Tsarin PLC na Dindindin suna Haifar da Boyayyun Shingaye ga Ci gaban Masana’antar Smart
Masana’antu da dama har yanzu suna dogara da tsofaffin kayan aikin PLC da aka haɗa wuri ɗaya. Wannan tsari yana kulle layukan samarwa cikin iyakar ƙarfi na dindindin. Bukatar kasuwa tana canzawa da sauri. Bayanai na masana’antu suna nuna cewa kashi 68% na masu ƙera kaya suna sake fasalin layukansu kowace shekara. PLC masu dindindin ba su iya daidaitawa sai an maye gurbinsu gaba ɗaya. Sakamakon haka, masana’antu na fuskantar awanni 8 zuwa 12 na tsayawar aiki ba a shirya ba. Haka kuma suna kashe ƙarin kashi 20–30% a kan maimaita bincike da gyaran kuskure. Waɗannan matsalolin suna hana sabunta tsarin aikin zamani a hankali a fannin automation na masana’antu. Saboda haka, PLC masu tsara-gunduma (modular) masu iya faɗaɗa ƙarfi sun zama babbar mafita ta zamani.
Allen-Bradley Modular PLCs suna Ba da Keɓantacciyar Tsarin Kayan Aiki
Rockwell Automation ta tsara dangin PLC na Allen-Bradley da cikakkiyar modularity. Dandalin yana raba na’urar sarrafawa, I/O modules, da tashoshin sadarwa. Masu amfani suna haɓaka ne kawai sashin da ake buƙata. Ba sa taɓa maye gurbin babban mai sarrafawa gaba ɗaya. Wannan salo yana rufe duk yanayin automation na masana’antar ta hanyar matakai uku na samfura. Micro800 tana tallafawa I/O points 8 zuwa 32 don sarrafa injin ɗaiɗaiku. CompactLogix tana sarrafa I/O points 32 zuwa 512 don layukan samarwa na matsakaici. ControlLogix tana sarrafa fiye da I/O points 10,000 don haɗa dukkan shuka cikin tsarin DCS. Bugu da ƙari, hot-swap modules suna rage lokacin gyaran kaya da kashi 90% a aikace a filin aiki.
Faɗaɗa Ƙarfi Gwargwadon Buƙata na Kawar da Tattalin Kuɗin da Aka Ɓata a Zuba Jarin Automation
Tsarin sayen PLC na gargajiya yana tilasta injiniyoyi su tanadi kusan kashi 30% na ƙarin ƙarfin kayan aiki. Yawancin wannan ƙarfin da aka tanada ba ya taɓa ɗaukar nauyin aiki. Sai dai yana ƙara tsadar gudanarwa na dogon lokaci ne kawai. Allen-Bradley modular PLCs suna amfani da tsarin deployment na “zero-resource-reservation”. Masana’antu suna ƙara I/O da modules na sadarwa ne kawai idan ainihin samarwa ta buƙace su. Sakamakon haka, farashin farkon zuba jari a automation yana raguwa da kashi 18–25% a matsakaita. Faɗaɗawar EtherNet/IP modular tana tallafawa fiye da haɗin na’urorin masana’antu 128 a lokaci guda. Wannan tsari yana ba da damar haɗuwa ba tare da tangarda ba tsakanin tsofaffi da sabbin raka’o’in samarwa. Haka kuma yana kawar da haɗarin rashin dacewa yayin sabunta automation na masana’antu a matakai.
Daidaiton Ecosystem yana Tabbatar da Dorewar Tsayin Rayuwar Tsarin
Daidaiton tsarin aiki kai tsaye yana ƙayyade tsawon rayuwar tsarin sarrafa masana’antu. Allen-Bradley PLCs suna haɗuwa kai tsaye da dandamalin FactoryTalk SCADA da DCS. Haka kuma suna goyon bayan manyan ka’idojin sadarwa kamar HART, Modbus TCP, da EtherNet/IP. Muhallin shirye-shirye guda ɗaya na RSLogix 5000 yana rage kuɗin koyo ga injiniyoyi sosai. Bayanai daga filin aiki sun nuna raguwar zagayen debugging na ayyuka da kashi 40%. Redundant power da network modules suna ƙara kwanciyar hankalin aiki zuwa kashi 99.98%. Saboda haka, masana’antar sarrafa tsari (process industries) da ke aiki awa 24 a rana, kwana 7 a mako za su iya dogaro da wannan tsari ba tare da katsewa ba.
