Yadda Rockwell Allen-Bradley Smart Drives ke Kawar da Lalacewar Control Link a Hanyar Sarrafa Masana’antu
Sau da yawa tsarin sarrafa masana’antu ta atomatik suna fama da asarar sigina da ba a iya gani. Wannan lalacewa kai tsaye tana rage ribar aiki. Masu masana’antu da yawa suna mai da hankali ne kawai kan amfani da makamashin motoci. Suna yi watsi da ɓarnar da ke faruwa a cikin hanyoyin sadarwar PLC, DCS, da na’urar tuƙi (drive).
Asarar Makamashi da Ba a Gani ba a Tsarin PLC da DCS na Gargajiya
Tsarin sarrafawa na gargajiya suna dogara da isar da sigina ta yadda aka watsar da cibiyar. Sauya yarjejeniya iri-iri da wayoyi da aka baza a ko’ina suna haifar da raguwa da lalacewar sigina yayin tafiya mai nisa. Dogayen igiyoyi suna haifar da asarar zafi (thermal loss) da tsangwamar filin lantarki (EMI). Bayanai na masana’antu suna nuna cewa tsoffin hanyoyin control link suna ɓatar da makamashi daga 15% zuwa 25% a duk shekara. Waɗannan asarori da ba a gani ba suna ƙara jimillar kuɗin mallakar tsarin (TCO). Haka kuma suna tayar da hankalin daidaiton masana’antu masu buƙatar daidaito. Saboda haka, inganta ingancin control link ya zama muhimmin ɓangare na sabunta masana’antu masu hankali (smart factory).
Tsarin Hadaɗɗen Na’urorin Rockwell Automation don Control mai Ƙarancin Asara
Rockwell Automation ta sake ƙera kayan aikin drives don tsarin sarrafawa da aka haɗa wuri guda. Jerin Allen-Bradley Kinetix 5500 da Kinetix 5700 suna tallafawa EtherNet/IP na asali. Suna sadarwa kai tsaye da dandamalin ControlLogix PLC ba tare da gateways ba. Wannan ƙira tana kawar da duk tsaka-tsakin sauya yarjejeniya. Tsarin haɗa igiya guda ɗaya yana rage aikin shimfiɗa wayoyi a wurin da kusan 60%. Ingantaccen rufaffiyar madauwari (closed-loop control) yana rage jinkirin martanin tsarin zuwa ƙasa da microseconds 125. Daidaita mota da drive daidai yana kawar da ƙarin fitar da iko da ba a buƙata. A sakamakon haka, masana’antu suna samun ƙarancin asara a control link.
Ka’idojin Fasaha da ke Bayan Ingancin Makamashi na Smart Drives
Na’urorin tuƙi na masana’antu na gargajiya suna amfani da tambayar bayanai ta hanyar passive polling don mu’amala da PLC. Maimaita neman bayanai cikin makance yana cinye bandwidth da makamashi fiye da kima. Allen-Bradley smart drives suna amfani da fasahar daidaita zagaye (cycle synchronization) mai aiki. Suna daidaita bayanan motsi da lokacin aiki na PLC a ainihin lokaci. Tsarin regenerative bus da aka gina a ciki yana maido da makamashin birki na motsi (kinetic energy). A manyan aikace-aikacen masana’antu, wannan yana rage asarar makamashi a control link har zuwa 40%. Inganta tsarin gini kuma yana rage EMI, yana tabbatar da isar da sigina mai ɗorewa a nesa mai tsawo.
Fahimtar Marubuci: Injiniyoyi da dama har yanzu suna auna inganci ne kawai a kan shaft ɗin mota. Wannan yana watsi da asarar da ke cikin isar da sigina da sauya yarjejeniya. Dabarar Rockwell tana maida auna inganci zuwa matakin tsarin gaba ɗaya, wanda yafi dacewa ga masana’antu na zamani.
Dalilin da ya sa Inganta Control Link a Matakin Tsarin Gaba ɗaya Har Yanzu ke da Gibin Masana’antu
Masana’antar sarrafa masana’antu ta dade tana mai da hankali kan ajiye makamashin mota a ƙarshen layi. Inganta asarar control link a matakin tsarin gaba ɗaya ba a ba shi kulawa sosai. Bincike ya danganta kimanin 30% na tsayuwar aiki ba ta shirya ba da lalacewar sigina. Tsarin drive da aka haɗa na Rockwell yana magance wannan gurbataccen tsarin kai tsaye. Yana haɗa motion control, dawowar sigina (feedback), da sarrafa makamashi a kan hanya (network) guda. Wannan ƙira ta dace da salo na tsarin sarrafawa na Industry 4.0 masu sauƙi kuma masu haɗewa. Yana samar da daidaiton aiki da rage kuɗi mai ɗorewa lokaci guda.
