CN116451973B - Warp knitting machine material preparation plan optimization method and material preparation method based on time sequence recursion - Google Patents
Warp knitting machine material preparation plan optimization method and material preparation method based on time sequence recursion Download PDFInfo
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Abstract
The invention discloses a warp knitting machine stock preparation plan optimization method based on time sequence recursion, which is characterized in that through simulated production in a production stage, when a certain pan head raw material is exhausted, pan head raw materials on other guide bars are screened one by one, through the proportion between the current available time length of the residual raw material and the time length of the latest raw material replacement, the raw material replacement times and stock preparation times are weighed, then advice of whether to replace the corresponding pan head raw material is obtained, and finally an optimized stock preparation plan is obtained. The invention also discloses a preparation method, based on the optimized preparation plan, production personnel can determine the number of the heads needing to be prepared in advance, the number of raw materials loaded by each head, the shutdown times and time, the preparation plan is issued to carry out head warping, the heads needing to be replaced in the whole production period are prepared in advance, an efficient and accurate preparation plan is provided for warp knitting production, the heads are controlled to be replaced in batches at the optimal shutdown time, the shutdown times of a machine station are reduced, and therefore the production benefit is greatly improved.
Description
Technical Field
The invention relates to a control method for production shutdown of a warp knitting machine, in particular to a warp knitting machine material preparation plan optimization method and a material preparation method based on time sequence recursion.
Background
The textile industry is one of the industries in advanced positions worldwide in China, the advantages of complete industry system and stable supply scale are maintained in recent years, contribution to economic and social development in China is consolidated, and the influence in the international textile supply chain is continuously increased. The warp knitting textile process has high technical content, wide application range and great development potential, and becomes an important mark for measuring the comprehensive strength of the textile industry, and the application range and the total production amount of the warp knitting textile process are continuously increased in recent years.
Warp knitting refers to a method for connecting warp wales and loops into a fabric in knitting, wherein a plurality of raw materials are knitted into a fabric with higher performance according to a certain technological rule through cooperation of a plurality of guide bars in the production process. Specifically, each yarn required for production is first loaded onto one of the heads by a warping process. And then each pan head is loaded on a warp beam corresponding to the required guide bar, and yarns are connected to the corresponding guide bar through threading. Finally, the disc head is driven to send raw materials to the guide bar for knitting production through the rotation of the warp beam. However, due to different technological parameters of raw materials, the size of the pan head capacity, the yarn feeding amount and other parameters, the rotation speed of the pan head and the yarn feeding amount are different. Meanwhile, the raw material capacity of each pan head is limited, in the mass order production process, the pan heads which consume raw materials are often required to be replaced by stopping for multiple times, and after the raw materials are replaced each time, the machine is adjusted and tested again so as to ensure that the produced fabrics meet the technological requirements of customers. However, the warp knitting raw materials have long preparation period and high disc head replacement cost, have great influence on production efficiency, and need to make reliable production and material preparation calculation in advance to improve production collaborative efficiency and production stability.
At present, most of material preparation plan generation methods are researched from the perspective of a supply chain, aiming at the problem of macroscopic material purchasing requirements in a factory, and the material preparation plan generation methods aiming at the material requirements of specific production links are few. In warp knitting practice, the usual stock preparation methods include two types: 1. preparing each raw material according to the maximum capacity to reduce the number of times of material preparation; 2. and uniformly replacing each time of shutdown. However, both methods have obvious defects, when preparing according to the maximum capacity of each raw material, because the consumption speed of each raw material is inconsistent, when one raw material is exhausted, the raw material needs to be stopped for replacement, so that repeated stopping is easy to cause, the production efficiency is reduced, and meanwhile, the quality of grey cloth is easy to be adversely affected by stopping each time; when the machine is stopped, all raw materials are uniformly replaced, so that the maximum capacity of the raw materials cannot be fully utilized, multiple material preparation is easy to cause, and the material preparation cost is increased. The method has the advantages of large manual dependence, high cost, low efficiency, slow response and the like, is difficult to meet the requirement of mass order production, and has great discount on the continuity of machine production. For this reason, a good material preparation plan needs to be made to ensure orderly supply of raw materials and stable production.