Ra’ayin Kwararre: Modular PLCs suna Daidaita da Sabbin Hanyoyin Industry 4.0
Daga shekaru 15 na gogewa a duniya a fannin automation, ana ganin al’ada guda da ta fi fitowa. Automation na masana’antu yana komawa daga gina tsarin sau ɗaya kawai zuwa sabunta shi a kai a kai. Ƙananan masana’antu da na matsakaici suna fifita automation mai arha kuma mai ƙarancin haɗari. Manyan shuke-shuke kuma suna mai da hankali kan haɗin gwiwar DCS da PLC na sarrafa aiki wuri guda. Modular Allen-Bradley PLCs suna dacewa da yanayin aiki mai sauƙi har ma da manyan ayyuka. Saboda bambancensu da PLC na gama-gari, wannan dandali yana daidaita sassauci, kwanciyar hankali, da iya faɗaɗawa. Masana’antun da suka rungumi tsarin modular tun yanzu za su samu gagarumin fa’ida ta gasa na shekaru masu zuwa.
Sharuɗɗan Aiki da Aka Tabbatar tare da Sakamakon da Aka Auna
Sabunta Samar da Abinci & Sha a Batches
Wani babban gurin burodi na yanki ya sabunta layuka biyu na gauraya kayan hadi da marufin kaya. Injiniyoyi sun maye gurbin PLC na dindindin da tsarin sarrafawa na modular CompactLogix. Sun ƙara analog modules don sarrafa zafin jiki da kwarara a ainihin lokaci. Ƙarfin samarwa na kullum ya tashi daga fam 14,000 zuwa fam 30,000. Adadin kayayyakin da suka cika ƙa’ida ya ƙaru daga kashi 92% zuwa 99.5%. Maganin ya ceci sama da dala $170,000 a kowace shekara a kuɗin makamashi da ma’aikata.
Canjin Hankali (Intelligent Transformation) na Layin Hada Motoci
Wani masana’antar kera motoci a Arewacin Amurka ta sabunta bita na jikin mota. Ta girka ControlLogix PLCs don daidaita aiki a sel ɗin robot 48. Faɗaɗa I/O na modular ta dace da sabbin daidaitawa guda shida a tsarin haɗa motar. Tsarin ya cimma daidaitaccen sarrafawa na lokaci guda ga robots da conveyor belts. Ingancin aikin layi ya ƙaru da kashi 22%. Lokacin tsayawar aiki ya ragu da kashi 25%. Kuskuren samarwa a cikin batches ya faɗi ƙasa da 0.03% bayan ingantawa.
Shirin Distributed Control na Rijiyoyin Man Fetur & Gas
Wani filin mai a Arewacin Amurka ya rungumi ControlLogix PLCs na modular don sarrafa rijiyoyi. An gudanar da aikin a matakai gwargwadon ainihin girman aikin hako mai. Wannan ya kauce wa zuba jari tun farko a kayan aikin da ke da mafi girman ƙayyadadden ƙarfi. Tsarin modular da ake iya sake saiti a hanya (dynamic configuration) yana daidaitawa da canjin ƙa’idojin aiki na rijiyoyi. Abokin ciniki ya rage zuba jari na farko a kayan aikin da kashi 23% a mataki na farko. Ingancin kula da tsarin ya ƙaru da kashi 50% ta hanyar gano matsala da gyarawa cikin modules.
Sake Fentawa Don Ajiye Makamashi a Tsarin Ruwan Gari
Wani tashar samar da ruwan sha ta birni ta girka Allen-Bradley Micro800 modular PLCs. Tsarin yana sa ido kan matsin lamba a hanyar bututun ruwa kuma yana daidaita saurin famfo ta hanyar PID control. Yana cimma samar da ruwa da matsin lamba mai daidaito. Jimillar cin gashin makamashin na’urorin famfo ya ragu da kashi 25%. Nauyin aikin duba kayan aiki da hannu na kullum ya ragu da kashi 60%.
Automation na Batch Reactor na Sinadarai
Wani mai kera sinadarai na musamman ya sabunta batch reactors guda uku da CompactLogix PLCs. Modular I/O ta ba da damar daidaitaccen sarrafa zafin jiki da matsin lamba ga kowane reactor. Lokacin kammala kowane batch ya ragu da kashi 18%. Samuwar amfanin kaya (product yield) ta ƙaru da kashi 12%. Lokacin tsayawar reactor ba a shirya ba ya ragu da kashi 35% cikin watanni shida.
Gyaran Layin Sarrafa Karafa
Wani kamfanin ƙarfe ya maye gurbin tsohon PLC na dindindin da tsarin ControlLogix modular. Tsarin yanzu yana sarrafa yankunan dumama 12 da tashoshin sanyaya huɗu a lokaci guda. Cin gashin makamashi a kowace ton na ƙarfe ya ragu da kashi 15%. Ƙarfin samarwa ya ƙaru da kashi 20%. Kuɗin kiyayewa ya ragu da kashi 40% saboda amfani da hot-swappable I/O modules.
Rubutun: Gu Jinghong, injiniyan automation na masana’antu da ya ƙware a mafifitan PLC & DCS ga masana’antar mai, gas da sinadarai.
