import copy import pandas as pd from base_optimizer.optimizer_common import * from base_optimizer.result_analysis import * def line_optimizer_model(component_data, pcb_data, machine_num, hinter=True): mdl = Model('pcb assembly line optimizer') mdl.setParam('Seed', 0) mdl.setParam('OutputFlag', hinter) # set whether output the debug information mdl.setParam('TimeLimit', 600) nozzle_type, component_type = [], [] for _, data in component_data.iterrows(): if not data.nz in nozzle_type: nozzle_type.append(data.nz) component_type.append(data.part) average_pos = 0 for _, data in pcb_data.iterrows(): average_pos += data.x slot_start = int(round(average_pos / len(pcb_data) + stopper_pos[0] - slotf1_pos[0]) / slot_interval) + 1 ratio = 1 J = len(nozzle_type) N = 10000 M = machine_num H = max_head_index I = len(component_data) S = min(len(component_data) * ratio, 60) K = len(pcb_data) CompOfNozzle = [[0 for _ in range(J)] for _ in range(I)] # Compatibility component_point = [0 for _ in range(I)] for idx, data in component_data.iterrows(): nozzle = component_data.iloc[idx].nz CompOfNozzle[idx][nozzle_type.index(nozzle)] = 1 component_point[idx] = data.points # objective related g = mdl.addVars(list_range(K), list_range(M), vtype=GRB.BINARY) d = mdl.addVars(list_range(K - 1), list_range(H), list_range(M), vtype=GRB.CONTINUOUS) # u = mdl.addVars(list_range(K), list_range(M), vtype=GRB.INTEGER) d_plus = mdl.addVars(list_range(J), list_range(H), list_range(K - 1), list_range(M), vtype=GRB.CONTINUOUS) d_minus = mdl.addVars(list_range(J), list_range(H), list_range(K - 1), list_range(M), vtype=GRB.CONTINUOUS) e = mdl.addVars(list_range(-(H - 1) * ratio, S), list_range(K), list_range(M), vtype=GRB.BINARY) f = mdl.addVars(list_range(S), list_range(I), list_range(M), vtype=GRB.BINARY, name='') x = mdl.addVars(list_range(I), list_range(S), list_range(K), list_range(H), list_range(M), vtype=GRB.BINARY) n = mdl.addVars(list_range(H), list_range(M), vtype=GRB.CONTINUOUS) obj = mdl.addVar(lb=0, ub=N, vtype=GRB.CONTINUOUS) mdl.addConstrs(g[k, m] >= g[k + 1, m] for k in range(K - 1) for m in range(M)) mdl.addConstrs( quicksum(x[i, s, k, h, m] for i in range(I) for s in range(S)) <= g[k, m] for k in range(K) for h in range(H) for m in range(M)) # nozzle no more than 1 for head h and cycle k mdl.addConstrs( quicksum(CompOfNozzle[i][j] * x[i, s, k, h, m] for i in range(I) for s in range(S) for j in range(J)) <= 1 for k in range(K) for h in range(H) for m in range(M)) # nozzle available number constraint mdl.addConstrs( quicksum(CompOfNozzle[i][j] * x[i, s, k, h, m] for i in range(I) for s in range(S) for h in range(H)) <= H for k in range(K) for j in range(J) for m in range(M)) # work completion mdl.addConstrs( quicksum(x[i, s, k, h, m] for s in range(S) for k in range(K) for h in range(H) for m in range(M)) == component_point[i] for i in range(I)) # nozzle change mdl.addConstrs(quicksum(CompOfNozzle[i][j] * x[i, s, k, h, m] for i in range(I) for s in range(S)) - quicksum( CompOfNozzle[i][j] * x[i, s, k + 1, h, m] for i in range(I) for s in range(S)) == d_plus[j, h, k, m] - d_minus[ j, h, k, m] for k in range(K - 1) for j in range(J) for h in range(H) for m in range(M)) mdl.addConstrs(2 * d[k, h, m] == quicksum(d_plus[j, h, k, m] for j in range(J)) + quicksum( d_minus[j, h, k, m] for j in range(J)) for k in range(K - 1) for h in range(H) for m in range(M)) mdl.addConstrs(n[h, m] == quicksum(d[k, h, m] for k in range(K - 1)) - 0.5 for h in range(H) for m in range(M)) # simultaneous pick for