should be noted that those skilled in the art would easily be able to make various modifications or alterations based on the present disclosure. Therefore, it should be noted that these modifications and alterations are included within the scope of the present disclosure. For example, functions included in each component or step can be rearranged so as not to cause logical inconsistencies, and multiple components or steps can be combined or divided into one. The embodiments of the present disclosure can also be realized as a storage medium (e.g., a non-transitory computer-readable recording medium) on which a program executed by a processor included in the device is recorded. It should be understood that these are also included within the scope of the present disclosure.

[0071] 101 Berth 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 termination unit 204 Data output unit for each process 205 Process computer 206 Business computer 301 Input information acquisition module 302 Receiving frontage module 303 Receiving lot inventory management module 304 Processing material inventory storage module 305 Inventory management module in processing material inventory storage yard 306 Processing equipment inventory storage module 307 Processing equipment tank-type inventory storage module 308 Processing equipment module 309 Controller module 310 Route module 311 Simulation result output module

Claims

1. A logistics simulator device for simulating the logistics of transporting materials to the next process, comprising: - An input information acquisition module that acquires an equipment list, a receiving plan, inventory information, a material processing plan, equipment capabilities, the start date and time, end date and time, and unit time of the simulation; - A controller module that executes the simulation according to the start date and time, end date and time, and the unit time of the simulation; - A route module that connects each of the equipment elements in the simulation based on the equipment list and the equipment capabilities, and searches for a transportable route; - A simulation result output module that outputs the inventory trend and job performance obtained for each discrete time. As an option with on-off control, it further comprises: a receiving bay 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 processed equipment module. - The receiving bay module generates one or more receiving bays and receiving lots for the processed materials according to the equipment list and the receiving plan. - The receiving lot inventory management module generates receiving jobs 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 equipment 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 processed equipment inventory yard module generates two or more processed equipment inventory yards based on the equipment 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 warehouses, which are aggregates of a plurality of tanks, based on the equipment list, and consumes or increases the inventory of the processed equipment tank-type warehouses. - The processed equipment module generates processed equipment based on the equipment list, and processes materials with the processed equipment in the simulation according to the material processing plan. A logistics simulator device.

2. The on-off control is set based on input data acquired by the input information acquisition module, and enables automatic setting of the equipment element. The logistics simulator device according to claim 1.

3. The incoming lot inventory management module generates an incoming lot based on predetermined rules when no incoming plan is given. The logistics simulator device according to claim 1 or 2.

4. The two or more processing equipment inventory 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. The logistics simulator device according to any one of claims 1 to 3.

5. When the inventory in the processing material inventory site tank becomes full or insufficient during the execution of a job, the in-site inventory management module for the processing material inventory interrupts the job and selects another processing material inventory site tank according to predetermined rules to resume the job. The logistics simulator device according to any one of claims 1 to 4.

6. The input information acquisition module acquires an equipment stop plan, and the controller module stops the corresponding equipment when the simulator discrete time reaches the equipment stop time based on the equipment stop plan. The logistics simulator device according to any one of claims 1 to 5.

7. The incoming lot inventory management module selects a receiving location according to predetermined rules. The logistics simulator device according to claim 3.

8. The granularity of the brand classification is set based on input data acquired by the input information acquisition module. The logistics simulator device according to any one of claims 1 to 7.

9. The in-site inventory management module for the processing material inventory treats the processing material inventory site as having pseudo-tanks for each brand, cuts out inventory according to the dispensing job sent from the controller module, replenishes inventory according to the receiving job, and manages it. The logistics simulator device according to any one of claims 1 to 8.

10. When 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. The logistics simulator device according to any one of claims 1 to 9.

11. Obtaining a simulation result from the logistics simulator device according to any one of claims 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. An operation plan creation method including this.

12. A program that causes a computer to function as a logistics simulator device that simulates the logistics of transporting materials to the next process, the program causing the computer to include: - 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 and searches for a transportable route based on the facility list and the facility capabilities; - a simulation result output module that outputs the inventory trend and job performance obtained for each discrete time; and, as an option with on-off control, causes the computer to function as a receiving bay 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 processed equipment module, wherein the receiving bay module generates one or more receiving bays and receiving lots for the processed materials according to the facility list and the receiving plan; the receiving lot inventory management module generates receiving jobs 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 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 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 warehouses, which are aggregates of a plurality of tanks, based on the facility list, and consumes or increases the inventory of the processed equipment tank-type warehouses; and the processed equipment module generates processed equipment based on the facility list, and processes materials with the processed equipment in the simulation according to the material processing plan.

13. The next process is a process of blending raw materials charged into a blast furnace. In the operation plan making method according to claim 11, when it is determined from the simulation result that the simulation has ended normally, an optimized operation plan which is the operation plan in this case is obtained, and the raw materials are conveyed based on the optimized operation plan. An operation method for an ironworks, including these steps.

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