Disclosure of Invention
In view of the above, the invention aims at constructing a material preparation plan optimization method aiming at warp knitting production characteristics, so as to solve the problems of low production efficiency, high labor dependence cost and the like caused by the fact that the consumption time nodes of each pan head raw material are different due to the fact that the consumption rates of the respective pan head raw materials are different, and frequent machine stopping is needed for warping and replacing the pan head raw materials.
The invention further aims at constructing a material preparation method aiming at warp knitting production characteristics, so as to solve the problems of low production efficiency, high labor dependence cost and the like caused by the fact that each pan head raw material consumption time node is different due to the fact that each pan head raw material consumption rate is different, and a machine is required to be frequently stopped for warping and replacing the pan head raw material.
A warp knitting machine stock plan optimization method based on time sequence recursion comprises the following steps:
step 1: information collection, namely acquiring raw material compositions corresponding to the order demand grey cloth and acquiring the total amount of all raw materials of the order demand grey cloth;
putting the corresponding pan head raw materials of all the constituent raw materials of the order on corresponding guide bars of a warp knitting machine, obtaining the pan head yarn feeding speed on each guide bar, obtaining the pan head capacity on each guide bar and obtaining the pan head allowance on each guide bar;
step 2: information processing, namely calculating total production time according to the total amount of raw materials of the grey cloth required by an order, and taking the difference value between the total production time and the produced time as production residual time;
taking the ratio of the allowance of the coil on each guide bar to the corresponding feeding speed of the coil as the consumption time of the allowance of the coil;
taking the ratio of the size of the disc head capacity on each guide bar to the corresponding disc head yarn feeding speed as the disc head capacity consumption duration;
step 3: presetting a reference change rate, taking the ratio of the head margin consumption time length to the head capacity consumption time length of the head with the shortest head capacity consumption time length in all heads on the guide bar as the change rate, and presetting the reference change rate;
step 4: performing recursion simulation, namely performing simulation production according to the yarn feeding speed of the heads on each guide bar, starting timing, and when the head allowance consumption time of the head on one of the guide bars is equal to zero, replacing the head of the corresponding guide bar into a full-load head, recording the stop time points, and forming a stop time set by the stop time points; recording the service time of the replaced disc head raw material on the guide bar, and updating a disc head replacement data set, a downtime set and production residual time;
simultaneously screening the non-residual depleted heads on the rest guide bars one by one, and respectively comparing the change rate of the heads on the rest guide bars with the reference change rate preset in the step 3 for one time;
when the change rate of the disc heads on the rest guide bars is smaller than the reference change rate in one comparison, replacing the rest disc heads into corresponding full-load disc heads; when the change rate of the disc heads on the rest guide bars is judged to be larger than the reference change rate, keeping the disc heads as is;
recording the service time of the replaced disc head raw materials on each guide bar, and updating a disc head replacement data set and the production residual time;
step 5: performing recursive optimization, repeating the recursive simulation of the step 4 to obtain a next stop time point, calculating the head margin consumption time of the non-raw material depleted heads on the guide bars at the next time point, calculating the head capacity consumption time, comparing the change rate once again, and correspondingly updating the stop time set, the head replacement data set and the production residual time;
when the production residual time is zero, automatically ending the repeated recursion simulation process; or ending the repeated recursion simulation process after intervention;
step 6: weighing and optimizing, adjusting the preset reference change rate in the step 3, and repeating the operations in the step 4 and the step 5 to obtain an additional downtime set and a disc head replacement data set;
step 7: after the downtime set and the disc head replacement data set are obtained, stopping simulating production, and comparing all preset downtime sets corresponding to the reference change rates with the disc head replacement data set to obtain a material preparation plan with balanced production downtime times and material preparation times.
Further, in step 3, the value range of the reference change rate is 0-1.
Further, in step 3, the reference rate of change is 0.8.
Further, in step 4, before each time of comparison of the change rate, the comparison of the production remaining time is performed, and when the comparison of the production remaining time is determined that the production remaining time is greater than the disc head capacity consumption duration of the disc head with the shortest disc head capacity consumption duration in all the disc heads, the one-time comparison of the change rate is performed;
when the production residual time is smaller than the disc head capacity consumption time of the disc head with the shortest disc head capacity consumption time in all disc heads, performing secondary comparison of the change rate;
when the change rate secondary comparison is carried out, screening the remaining non-raw material depleted heads one by one, and when the fact that the remaining head allowance consumption time is smaller than the head capacity consumption time of the head with the shortest head capacity consumption time in all heads is judged, replacing the head, wherein the consumption time of the replaced head is equal to the head capacity consumption time of the head with the shortest head capacity consumption time in all heads, so that the next production stage can be directly finished without stopping;
when the consumption time of the remaining head margins is longer than the head capacity consumption time of the head with the shortest head capacity consumption time in all heads, the head capacity consumption time is kept as it is, and screening is completed until the whole production is completed;
in step 6, after the simulation of the whole production period is completed, the simulation production is stopped, and the material preparation plan comprises the arrangement of the whole production period.