Aikace-aikacen Masana’antu da Aka Tabbatar tare da Sakamakon Da Aka Auna
Matsayin Nazari na 1: Layin Buga Karfe na Motoci (Automotive Hydraulic Stamping Line)
Wani masana’antar sassa na motoci na mataki na biyu a Arewacin Amurka ta inganta dakin buga karfen ta. Ta maye gurbin tsoffin drives masu zaman kansu da Kinetix 5700 intelligent drives. Tsarin regenerative bus yana maido da makamashin birki da ke maimaituwa akai-akai. Bayanai na karɓar aiki daga ɓangare na uku sun tabbatar da ragin amfani da makamashi a control link da 40%. Lokutan tsayuwar aiki da ke da nasaba da sigina sun ragu da 35% a duk shekara. Masana’antar ta ajiye dala $620,000 a shekarar farko kaɗai.
Matsayin Nazari na 2: Layin Marufi Mai Ƙafafu da yawa a Masana’antar Abinci
Wata babbar masana’antar sarrafa abinci ta cikin gida ta sabunta layukan sarrafa ta ta atomatik. Ta girke Kinetix 5500 drives tare da tsarin Rockwell PLC. Haɗin hanyar EtherNet/IP ɗaya ya warware duk rikice-rikicen sigina masu amfani da yarjejeniyoyi daban-daban. Ci gaba da sa ido a filin ya nuna raguwa da 21% a asarar makamashi na tsarin sarrafawa. Kuɗin dubawa da kiyayewa na wayoyi na shekara-shekara sun ragu da 58%. Lokacin dawowa da kudin zuba jari bai wuce watanni 11 ba.
Matsayin Nazari na 3: Sarrafa Dandamalin Rijiyoyi a Masana’antar Makamashi
Wani mai aiki na yanki a fannin makamashi ya girke sama da 130 na’urorin Allen-Bradley regenerative drives. Tsarin ya cimma kimanin 17% na maido da makamashi a wurin tare da 95% na sake amfani da shi. Cikakken aiwatarwa ya samar da kusan dala miliyan $3 na ajiye kuɗin aiki a kowane wata. Tsayuwar aiki ba ta shirya ba saboda matsalolin sigina ta ragu da 42%.
Matsayin Nazari na 4: Layin Jigilar Kayan Karfe Mai Ci gaba
Wani mai sarrafa karafa na Turai ya sabunta tsoffin drives 28 zuwa na’urorin Kinetix 5700. Amfanin makamashi na control link ya ragu da 33%. Kuskuren na’urorin gano sigina (sensors) da EMI ke haifarwa sun ragu da 67%. Layin ya kai samun aiki (uptime) na 99.5% karo na farko cikin shekaru biyar.
Sabbin Hanyoyin Smart Drive na Gaba da Hankalin Kai (Intelligent Autonomy)
Makomar sarrafa masana’antu ta atomatik tana buƙatar haɗuwa, ƙarancin asara, da hankalin kai. Cikakkiyar haɗuwar PLC da drives za ta maye gurbin kayan aiki na gargajiya da aka rarraba. Sabbin drives na gaba za su ƙunshi edge computing da gano kura-kurai a ainihin lokaci. Za su tallafa gano asarar link kai tsaye da daidaita sigogi da kansu a waya. Waɗannan ingantattun fasahohi masu hankali za su ƙara rage kuɗin aiki na hannu da ɓarnar makamashi da ba a iya gani.
Hasashen Marubuci: Sauyawa daga passive polling zuwa active synchronization farkon mataki ne kawai. A nan gaba, drives za su iya hango lalacewar link kafin ta shafi samarwa. Wannan yana mayar da sarrafa masana’antu daga gyaran da ke bin matsala zuwa ainihin ingantawar hasashen matsala (predictive optimization).
Yanayin Aikace-aikace na Smart Drives a Aiki
- Layukan buga karfe da kera motoci (automotive stamping and assembly) da ke da yawan farawa-da-tsayawa
- Layukan marufi masu saurin gaske da ke buƙatar daidaita ƙafafu da yawa (multi-axis synchronization)
- Sarrafa dandamalin rijiyoyi da bututun mai/gaas masu nisa da dogayen igiyoyi
- Samar da abinci da abin sha da ke buƙatar wanke-wanke (washdown) da sahihanci
- Tsarin jigilar kaya (material handling) da ke buƙatar regenerative braking
- Matatun buga karfe da ke da kaya masu nauyi da jujjuyawa (high inertial loads)
Ya rubuta Gu Jinghong, injiniyan sarrafa masana’antu na musamman a maganganun PLC & DCS don masana’antar mai, gas da sinadarai.
