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In wire-arc additive manufacturing, a wire is molten by an electrical or laser arc and deposited droplet-by-droplet to construct the desired workpiece, given as a set of two-dimensional layers. The weld source can move freely over a substrate plate, processing each layer, but there is also the possibility of moving without welding. A primary reason for stress inside the material is the large thermal gradient caused by the weld source, resulting in lower product quality. Thus, it is desirable to control the temperature of the workpiece during the process. One way of its optimization is the trajectory of the weld source. We consider the problem of finding a trajectory of the moving weld source for a single layer of an arbitrary workpiece that maximizes the quality of the part and derive a novel mixed-integer PDE-constrained model, including the calculation of a detailed temperature distribution measuring the overall quality. The resulting optimization problem is linearized and solved using the state-of-the-art numerical solver IBM CPLEX. Its performance is examined by several computational studies.
We describe the problem of re-balancing a number of units distributed over a geographic area. Each unit consists of a number of components. A value between 0 and 1 describes the current rating of each component. By a piecewise linear function this value is converted into a nominal status assessment. The lowest of the statuses determines the efficiency of a unit, and the highest status its cost. An unbalanced unit has a gap between these two. To re-balance the units, components can be transferred. The goal is to maximize the efficiency of all units. On a secondary level, the cost for the re-balancing should be minimal. We present a mixed-integer nonlinear programming formulation for this problem, which describes the potential movement of components as a multi-commodity flow. The piecewise linear functions needed to obtain the status values are reformulated using inequalities and binary variables. This results in a mixed-integer linear program, and numerical standard solvers are able to compute proven optimal solutions for instances with up to 100 units. We present numerical solutions for a set of test instances and a bi-criteria objective function, and discuss the trade-off between cost and efficiency.
The German Armed Forces provide an operation contingent to support the North Atlantic Treaty Organization (NATO) Response Force (NRF). For this purpose, a „warehouse” containing accommodations, food supplies, medical supplies, and spare parts for the systems has to be available. Such a warehouse is restricted in weight, in order to be quickly movable in an upcoming deployment situation. It should be able to supply the NRF troops for a certain amount of time (e.g., one month) without re-supply from the outside. To ensure optimal use of such a restricted warehouse, we developed the computer program „The OPtimization of a Spare Parts Inventory” (TOPSPIN) to find an optimal mix of spare parts to restore a set of systems to functionality. Each system is composed of several parts, and it can only be used again in the mission if all broken parts are replaced. The failure rate of the individual parts follows a given random distribution, and during deployment it is expected to be higher than in the homeland. Due to the stochastic nature of the problem, we generate scenarios that simulate the actual failure of the parts. The backbone of TOPSPIN is a mixed-integer linear program that determines an optimal, scenario-robust mix of spare parts and is solved using standard state-of-the-art numerical solvers. Using input data provided by the Logistikzentrum, we analyze how many scenarios need to be generated in order to determine reliable solutions. Moreover, we analyze the composition of the warehouse over a variety of different weight restrictions, and we calculate the number of repairable systems as a function of this bound.
We consider two mathematical problems that are connected and occur in the layer-wise production process of a workpiece using Wire-Arc Additive Manufacturing. As the first task, we consider the automatic construction of a honeycomb structure, given the boundary of a shape of interest. In doing this we employ Lloyd’s algorithm in two different realizations. For computing the incorporated Voronoi tesselation we consider the use of a Delaunay triangulation or alternatively, the eikonal equation. We compare and modify these approaches with the aim of combining their respective advantages.
Then in the second task, to find an optimal tool path guaranteeing minimal production time and high quality of the workpiece, a mixed-integer linear programming problem is derived. The model takes thermal conduction and radiation during the process into account and aims to minimize temperature gradients inside the material. Its solvability for standard mixed-integer solvers is demonstrated on several test-instances. The results are compared with manufactured workpieces.
We consider the problem of planning an inspection flight to a given set of waypo- ints using an inhomogeneous fleet of multirotor, battery-driven micro aerial vehicles (MAVs). Therein, two subproblems must be solved. On the one side, the detailed trajectories of all MAVs must be planned, taking technical and environmental restrictions into account and on the other side, the MAVs must be assigned to the waypoints considering their installed equipment. The goal is to visit all waypoints in minimal time. The strong interaction of the two subproblems makes it necessary to tackle them simultaneously. Several aspects are taken into account to allow realistic solutions. A two-level time grid approach is applied to achieve smooth trajectories, while the flight dynamics of the MAVs are modeled in great detail. Safety distances must be maintained between them and they can recharge at charging stations located within the mission area. There can be polyhedral restricted air spaces that must be avoided. Furthermore, weather conditions are incorporated by polyhedral wind zones affecting the drones and each waypoint has a time window within it must be visited. We formulate this problem as a mixed-integer linear program and show whether the state-of-the-art numerical solver Gurobi is applicable to solve model instances.