Further, in step 6, the production cycle arrangement is shown by means of a Gantt chart.
According to the warp knitting machine material preparation method, the warp knitting machine material preparation plan optimization method is adopted, and before actual production, a material preparation plan of the whole production period is obtained through simulation of the whole production period; or in the actual production process, based on the current production situation of the production stage, simulating the production of the next production stage to obtain a material preparation plan of the next production stage; or in the actual production process, the production simulation of the rest production stage is carried out based on the current production state of the production stage to obtain a stock preparation plan of the rest production stage.
Further, after the stock preparation plan in the step 7 is obtained, the stock preparation plan is issued to carry out pan head warping, and the pan heads which need to be replaced are prepared in advance.
After the technical scheme is adopted, the warp knitting machine material preparation plan optimization method based on time sequence recursion has the following beneficial effects: through the simulation production of the production stage, when certain pan head raw materials are exhausted, the pan head raw materials on the rest guide bars are screened one by one, the raw material replacement times and the material preparation times are weighed according to the proportion between the current available time length of the rest raw materials and the time length of the last replacement raw materials, then suggestions of whether to replace the corresponding pan head raw materials are obtained, and finally an optimized material preparation plan is obtained.
After the technical scheme is adopted, the material preparation method has the following beneficial effects: the production personnel can determine the number of the heads needing to be prepared in the whole production period or in the next production stage in advance when the production starts, the number of raw materials loaded by each head, the shutdown times and time are reduced, a stock preparation plan is issued to carry out head warping, the heads needing to be replaced in the whole production period are prepared in advance, an efficient and accurate stock preparation plan is provided for warp knitting production, batch replacement of the heads at the optimal shutdown time is controlled, the shutdown times of a machine are reduced, and therefore the production benefit is greatly improved.
Drawings
FIG. 1 is a flow chart of the warp knitting machine stock plan optimization method of the present invention;
FIG. 2 is a schematic view of shutdown nodes of a conventional warp knitting machine stock planning method;
FIG. 3 is a schematic view of shutdown nodes of the warp knitting machine stock plan optimization method of the present invention.
Detailed Description
In order to further explain the technical scheme of the invention, the invention is explained in detail by specific examples.
Example 1
1. Optimization method
A warp knitting machine stock plan optimization method based on time sequence recursion is shown in fig. 1, and comprises the following steps:
step 1: information collection, namely acquiring raw material compositions corresponding to the order demand grey cloth and acquiring the total amount of all raw materials of the order demand grey cloth;
putting the corresponding pan head raw materials of all the constituent raw materials of the order on corresponding guide bars of a warp knitting machine, obtaining the pan head yarn feeding speed on each guide bar, obtaining the pan head capacity on each guide bar and obtaining the pan head allowance on each guide bar;
the pan head capacity refers to the maximum raw material loading capacity of the pan head, that is, the size of the pan head raw material in a full-load state (hereinafter referred to as full-load pan head). The balance of the pan head is the residual raw material which is not consumed on the pan head.
Step 2: information processing, namely calculating total production time according to the total amount of raw materials of the grey cloth required by an order, and taking the difference value between the total production time and the produced time as production residual time; in the present invention, the production remaining time includes the sum of the remaining effective production time, excluding the downtime.
Taking the ratio of the allowance of the coil on each guide bar to the corresponding feeding speed of the coil as the consumption time of the allowance of the coil;
taking the ratio of the size of the disc head capacity on each guide bar to the corresponding disc head yarn feeding speed as the disc head capacity consumption duration;
step 3: presetting a reference change rate, taking the ratio of the head margin consumption time length of each head to the head capacity consumption time length of the head with the shortest head capacity consumption time length in all heads on the guide bar as the change rate, and presetting the reference change rate. The change rate of the invention is the ratio between the available time length of the current residual raw materials and the time length of the last raw material replacement, is used for balancing the raw material replacement times and the material preparation times, is manually set according to the requirements of a production site, and can effectively reduce the material preparation times when the change rate value is smaller, namely, the change is performed when the residual quantity of each raw material is smaller, but can also increase the shutdown times, and when the change rate value is larger, namely, the change is performed when the shutdown is performed, the raw materials are replaced as much as possible to reduce the shutdown times, but the material preparation is performed for a plurality of times.
