187 lines
8.3 KiB
Python
187 lines
8.3 KiB
Python
from base_optimizer.optimizer_common import *
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def list_range(start, end=None):
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return list(range(start)) if end is None else list(range(start, end))
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@timer_wrapper
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def optimizer_aggregation(component_data, pcb_data):
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# === phase 0: data preparation ===
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M = 1000 # a sufficient large number
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a, b = 1, 6 # coefficient
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component_list, nozzle_list = defaultdict(int), defaultdict(int)
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cpidx_2_part, nzidx_2_nozzle = {}, {}
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for _, data in pcb_data.iterrows():
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part = data['part']
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if part not in cpidx_2_part.values():
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cpidx_2_part[len(cpidx_2_part)] = part
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component_list[part] += 1
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idx = component_data[component_data['part'] == part].index.tolist()[0]
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nozzle = component_data.loc[idx]['nz']
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if nozzle not in nzidx_2_nozzle.values():
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nzidx_2_nozzle[len(nzidx_2_nozzle)] = nozzle
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nozzle_list[nozzle] += 1
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I, J = len(component_list.keys()), len(nozzle_list.keys()) # the maximum number of component types and nozzle types
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L = I + 1 # the maximum number of batch level
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K = max_head_index # the maximum number of heads
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HC = [[M for _ in range(J)] for _ in range(I)] # represent the nozzle-component compatibility
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for i in range(I):
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for _, item in enumerate(cpidx_2_part.items()):
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index, part = item
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cp_idx = component_data[component_data['part'] == part].index.tolist()[0]
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nozzle = component_data.loc[cp_idx]['nz']
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for j in range(J):
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if nzidx_2_nozzle[j] == nozzle:
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HC[index][j] = 0
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# === phase 1: mathematical model solver ===
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mdl = Model('SMT')
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mdl.setParam('OutputFlag', 0)
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# === Decision Variables ===
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# the number of components of type i that are placed by nozzle type j on placement head k
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X = mdl.addVars(list_range(I), list_range(J), list_range(K), vtype=GRB.INTEGER, ub=max(component_list.values()))
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# the total number of nozzle changes on placement head k
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N = mdl.addVars(list_range(K), vtype=GRB.INTEGER)
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# the largest workload of all placement heads
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WL = mdl.addVar(vtype=GRB.INTEGER, lb=0, ub=len(pcb_data))
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# whether batch Xijk is placed on level l
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Z = mdl.addVars(list_range(I), list_range(J), list_range(L), list_range(K), vtype=GRB.BINARY)
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# Dlk := 2 if a change of nozzles in the level l + 1 on placement head k
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# Dlk := 1 if there are no batches placed on levels higher than l
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# Dlk := 0 otherwise
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D = mdl.addVars(list_range(L), list_range(K), vtype=GRB.BINARY, ub=2)
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D_plus = mdl.addVars(list_range(L), list_range(J), list_range(K), vtype=GRB.INTEGER)
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D_minus = mdl.addVars(list_range(L), list_range(J), list_range(K), vtype=GRB.INTEGER)
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# == Objective function ===
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mdl.modelSense = GRB.MINIMIZE
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mdl.setObjective(a * WL + b * quicksum(N[k] for k in range(K)))
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# === Constraint ===
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mdl.addConstrs(
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quicksum(X[i, j, k] for j in range(J) for k in range(K)) == component_list[cpidx_2_part[i]] for i in range(I))
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mdl.addConstrs(quicksum(X[i, j, k] for i in range(I) for j in range(J)) <= WL for k in range(K))
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mdl.addConstrs(
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X[i, j, k] <= M * quicksum(Z[i, j, l, k] for l in range(L)) for i in range(I) for j in range(J) for k in
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range(K))
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mdl.addConstrs(quicksum(Z[i, j, l, k] for l in range(L)) <= 1 for i in range(I) for j in range(J) for k in range(K))
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mdl.addConstrs(
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quicksum(Z[i, j, l, k] for l in range(L)) <= X[i, j, k] for i in range(I) for j in range(J) for k in range(K))
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mdl.addConstrs(quicksum(Z[i, j, l, k] for j in range(J) for i in range(I)) >= quicksum(
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Z[i, j, l + 1, k] for j in range(J) for i in range(I)) for k in range(K) for l in range(L - 1))
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mdl.addConstrs(quicksum(Z[i, j, l, k] for i in range(I) for j in range(J)) <= 1 for k in range(K) for l in range(L))
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mdl.addConstrs(D_plus[l, j, k] - D_minus[l, j, k] == quicksum(Z[i, j, l, k] for i in range(I)) - quicksum(
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Z[i, j, l + 1, k] for i in range(I)) for l in range(L - 1) for j in range(J) for k in range(K))
