174 lines
8.2 KiB
Python
174 lines
8.2 KiB
Python
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
|