In step 3, the reference rate of change is preferably 0.8.
Step 4: performing recursion simulation, namely performing simulation production according to the yarn feeding speed of the heads on each guide bar, starting timing, and when the head allowance consumption time of the head on one of the guide bars is equal to zero, replacing the head of the corresponding guide bar to be a full-load head, and recording the stop time points, wherein the stop time points form a stop time set; recording the use time of the changed (down) disc head raw material on the guide bar, and updating a disc head change data set, a downtime set and production residual time;
meanwhile, screening all the heads which are not in residual consumption on the rest guide bars one by one, respectively comparing the change rate of the heads on the rest guide bars with the reference change rate preset in the step 3 for one time, and traversing whether the residual consumption time length/the minimum material preparation consumption time length of the rest heads is smaller than the reference change rate or not;
specifically, when one comparison is performed, when the change rate of the heads on the rest guide bars is smaller than the reference change rate, replacing the rest heads to be corresponding full heads; when the change rate of the disc heads on the rest guide bars is judged to be larger than the reference change rate, keeping the disc heads as is; therefore, the disc head with the minimum disc head capacity can be prevented from being consumed in the next production cycle, and the disc head allowance is consumed first, so that frequent shutdown can be avoided.
Recording the use time of the changed (down) disc head raw materials on each guide bar, and updating a disc head change data set and the production residual time;
step 5: performing recursive optimization, repeating the recursive simulation of the step 4 to obtain a next stop time point, calculating the head margin consumption time of the non-raw material depleted heads on the guide bars at the next time point, calculating the head capacity consumption time, comparing the change rate once again, and correspondingly updating the stop time set, the head replacement data set and the production residual time;
when the production residual time is zero, automatically ending the repeated recursion simulation process; or, after the intervention, ending the repeated recursion simulation process, specifically, repeating the step 4 for at least one time. In the invention, the number of repeated simulation can be preset according to the actual production requirement.
And displaying the production cycle arrangement through a Gantt chart mode according to the downtime set and the disc head replacement data set obtained through simulated production.
Step 6: weighing and optimizing, adjusting the preset reference change rate in the step 3, and repeating the operations in the step 4 and the step 5 to obtain an additional downtime set and a disc head replacement data set;
in the invention, the value range of the reference change rate in the step 3 is 0-1. The embodiment is specifically 0.7-0.9. And (3) repeating the operation of simulating production to obtain different Gantt charts and different production cycle arrangements.
Step 7: after the downtime set and the disc head replacement data set are obtained, stopping simulating production, and comparing all preset downtime sets corresponding to the reference change rates with the disc head replacement data set to obtain a material preparation plan with balanced production downtime times and material preparation times.
In step 7, different Gantt charts are compared to obtain a preparation plan with balanced production stop times and preparation times, and specifically, how many disc heads need to be replaced on each guide bar, how many raw materials loaded on each disc head need to be prepared, and how many preparation times are needed in total, and the whole production cycle arrangement is displayed in a Gantt chart mode.
According to the warp knitting machine material preparation method, the warp knitting machine material preparation plan optimization method is adopted, and before actual production, a material preparation plan of the whole production period is obtained through simulation of the whole production period; or in the actual production process, based on the current production situation of the production stage, simulating the production of the next production stage to obtain a material preparation plan of the next production stage; or in the actual production process, the production simulation of the rest production stage is carried out based on the current production state of the production stage to obtain a stock preparation plan of the rest production stage.
Further, after the stock preparation plan is obtained, the stock preparation plan of the next production stage, the rest production stage or the whole production period can be issued to carry out the pan head warping, and the pan heads which need to be replaced in the corresponding process are prepared in advance.
