Research On Layout Design And Simulation For Solar Module Workshop

Facility layout design is a critical part in the procedure of manufacturing system design.Under the circumstance of lean production and digital factory,a great many of enterprises are facing the challenge of product diversification and shorten lead time,which raises higher requirements of layout design.In the condition of ensuring the implementation of essential functions,layout design should realize the maximal reduction of material handling cost.Meanwhile,with the rapid development of computer science,system simulation is generally applied in the manufacturing system design.It is not only widely used in validation after system design,but also used as part of establishing digital factory.Therefore,this paper has conducted research of layout design and system simulation for a solar module assembly workshop.Firstly,the related theories and algorithms of facility layout design has been introduced in the basis of analyzing and summarizing the recent research status in the field of facility layout design,computer aided layout design,and system simulation.By the method of the systematic layout plan(SLP),three layout scenarios for solar module assembly workshop has been proposed.Concretely,the work started with P-Q analysis,production composition analysis,process analysis,then divided production area into different departments,constructed logistics and non-logistics relationship chart,further obtained position relationship diagram and space relationship diagram,and finally got 3 layouts scenarios.Secondly,layout optimization has been performed using genetic algorithm.Mathematical model for facility layout problem has been built which combines space filling curves(SFC)and genetic algorithm.The algorithm,which has been implemented on the MATLAB 2014 a software,was designed in detail in terms of encoding,fitness function,selection,crossover,and mutation.And the result obtained is much better than the initial layouts which verified our algorithm.Finally,it has been conducted that the simulation of production line based on Visual Components and real-time connections with soft PLC program.Device simulation models for solar module assembly line have been established after the concept of visual components structure being introduced.A layout model of simulation production line has been built using the device simulation models.The statistics data collected after simulation helps us to analyze the WIP balance problem,resource utilization,and position adjustments for robot.After that,the TwinCAT PLC has been connected to the simulation platform,which allow the PLC program to control the machine model in Visual Components.A simulation experiment has been conducted to validate it's feasibility.