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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.
In wire-arc additive manufacturing (WAAM), the desired workpiece is built layerwise by a moving heat source depositing droplets of molten wire on a substrate plate. To reduce material accumulations, the trajectory of the weld source should be continuous, but transit moves without welding, called deadheading, are possible. The enormous heat of the weld source causes large temperature gradients, leading to a strain distribution in the welded material which can lead even to cracks. In summary, it can be concluded that the temperature gradient reduce the quality of the workpiece. We consider the problem of finding a trajectory of the weld source with minimal temperature deviation from a given target temperature for one layer of a workpiece with welding segments broader than the width of the weld pool. The temperature distribution is modeled using the finite element method. We formulate this problem as a mixed-integer linear programming model and demonstrate its solvability by a standard mixed-integer solver.
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 present a general numerical solution method for control problems with PDE-defined state variables over a finite set of binary or continuous control variables. We show empirically that a naive approach that applies a numerical discretization scheme to the PDEs (and if necessary a linearization scheme) to derive constraints for a mixed-integer linear program (MILP) leads to systems that are too large to be solved with state-of-the-art solvers for MILPs, especially if we desire an accurate approximation of the state variables. Our framework comprises two techniques to mitigate the rise of computation times with increasing discretization level parameters:
First, the linear system is solved for a basis of the control space in a preprocessing step. Second, certain constraints are just imposed on demand via the IBM ILOG CPLEX feature of a lazy constraint callback. These techniques are compared with an approach where the relations obtained by the discretization of the continuous constraints are directly included in the MILP. We demonstrate our approach on two examples: modeling of the spread of wildfire and the mitigation of water contamination. In both examples the computational results demonstrate that the solution time is significantly reduced by our methods. In particular, the dependence of the computation time on the size of the spatial discretization of the PDE is significantly reduced.