As a preferred embodiment, in step 4, before each comparison of the change rate, the comparison of the remaining production time is performed, and it is determined whether the remaining production time is longer than the minimum stock consumption time period when a certain pan head raw material is exhausted and stopped. Specifically, when the production residual time is judged to be longer than the disc head capacity consumption time of the disc head with the shortest disc head capacity consumption time in all the disc heads during the comparison of the production residual time, the change rate is compared once;
when the production residual time is judged to be smaller than the disc head capacity consumption time of the disc head with the shortest disc head capacity consumption time among all the disc heads, performing change rate secondary comparison, and traversing whether the remaining disc head allowance consumption time is smaller than the minimum stock preparation consumption time;
specifically, when the change rate secondary comparison is carried out, screening is carried out on all the heads which are used up by the rest non-raw materials one by one, when the fact that the remaining head allowance consumption time is smaller than the head capacity consumption time of the head with the shortest head capacity consumption time in all the heads is judged, namely the change rate is smaller than 1, the heads are replaced, the consumption time of the replaced heads (capacity) is equal to the head capacity consumption time of the head with the shortest head capacity consumption time in all the heads, and the next production stage can be ensured to be directly finished without stopping;
when the consumption time of the remaining head margins is larger than the head capacity consumption time of the head with the shortest head capacity consumption time in all heads, namely the change rate is more than 1, the head capacity consumption time is kept as it is, and screening is completed until the whole production is completed;
in step 6, after the simulation of the whole production period is completed, the simulation production is stopped, and the material preparation plan comprises the arrangement of the whole production period.
By adopting the technical scheme, the warp knitting machine material preparation plan optimization method based on time sequence recursion can calculate the material preparation plan and the shutdown times of the whole production period in advance before actual production starts, and particularly, the number of raw materials to be loaded on each pan head and the time point at which the operation of shutting down and replacing the pan head can be performed.
2. Optimizing results
According to the conventional production plan, raw materials on each disc head are filled to be fully loaded as shown in fig. 2, each row represents each guide bar, the sections of different filling patterns of each row represent different disc heads, the section length represents the raw materials fully loaded on each disc head on each guide bar, the connection position of the sections of different filling patterns represents the need of stopping for replacing the disc heads once, as shown in fig. 2, 14 times of stopping are required in total, after the operation of the material preparation optimization method of the invention is carried out, as shown in fig. 3, the raw materials of a plurality of disc heads can be controlled to be exhausted together at a certain time point by calculating the raw materials needed to be loaded by each disc head, and a plurality of disc heads can be replaced simultaneously once by stopping, so that the stop times are greatly reduced, and the production consistency and efficiency are improved. Only 8 shutdowns (preset to 0.8 with reference to the rate of change) were required after optimization as shown in fig. 3.
It should be noted that, the optimization method of the present invention is not only suitable for the actual production, but also suitable for the simulation of the next production stage or the rest of production stages in the actual production process, and the stock preparation plan of the next production stage is obtained by the production current situation of the present production stage and the production simulation of the next production stage. And obtaining a material preparation plan of the residual production stage by simulating the production of the residual production stage according to the current production state of the production stage. Such as: in the actual production process, in the initial state of starting up and production, other orders, the rest stock heads and the like are put on the guide bar, and then the stock heads are used for carrying out a stock preparation plan in the production stage after being exhausted.
Example 2
This embodiment differs from embodiment 1 in that: the calculation method of the optimization method is further defined.
In the embodiment, in step (1), the gray fabric information and the corresponding raw materials are obtained according to the order information i I=1, 2..m, i is a positive integer, W i The different i values of (a) correspond to different raw materials, i.e., to the i-th raw material.
Obtaining the number of meters MR of the downloaded raw material i I=1, 2..m, i is a positive integer, MR i The difference in i value of (c) indicates the number of meters of the material to be processed for each different material. The number of meters of the raw material that have been placed is the number of meters of the raw material that have been prepared for the order. The number of raw material meters down is typically the number of raw materials that the operator issues to warping.
Acquiring the capacity SF of the pan head (raw material) on each guide bar i I=1, 2..m, i is a positive integer, SF i The different i values of (i) correspond to the head capacities on the different bars (i.e. different raw materials).
Obtain the disc heads (original)Material) margin size S i I=1, 2..m, i is a positive integer, S i The difference in i values of (c) indicates the amount of the remaining material on the heads of the different bars.
Obtaining the feeding speed (consumption speed) V of the pan head on each guide bar i I=1, 2..m, i is a positive integer, V i The different values of i correspond to the speed of the feed of the heads on each of the different bars.