s in range(-(H - 1) * ratio, S): rng = list(range(max(0, -math.floor(s / ratio)), min(H, math.ceil((S - s) / ratio)))) for k in range(K): mdl.addConstrs( quicksum(x[i, s + h * ratio, k, h, m] for h in rng for i in range(I)) <= N * e[s, k, m] for m in range(M)) mdl.addConstrs( quicksum(x[i, s + h * ratio, k, h, m] for h in rng for i in range(I)) >= e[s, k, m] for m in range(M)) # pickup movement # mdl.addConstrs(u[k, m] >= s1 * e[s1, k, m] - s2 * e[s2, k, m] for s1 in range(-(H - 1) * ratio, S) for s2 in # range(-(H - 1) * ratio, S) for k in range(K)) # feeder related mdl.addConstrs(quicksum(f[s, i, m] for s in range(S) for m in range(M)) <= 1 for i in range(I)) mdl.addConstrs(quicksum(f[s, i, m] for i in range(I)) <= 1 for s in range(S) for m in range(M)) mdl.addConstrs( quicksum(x[i, s, k, h, m] for h in range(H) for k in range(K)) >= f[s, i, m] for i in range(I) for s in range(S) for m in range(M)) mdl.addConstrs( quicksum(x[i, s, k, h, m] for h in range(H) for k in range(K)) <= N * f[s, i, m] for i in range(I) for s in range(S) for m in range(M)) mdl.addConstrs( quicksum(f[s, i, m] for i in range(I)) >= quicksum(f[s + 1, i, m] for i in range(I)) for s in range(S - 1) for m in range(M)) # objective T_cy, T_nz, T_pu, T_pl = 2, 3, 1, 1 mdl.addConstrs(obj >= T_cy * quicksum(g[k, m] for k in range(K)) + T_nz * quicksum( d[k, h, m] for h in range(H) for k in range(K - 1)) + T_pl * quicksum( e[s, k, m] for s in range(-(H - 1) * ratio, S) for k in range(K)) + T_pl * quicksum( x[i, s, k, h, m] for i in range(I) for s in range(S) for k in range(K) for h in range(H)) for m in range(M)) mdl.setObjective(obj, GRB.MINIMIZE) mdl.optimize() pcb_part_indices = defaultdict(list) for idx, data in pcb_data.iterrows(): pcb_part_indices[data.part].append(idx) assembly_info = [] for m in range(M): partial_component_data, partial_pcb_data = copy.deepcopy(component_data), pd.DataFrame(columns=pcb_data.columns) partial_component_data['points'] = 0 part_index = defaultdict(int) for idx, data in component_data.iterrows(): part_index[data.part] = idx component_result, cycle_result, feeder_slot_result = [], [], [] for k in range(K): if abs(g[k, m].x) < 1e-3: continue component_result.append([-1 for _ in range(H)]) cycle_result.append(1) feeder_slot_result.append([-1 for _ in range(H)]) for h in range(H): for i in range(I): for s in range(S): if abs(x[i, s, k, h, m].x) < 1e-3: continue if component_result[-1][h] != -1: assert 1 component_result[-1][h] = i feeder_slot_result[-1][h] = slot_start + s * 2 idx = pcb_part_indices[component_data.iloc[i].part][0] partial_pcb_data = pd.concat([partial_pcb_data, pd.DataFrame(pcb_data.iloc[idx]).T]) pcb_part_indices[component_data.iloc[i].part].pop(0) partial_component_data.loc[i, 'points'] += 1 print(component_result) print(cycle_result) print(feeder_slot_result) placement_result, head_sequence = greedy_placement_route_generation(partial_component_data, partial_pcb_data, component_result, cycle_result, feeder_slot_result, hinter=False) print('----- Placement machine ' + str(m + 1) + ' ----- ') info = placement_info_evaluation(partial_component_data, partial_pcb_data, component_result, cycle_result, feeder_slot_result, placement_result, head_sequence, hinter=False) optimization_assign_result(partial_component_data, partial_pcb_data, component_result, cycle_result, feeder_slot_result, nozzle_hinter=True, component_hinter=True, feeder_hinter=True) info.print() assembly_info.append(info) print('------------------------------ ') return assembly_info