面向钢铁企业智能制造的卷材切割优化算法

Coil-cutting optimization algorithm for intelligent manufacturing in steel enterprises

  • 摘要: 中国钢铁企业面临技术创新、产品竞争力和绿色低碳发展等挑战,智能制造成为推动企业转型升级的关键. 通过对钢铁企业智能制造概念、内涵、体系架构进行深入分析,聚焦智能制造全流程优化这一特征,从钢铁企业订单加工的关键工序入手,提出一种两阶段卷材切割算法对下料方案进行优化,可规定切割卷材宽度范围,并同时考虑板料及卷料订单的需求进行排样,以最小化切割损耗为目标,提高钢铁企业卷材加工的利用率、连贯性和灵活性. 通过随机仿真实验和文献实验算例验证了算法的有效性,随机实验结果显示优化后的下料利用率均在97%以上,显著优于传统人工计算方法,大幅缩短了排样时间,同时在文献算例上的实验结果也高于对比算法且切割操作成本更低. 借助应用卷材切割智能优化,有助于推动整个钢铁行业的技术进步和产业升级.

     

    Abstract: The steel industry is a crucial pillar of national economies. China, in particular, is a major global steel producer. However, it faces significant challenges with regard to technological innovation, product competitiveness, and green and low-carbon development. Intelligent manufacturing has emerged as the key factor driving corporate transformation and upgrading in the steel industry. This paper first presents an in-depth analysis of the concept, essence, and architecture of intelligent manufacturing in steel enterprises. A comprehensive framework encompassing four modules—technological foundation, production operations, organizational change, and corporate benefits—is proposed. This framework considers the process-oriented nature, high energy consumption, and high emissions of steel enterprises. It also considers the technological and organizational innovations required to ensure balanced and sustainable development. Steel coil cutting, which serves as a link between raw material processing and customer order fulfillment, is an essential aspect in achieving full-process optimization in steel enterprises. Optimization of steel coil-cutting plans reflects intelligent decision-making and economic goals within an intelligent manufacturing framework. However, many steel enterprises lack efficient optimization solutions for steel coil cutting. This limits processing efficiency and economic benefits, hindering the improvement of enterprise information systems and intelligent manufacturing levels. Therefore, achieving intelligent steel coil cutting, reducing raw material losses during cutting, and realizing real-time monitoring and optimized management of the production process are crucial in transitioning enterprises toward intelligent manufacturing. This paper presents a mathematical model for the steel coil-cutting problem on the basis of the actual cutting processes in factories. This model considers factors such as two-stage constraints, coil material, order requirements, coil-width limitations, and cutting losses. A steel coil-cutting optimization algorithm is proposed with the objective of minimizing cutting losses. This algorithm facilitates the specification of the width range of the cut coils and simultaneously considers the nesting of the sheet and strip orders. It generates initial cutting plans by using a combination of value and random selections. To avoid local optima, the algorithm dynamically adjusts the order values. It iterates through the "value correction–nesting plan generation–demand update" steps until the order demands are met and then outputs the final cutting plan. The effectiveness of the algorithm is verified through random simulation experiments and using experimental datasets from the literature. The results of the random experiments show that the optimized coil utilization rate is over 97%, significantly outperforming traditional manual methods. Moreover, the algorithm considerably reduces the nesting time. On the datasets used, the proposed algorithm also outperforms two other algorithms in terms of cutting utilization. The two-stage cutting method yields lower operational and time costs compared to the four-stage cutting employed by the extant algorithms. With its effectiveness thus validated, the coil-cutting optimization algorithm can be deployed in steel enterprises to better satisfy personalized and diverse market demands during processing. The algorithm affords positive technological, operational, and beneficial effects. It provides a practical path and innovative model for steel enterprises to achieve intelligent manufacturing transformation. Furthermore, it will potentially drive technological progress and industrial upgrades in the steel industry.

     

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