Further, in the step (2), the consumed time of the number of the rice of the raw material which is already down is calculated to be MRt i =MR i /V i Duration St of the end of each head margin i =S i /V i The full-load consumption time SFt of each disc head capacity i =SF i /V i The rest time Z of order production is set up, and the source SO of the raw material of the head of a pan on each guide bar is set up i =0 or 1 or 2; i=1, 2..m, wherein 0 represents a new raw material, 1 represents the number of meters of the raw material that has been discharged, and 2 represents an inventory pan head;
further, in the invention, the calculation method of the stock planning method based on time sequence recursion comprises the following steps:
s1: simulating to perform machine production, and enabling St to be performed at the beginning of production i =MRt i The consumed time of the number of meters of the raw materials is the same as the consumed time of the allowance of the pan head; in the initial state (the state of not starting up the simulation), the number of meters of the raw material is the allowance of the pan head.
S2: when t=min { St i， i=1, 2..m } i.e. after a time period T, a downtime point T is formed due to the exhaustion of one or more of the disc head stock i ；
The head for exhausting the raw material is the J-th head, namely, the source of the raw material of the guide bar is automatically changed into SO j =0, the depleted stock heads are replaced with full heads, i.e. St j =SFt j。
Simultaneously, the sources of the pan head raw materials on the guide bars are sequentially judged, and the pan head raw materials on the guide bars are used for SO i The pan head of > =1 is not changed, namely, the number of the down raw material meters on each guide bar is not changed; for SO i Disc head < 1 (i.e. SO i Pan head=0), i.e. counting the pre-added material on each barCalculating, letting SO i <1 is the Kth pan head, the margin consumption time of the Kth pan head is St k When the head with the least full capacity consumption time is the Q-th head of all heads, the head capacity SF Q The duration of consumption is SFt Q ，St k /SFt Q The ratio of (2) is the change rate, which is the rate of change, e (0, 1).
Preferably, when the rate of change of the Kth disc head<0.8, the Kth pan head material, namely St is replaced k =SFt k . Therefore, the disc head with the minimum disc head capacity can be prevented from being consumed in the next production cycle, and the disc head allowance is consumed first, so that frequent shutdown can be avoided.
And the method is set according to actual production requirements and is used for balancing production shutdown times and material preparation times.
After each shutdown and disc head replacement, updating the disc head allowance consumption time duration set { St } i I=1, 2..m } and the updated downtime set { T } is recorded i I=1, 2..m }, and a disc head replacement dataset { W } i S j ，i=1，2...m，j=1，2...m}，W i S j The j-th pan head use time of the i-th raw material is shown. And so on;
s3: when stopping for the xth time, if Z<=min{SFt Q While traversing { St } in turn i I=1, 2..m }, for the nth disc head St n <min{SFt Q Changing the pan head raw material to make St n =min{SFt Q }. The next production period can be directly finished without stopping the machine. Updating the disc head margin consumption time duration set { St i I=1, 2..m } and the updated downtime set { T } is recorded i I=1, 2..m }, and disc head replacement data set { W } i S j ，i=1，2...m，j=1，2...m}。
The above examples and drawings are not intended to limit the method of the present invention, and any appropriate changes or modifications made thereto by those of ordinary skill in the art should be construed as not departing from the scope of the present invention.
