Scheduling Optimization And Energy Consumption Online Monitoring System For Multi-Variety Mixed Coating Production

With the increasing competition of the market and the worsening of the environmental pollution,the demand for the energy efficiency in the production process is higher.Especially,the multi-variety and small batch production mode further improves the complexity of energy consumption control.Automotive coating production process is accompanied by a large amount of energy consumption,which has become an important research direction of the energy saving in manufacturing industry.In this paper,an optimal scheduling method for coating process in mass customization production mode is studied.And the scheduling optimization and energy consumption online monitoring system for multi-variety mixed coating production is designed and developed.The process parameters and energy consumption data are obtained through on-line monitoring,which provides a strong guarantee for improving the quality and energy efficiency of automobile coating production.This paper analyzes the reasons of invalid energy consumption in the coating process,and the invalid energy consumption is reduced by optimizing arranging sequence of production orders.Firstly,a multi-objective optimization model of production scheduling for coating line was established to obtain the optimized arranging sequence with the objectives of minimizing invalid energy consumption,coating cost and production time based on the invalid energy consumption.Then the multi-objective non-dominated fast sorting Genetic Algorithm and improved Particle Swarm Optimization are used to optimize the multi-objective mathematical model respectively.On the basis of traditional Genetic Algorithm,the classification of non-dominant frontier for chromosome population is divided by fast and simple forward comparing operation,which improved the speed of traditional sorting mode.And the crowding distance of niche technology was adopted to sequence the chromosome in the same sort of non-dominated layers,which maintained the diversity of the chromosome population.Finally,the Pareto solution is used to select the optimal arranging sequence by Analytic Hierarchy Process.The results and the efficiency of the solution for two algorithms are compared,and the improved Genetic Algorithm is determined to solve the scheduling optimization module in the scheduling optimization and energy consumption online monitoring system for multi-variety mixed coating production.The scheduling optimization and energy consumption online monitoring system for multi-variety mixed coating production is developed by the Visual Studio 2012 and based on C#language,MATLAB and SQL Server database.The system includes six functional modules,such as system management,scheduling,report view,energy consumption statistics,quality analysis and real-time monitoring.System management achieved the entry for the basic data and the definition for personal,user and role permissions;The scheduling module is the core of the entire system.According to the given order content,the scheduling optimization of coating production is realized by the multi-objective non-dominate sorting genetic algorithm.The report view achieved the storage,query and analysis for the process parameters in the coating production line.The energy consumption statistics realized the energy consumption statistics of the daily production and parts production.The quality analysis realized that the average value and variance of the film thickness and the film gloss were calculated and analyzed.The real-time monitoring achieved the dynamic real-time monitoring for the whole coating production line.The feasibility and effectiveness of the system is verified by the practical application of a automobile coating workshop in Shandong.