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mdl.addConstrs(
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D[l, k] == quicksum((D_plus[l, j, k] + D_minus[l, j, k]) for j in range(J)) for k in range(K) for l in
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range(L))
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mdl.addConstrs(2 * N[k] == quicksum(D[l, k] for l in range(L)) - 1 for k in range(K))
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mdl.addConstrs(
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0 >= quicksum(HC[i][j] * Z[i, j, l, k] for i in range(I) for j in range(J)) for l in range(L) for k in range(K))
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# === Main Process ===
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component_result, cycle_result = [], []
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feeder_slot_result, placement_result, head_sequence = [], [], []
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mdl.setParam("TimeLimit", 100)
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mdl.optimize()
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if mdl.Status == GRB.OPTIMAL:
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print('total cost = {}'.format(mdl.objval))
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# convert cp model solution to standard output
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model_cycle_result, model_component_result = [], []
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for l in range(L):
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model_component_result.append([None for _ in range(K)])
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model_cycle_result.append([0 for _ in range(K)])
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for k in range(K):
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for i in range(I):
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for j in range(J):
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if abs(Z[i, j, l, k].x - 1) <= 1e-3:
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model_component_result[-1][k] = cpidx_2_part[i]
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model_cycle_result[-1][k] = round(X[i, j, k].x)
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# remove redundant term
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if sum(model_cycle_result[-1]) == 0:
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model_component_result.pop()
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model_cycle_result.pop()
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head_component_index = [0 for _ in range(max_head_index)]
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while True:
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head_cycle = []
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for head, index in enumerate(head_component_index):
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head_cycle.append(model_cycle_result[index][head])
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if len([cycle for cycle in head_cycle if cycle > 0]) == 0:
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break
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component_result.append([None for _ in range(max_head_index)])
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min_cycle = min([cycle for cycle in head_cycle if cycle > 0])
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for head, index in enumerate(head_component_index):
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if model_cycle_result[index][head] != 0:
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component_result[-1][head] = model_component_result[index][head]
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else:
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continue
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model_cycle_result[index][head] -= min_cycle
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if model_cycle_result[index][head] == 0 and index + 1 < len(model_cycle_result):
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head_component_index[head] += 1
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cycle_result.append(min_cycle)
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part_2_index = {}
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for index, data in component_data.iterrows():
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part_2_index[data['part']] = index
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for cycle in range(len(component_result)):
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for head in range(max_head_index):
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part = component_result[cycle][head]
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component_result[cycle][head] = -1 if part is None else part_2_index[part]
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feeder_slot_result = feeder_assignment(component_data, pcb_data, component_result, cycle_result)
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# === phase 2: heuristic method ===
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mount_point_pos = defaultdict(list)
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for pcb_idx, data in pcb_data.iterrows():
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part = data['part']
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part_index = component_data[component_data['part'] == part].index.tolist()[0]
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mount_point_pos[part_index].append([data['x'], data['y'], pcb_idx])
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for index_ in mount_point_pos.keys():
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mount_point_pos[index_].sort(key=lambda x: (x[1], x[0]))
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for cycle_idx, _ in enumerate(cycle_result):
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for _ in range(cycle_result[cycle_idx]):
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placement_result.append([-1 for _ in range(max_head_index)])
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for head in range(max_head_index):
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if component_result[cycle_idx][head] == -1:
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continue
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index_ = component_result[cycle_idx][head]
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placement_result[-1][head] = mount_point_pos[index_][-1][2]
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mount_point_pos[index_].pop()
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head_sequence.append(dynamic_programming_cycle_path(pcb_data, placement_result[-1], feeder_slot_result[cycle_idx]))
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else:
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warnings.warn('No solution found!', UserWarning)
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return component_result, cycle_result, feeder_slot_result, placement_result, head_sequence
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