Claims (7)
1. The warp knitting machine material preparation plan optimization method based on time sequence recursion is characterized by comprising the following steps of:
step 1: information collection, namely acquiring raw material compositions corresponding to the order demand grey cloth and acquiring the total amount of all raw materials of the order demand grey cloth;
putting the corresponding pan head raw materials of all the constituent raw materials of the order on corresponding guide bars of a warp knitting machine, obtaining the pan head yarn feeding speed on each guide bar, obtaining the pan head capacity on each guide bar and obtaining the pan head allowance on each guide bar;
step 2: information processing, namely calculating total production time according to the total amount of raw materials of the grey cloth required by an order, and taking the difference value between the total production time and the produced time as production residual time;
taking the ratio of the allowance of the coil on each guide bar to the corresponding feeding speed of the coil as the consumption time of the allowance of the coil;
taking the ratio of the size of the disc head capacity on each guide bar to the corresponding disc head yarn feeding speed as the disc head capacity consumption duration;
step 3: presetting a reference change rate, taking the ratio of the head margin consumption time length to the head capacity consumption time length of the head with the shortest head capacity consumption time length in all heads on the guide bar as the change rate, and presetting the reference change rate;
step 4: performing recursion simulation, namely performing simulation production according to the yarn feeding speed of the heads on each guide bar, starting timing, and when the head allowance consumption time of the head on one of the guide bars is equal to zero, replacing the head of the corresponding guide bar into a full-load head, recording the stop time points, and forming a stop time set by the stop time points; recording the use time of the head raw material which is replaced on the guide bar, and updating a head replacement data set, a downtime set and production residual time;
simultaneously screening the non-residual depleted heads on the rest guide bars one by one, and respectively comparing the change rate of the heads on the rest guide bars with the reference change rate preset in the step 3 for one time;
when the change rate of the disc heads on the rest guide bars is smaller than the reference change rate in one comparison, replacing the rest disc heads into corresponding full-load disc heads; when the change rate of the disc heads on the rest guide bars is judged to be larger than the reference change rate, keeping the disc heads as is;
recording the service time of the replaced disc head raw materials on each guide bar, and updating a disc head replacement data set and the production residual time;
step 5: performing recursive optimization, repeating the recursive simulation of the step 4 to obtain a next stop time point, calculating the head margin consumption time of the non-raw material depleted heads on the guide bars at the next time point, calculating the head capacity consumption time, comparing the change rate once again, and correspondingly updating the stop time set, the head replacement data set and the production residual time;
when the production residual time is zero, automatically ending the repeated recursion simulation process; or ending the repeated recursion simulation process after intervention;
step 6: weighing and optimizing, adjusting the preset reference change rate in the step 3, and repeating the operations in the step 4 and the step 5 to obtain an additional downtime set and a disc head replacement data set;
step 7: after the downtime set and the disc head replacement data set are obtained, stopping simulating production, and comparing all preset downtime sets corresponding to the reference change rates with the disc head replacement data set to obtain a material preparation plan with balanced production downtime times and material preparation times.
2. The warp knitting machine stock preparation plan optimizing method as claimed in claim 1, characterized in that:
in the step 3, the value range of the reference change rate is 0-1.
3. The warp knitting machine stock preparation plan optimizing method as claimed in claim 1, characterized in that: in step 3, the reference rate of change is 0.8.
4. The warp knitting machine stock preparation plan optimizing method as claimed in claim 1, characterized in that:
in step 4, before each time of comparison of the change rate, the comparison of the production residual time is performed, and when the comparison of the production residual time is judged to be longer than the disc head capacity consumption time of the disc head with the shortest disc head capacity consumption time in all the disc heads, the one-time comparison of the change rate is performed;
when the production residual time is smaller than the disc head capacity consumption time of the disc head with the shortest disc head capacity consumption time in all disc heads, performing secondary comparison of the change rate;
when the change rate secondary comparison is carried out, screening the remaining non-raw material depleted heads one by one, and when the fact that the remaining head allowance consumption time is smaller than the head capacity consumption time of the head with the shortest head capacity consumption time in all heads is judged, replacing the head, wherein the consumption time of the replaced head is equal to the head capacity consumption time of the head with the shortest head capacity consumption time in all heads, so that the next production stage can be directly finished without stopping;
when the consumption time of the remaining head margins is longer than the head capacity consumption time of the head with the shortest head capacity consumption time in all heads, the head capacity consumption time is kept as it is, and screening is completed until the whole production is completed;
in step 6, after the simulation of the whole production period is completed, the simulation production is stopped, and the material preparation plan comprises the arrangement of the whole production period.
5. A warp knitting machine stock preparation plan optimizing method as claimed in claim 1, characterized by: in step 6, the production cycle arrangement is shown by means of a Gantt chart.
6. A warp knitting machine stock preparation method adopting the warp knitting machine stock preparation plan optimizing method as claimed in any one of claims 1 to 4, characterized in that: before actual production, a material preparation plan of the whole production period is obtained through simulation of the whole production period; or in the actual production process, based on the current production situation of the production stage, simulating the production of the next production stage to obtain a material preparation plan of the next production stage; or in the actual production process, the production simulation of the rest production stage is carried out based on the current production state of the production stage to obtain a stock preparation plan of the rest production stage.
7. A warp knitting machine stock preparation method as claimed in claim 6, characterized in that: and (3) after the material preparation plan in the step (7) is obtained, issuing the material preparation plan to carry out disc head warping, and preparing the disc head which needs to be replaced in advance.
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