Two-Dimensional Cut Plan Optimization for Cutter Suction Dredgers
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When referring to this work, full bibliographic details including the author, title, awarding institution and date of the thesis must be given e.g. AUTHOR (year of submission) "Full thesis title", University of Southampton, name of the University School or Department, PhD Thesis, pagination http://eprints.soton.ac.uk UNIVERSITY OF SOUTHAMPTON FACULTY OF ENGINEERING, SCIENCE AND MATHEMATICS School of Civil Engineering andtheEnvironment Two-dimensional Cut Plan Optimization for Cutter Suction Dredgers Marcus J. M. deRuyter A dissertation submittedfor the degree of Doctor of Philosophy April 2009 UNIVERSITY OF SOUTHAMPTON ABSTRACT FACULTY OF ENGINEERING, SCIENCE AND MATHEMATICS School of Civil EngineeringandtheEnvironment Doctor of Philosophy Two-dimensional Cut Plan Optimization for Cutter Suction Dredgers by M.J.M deRuyter Optimal cut plans for cutter suctiondredgers aim tomaximizeoperational efficiency. Maximizingoperational efficiency involves minimizationof stoppagetime resultingfrom non-productivedredger movements. Toautomateasystematic search for optimal two dimensional cut plans for cutter suctiondredgers twomodels withanadaptivesimulated annealing-basedsolution approach weredeveloped. Thefirst model, the dredgecut nestingmodel, optimizes irregular stock cuttingproblems wherestencils represent dredgecuts andsheets represent dredgingareas. Stencils are collections of unit dredge cuts withdimensions relatedtoan effective cuttingwidth which can beachieved withthe cutter suctiondredger considered. Theobjectives of the dredge cut nestingmodel are tomaximizesheet coverageandtominimizestencil overlap. Centroids of unit dredgecuts of final nest layouts areextractedandused as gridnodes in thesecond model. Thesecondmodel, the dredger routingmodel, optimizes asymmetric travelling salesperson problems withturningcosts. Theobjectives of thedredger routingmodel are tominimizetotal route lengthand sum of turningangles, andto maximizeaveragelink length. A link consists of twoor more routeedges whicharealignedwitheachother to withinspecified limits. A significant result of this researchis that an engineeringapplication of both models showed that two-dimensional cut plans for cutter suctiondredgers can besystematically optimized and that dredger routes withminimum turningcosts can be found. However, results alsoshowed that thedredger routingmodel is not yet sophisticatedenoughtofind cut plans for cutter suctiondredgers for whichoverall project execution timeis minimal. List of Contents List of Contents...................................................................................................................i List of Figures................................................................................................................... iii List of Tables .....................................................................................................................v List of Symbols ................................................................................................................ vii Author’s Declaration ........................................................................................................ xii Acknowledgements......................................................................................................... xiii 1 Introduction ...................................................................................................................1 2 Background...................................................................................................................3 2.1 Cutter Suction Dredger Operation ..........................................................................3 2.2 ResearchProblem..................................................................................................8 3 LiteratureReview ........................................................................................................12 3.1 Earthwork Optimization ........................................................................................12 3.2 DredgingOptimization..........................................................................................19 3.3 NestingProblems.................................................................................................26 3.3.1 Applicability of Cutting andPacking Research.............................................26 3.3.2 Diversity of Real-worldCuttingand PackingProblems................................26 3.3.3 Complexity of CuttingandPackingProblems..............................................27 3.4 RoutingProblems.................................................................................................37 3.5 OptimizationMethods...........................................................................................40 3.5.1 Stock CuttingProblem Optimization ............................................................41 3.5.2 TravellingSalesperson Problem Optimization .............................................43 3.5.3 Genetic Algorithms......................................................................................47 3.5.4 Simulated AnnealingAlgorithms..................................................................50 4 Hypothesis, ObjectiveandScope................................................................................63 5 Materials andMethods................................................................................................64 5.1 Experimental Equipment ......................................................................................64 5.2 DredgeCut NestingModel ...................................................................................64 5.3 Dredger RoutingModel ........................................................................................68 5.4 Experimental Design ............................................................................................75 5.4.1 Model Validation..........................................................................................75 5.4.2 Variationof NestingProblem Variables .......................................................79 5.4.3 Variationof RoutingProblem Variables.......................................................84 5.4.4 EngineeringApplication...............................................................................86 6 Results andDiscussion...............................................................................................91 6.1 Validationof Dredge Cut Nesting Model...............................................................91 6.2 Validationof Dredger Routing Model....................................................................99 6.3 DredgeCut Nesting– RelaxedSheet Boundaries..............................................103 i 6.4 DredgeCut Nesting– ReducedSheet Areas .....................................................109 6.5 DredgeCut Nesting– ReducedSheet Areas for SquareStencils.......................118 6.6 DredgeCut Nesting– Cost Penalty Increase for SquareStencils.......................126 6.7 Dredger Routing–64 NodeSquareGridProblem..............................................130 6.8 Dredger Routing–256 NodeSquareGridProblem............................................133 6.9 DredgeCut Nesting– Engineering Application...................................................137 6.10 Dredger Routing–EngineeringApplication....................................................142 7 Conclusion ................................................................................................................155 8 Future Work ..............................................................................................................157 Appendix A –Mass Haul Diagram –Worked Example ..................................................160 Appendix B –Daily Report Cutter SuctionDredger “Cyrus” ...........................................164 Appendix C –MainCharacteristics Cutter Suction Dredger “Cyrus” ..............................165 Appendix D –Sheets EngineeringApplicationDredgeCut Nesting ...............................166 Appendix E –Preliminary EngineeringApplicationDredgeCut Nesting.........................167 Appendix F –Final Nest Layout EngineeringApplication...............................................168 Appendix G –Route Nodes Engineering Application .....................................................169 References ....................................................................................................................170 ii List of Figures Figure1.1 Medium sizecutter suctiondredger ..................................................................1 Figure2.1 Overview medium sizecutter suction dredger...................................................3 Figure2.2 Routineinspectionof a sand/clay cutterhead....................................................4 Figure2.3 Typical cutterheadswingtrack..........................................................................5 Figure2.4 Singlecut dredgingproject................................................................................8