Since the beginning of its development in the 1950s, mixed integer programming (MIP) has been used for a variety of practical application problems, such as sequence optimization. Exact solution techniques for MIPs, most prominently branch-and-cut techniques, have the advantage (compared to heuristics such as genetic algorithms) that they can generate solutions with optimality certificates. The novel process of additive manufacturing opens up a further perspective for their use. With the two common techniques, Wire Arc Additive Manufacturing (WAAM) and Laser Powder Bed Fusion (LPBD), the sequence in which a given component geometry must be manufactured can be planned. In particular, the heat transfer within the component must be taken into account here, since excessive temperature gradients can lead to internal stresses and warpage after cooling. In order to integrate the temperature, heat transfer models (heat conduction, heat radiation) are integrated into a sequencing model. This leads to the problem class of MIPDECO: MIPs with partial differential equations (PDEs) as further constraints. We present these model approaches for both manufacturing techniques and carry out test calculations for sample geometries in order to demonstrate the feasibility of the approach.
We formulate the mission planning problem for a meet of unmanned aerial vehicles (UAVs) as a mixed-integer nonlinear programming problem (MINLP). The problem asks for a selection of targets from a list to the UAVs, and trajectories that visit the chosen targets. To be feasible, a trajectory must pass each target at a desired maximal distance and within a certain time window, obstacles or regions of high risk must be avoided, and the fuel limitations must be obeyed. An optimal trajectory maximizes the sum of values of all targets that can be visited, and as a secondary goal, conducts the mission in the shortest possible time. In order to obtain numerical solutions to this model, we approximate the MINLP by a mixed-integer linear program (MILP), and apply a state-of-the-art solver (GUROBI) to the latter on a set of test instances.
The multiple traveling salesmen problem with moving targets is a generalization of the classical traveling salesmen problem, where the targets (cities or objects) are moving over time. Additionally, for each target a visibility time window is given. The task is to find routes for several salesmen so that each target is reached exactly once within its visibility time window and the sum of all traveled distances of all salesmen is minimal. We present different modeling formulations for this TSP variant. The time requirements are modeled differently in each approach. Our goal is to examine what formulation is most suitable in terms of runtime to solve the multiple traveling salesmen problem with moving targets with exact methods. Computational experiments are carried out on randomly generated test instances to compare the different modeling approaches. The results for large-scale instances show, that the best way to model time requirements is to directly insert them into a formulation with discrete time steps.
Planning the construction of new transport routes or power lines on terrain is usually carried out manually by engineers, with no guarantee of optimality. We introduce a new approach for the computation of an optimal trajectory for the construction of new transit routes and power lines between two locations on a submanifold U _ R3 representing the topography of a terrain. U is approximatively modeled by a special weighted grid. On this grid, the shortest paths for the construction of new routes are determined, whereby we consider three optimization criteria: routes with minimum distance, routes with lowest construction costs and routes with minimum absolute altitude variations or minimum absolute gradients. Subsequently, a combination of these criteria is used to expand this problem into a multi-criteria optimization problem. A shortest path algorithm, such as the Dijkstra algorithm, is used to compute optimal compromises for the construction of new routes.
One of the standard approaches for solving time-dependent discrete optimization problems, such as the travelling salesman problem with time-windows or the shortest path problem with time-windows is to derive a so-called time-indexed formulation. If the problem has an underlying structure that can be described by a graph, the time-indexed formulation is usually based on a different, extended graph, commonly referred to as the time-expanded graph. The time-expanded graph can often be derived in such a way that all time constraints are incorporated in its topology, and therefore algorithms for the corresponding time-independent variant become applicable. The downside of this approach is, that the sets of vertices and arcs of the time-expanded graph are much larger than the ones of the original graph. In recent works, however, it has been shown that for many practical applications a partial graph expansion, that might contain time infeasible paths, often suffices to find a proven optimal solution. These approaches, instead, iteratively refine the original graph and solve a relaxation of the time-expanded formulation in each iteration. When the solution of the current relaxation is time feasible an optimal solution can be derived from it and the algorithm terminates. In this work we present new ideas, that allow for the propagation of information about the optimal solution of a coarser graph to a more refined graph and show how these can be used in algorithms, which are based on graph refinement. More precisely we present a new algorithm for solving Mixed Integer Linear Program (MILP) formulations of time-dependent problems that allows for the graph refinement to be carried out during the exploration of the branch-and-bound tree instead of restarting whenever the optimal solution was found to be infeasible. For demonstrating the practical relevance of this algorithm we present numerical results on its application to the shortest path problem with time-windows and the traveling salesman problem with time-windows.