物联网环境下生产车间调度控制方法研究

Current information systems for production management, such as enterprise resource planning systems (ERP), manufacturing execution systems (MES), have a common problem that the work plans generated by such systems lack operability, which are usually very difficult to be executed in the plant workshop floor. The reason is that it is hard for such systems to acquire the exact real-time information about the low level manufacturing process in the workshop. This makes the high level planning systems produce work plans only relying on rough statistical data from a long time horizon. Thus, the work plans accrued from these systems are often very coarse and are short of detailed information for supporting smooth operations in the low executing level. It is the divorce of the high planning level and the low executing level that leads to the operability problem faced by current information systems. .Fortunately, the emerging technologies of the internet of things (IOT) create an opportunity to solve such embarrassing problem. Under the IOT environment, the things in the workshop such as the machines, tools, bins for workpieces and so on become 'smart things', because they can be equipped with RFIDs and sensors, which endow them with the abilities to sense, inference, make decisions, and communicate with each other and feed back information to the high planning level. Therefore, IOT technologies can bridge the gaps between the planning level and the executing level in the enterprises. Furthermore, the IOT technologies are able to cause a revolutionary transformation of the current information systems. On one hand, IOT facilitate the planning level to create closed loop work plans based on the exact real-time information feedback from the executing level, which makes the work plans easy to be operated in the executing level. In other words, it improves the performance of the planning level. On the other hand, under the IOT environment, the smart things (e.g. machines, tool, bins and so on) acquire the ability of self-organization, self-management, self-control, and mutual recognition, communication, and negotiation. Thus, they can learn and master how to implement simple operations by themselves, so as to accomplish the low level tasks with fewer prescriptions from the planning level. This transfers a part of management tasks from the planning level to the executing. In this way, IOT relieves the planning burden of the high level of the information systems. .In this project, the focus is on researching the workshop scheduling and control methods under the IOT environment. The workshop scheduling and control framework under the IOT environment, the closed loop work planning method in the planning level and the distributed cooperative control method in the executing level will be the three main tasks in this project. The objective is to study how to design a new information system framework to effectively integrate the human, the things, and the environments.

当前的生产管理信息系统和制造执行系统普遍存在生成的作业计划在车间层难以执行操作的问题。其主要原因是这些系统难以准确获得车间底层的实时信息，只能基于统计信息制作粗糙的作业计划，造成计划层与执行层脱节。物联网技术可以使车间底层的物（如机器、工具等）具备感知、通信和一定的推理决策能力，成为"智慧物"，为计划层实时、准确获得执行层信息提供了技术支撑。这会使得生产管理系统的设计发生变革，一方面可以使计划层根据执行层实时信息反馈做闭环作业计划，使计划更具可操作性；另一方面，物的智慧化也可以通过自组织协同控制自主的完成底层细节任务，减轻计划层的管理负担。本项目的主要工作就是根据物联网环境下车间调度控制的新特点，研究计划层与执行层的调度控制框架、基于执行层实时信息反馈的闭环作业计划方法和面向"智慧物"的协同控制方法，以使计划层与执行层能紧密衔接，并提出新的生产管理信息化模式，以提升企业管理绩效。

当前的生产管理信息系统和制造执行系统普遍存在生成的作业计划在车间层难以执行操作的问题。其主要原因是这些系统难以准确获得车间底层的实时信息，只能基于统计信息制作粗糙的作业计划，造成计划层与执行层脱节。为解决此问题，本项目主要提出了基于RFID的车间制造资源定位方法、车间制造资源定位数据语义分析方法、基于动态环境信息的机器作业分配方法、面向分层生产计划调度的反馈控制方法，以及面向分层生产计划与控制的数据分析方法。这些方法分别从车间底层细粒度数据获取、面向生产计划与控制应用的车间底层细粒度数据的语义分析、实时底层数据应用于制造资源协同控制，以及底层细粒度历史数据通过数据分析应用于不同的生产计划与控制层次等方面，为解决生产作业计划与执行脱节问题提供了可操作方案。