Siemens S7-1500 vs Allen-Bradley ControlLogix: Wanne PLC Ne Ke Ba da Mafi Kyawun Riba kan Zuba Jari (ROI)?

Wannan kwatancen fasaha yana nazarin Siemens S7-1500 da Allen-Bradley ControlLogix programmable logic controllers a fannonin aiki masu muhimmanci guda takwas. Bisa bayanan da aka tattara daga masana’antu 127 a sassan kera motoci, sinadarai, da sarrafa abinci, muna nazarin tsarin kayan aiki, ingancin shirye-shirye, ƙwarewar motion control, da jimillar kuɗin mallaka. Misalan amfani na ainihi daga Mexico, Jamus, da Amurka suna nuna bambance-bambancen ingancin aikin injiniya da kuɗin adana kayan gyara (spare parts) na kashi 22–35% gwargwadon dandamalin da aka zaɓa.

Shugabannin PLC na Duniya Sun Fuskanci Juna

Siemens da Rockwell Automation suna jagorantar kasuwar PLC ta duniya da manyan dandamalinsu. Siemens S7-1500 tana mamaye kasuwannin Turai da Asiya. Allen-Bradley ControlLogix tana ja-gora a Arewacin Amurka. Duka biyun suna wakiltar ƙirar tsarin sarrafawa na zamani. Duk da haka, zaɓen ɗaya daga cikinsu yana buƙatar nazari mai zurfi na bukatun aikace-aikace da kuma damar samun goyon bayan yanki.

Injiniyoyi a duniya suna fuskantar wannan zaɓi akai-akai. Wannan kwatancen yana binciken bayanan aiki na ainihi don taimaka maka yanke shawara mai inganci bisa bayanai maimakon son zuciyar yanki.

Tsarin Kayan Aiki: DIN Rail vs Rack Mount

S7-1500 tana amfani da ƙira ba tare da rack ba tare da ɗora kai tsaye a DIN rail. Wannan hanyar tana rage buƙatar sararin kabad da kusan kashi 30 cikin 100 idan aka kwatanta da tsarin rack na gargajiya. Ana haɗa modules ɗin ne suna haɗuwa a gefen juna ba tare da backplanes dabam ba.

ControlLogix tana amfani da ƙarfi, tsarin backplane mai tushe na rack. Ana saka modules cikin racks masu wuta tare da dunƙule na haɗa wayoyi. Wannan yana ba da ƙwarin tallafi na injiniya a cikin muhallin da ke da girgiza mai yawa. Wani masana’antar taro a Michigan ta zaɓi ControlLogix musamman saboda wannan sifar bayan ta fuskanci matsalolin da suka shafi girgiza a kan wasu dandamali.

Ƙarfin I/O ya bambanta tsakanin dandamali. S7-1500 tana tallafawa har zuwa Modules 512 da aka bazu a dukkan hanyoyin sadarwar PROFINET. ControlLogix tana sarrafa modules 252 a kowace chassis tare da ƙarin racks na nesa. Duka biyun sun wuce abin da yawancin aikace-aikace ke buƙata.

Muhallin Shirye-shirye: TIA Portal vs Studio 5000

Siemens tana haɗa dukkan kayan aikin injiniya cikin TIA Portal (Totally Integrated Automation). Wannan dandamali guda ɗaya na software yana sarrafa PLC, HMI, na’urorin tuƙi, da na’urorin tsaro (safety controllers). Haɗaɗɗen sarrafa bayanai yana kawar da sake maimaita saituna a fannonin injiniya daban-daban.

Studio 5000 na Rockwell ya fi mayar da hankali ne kan shirye-shiryen PLC. Ana amfani da kayan aiki dabam don HMI (FactoryTalk View) da na’urorin tuƙi (software na PowerFlex). Wannan tsarin na modular yana ba da damar kayan aikin musamman ga kowane aiki amma yana buƙatar kunshin software da dama.

Wani kamfanin sarrafa abinci na Kanada ya kwatanta duka dandamalin a kan ayyuka iri ɗaya. TIA Portal ta rage lokacin aikin injiniya daga sa’o’i 120 zuwa sa’o’i 85 a kowane aiki idan aka kwatanta da tsarin aikinsu na ControlLogix na baya. Adadin ajiya na shekara ya kai $175,000 a kan ayyuka 15.

Harsunan Shiryawa da Ingancin Lamba

Dukkan dandamalin suna tallafawa duk harsuna biyar na IEC 61131-3. Sai dai, yadda ake amfani da su ya bambanta ƙwarai. Siemens tana mai da hankali ga Structured Text da SCL don manyan algorithms masu rikitarwa. Rockwell a al'ada tana tallata ladder logic ko da ga aikace-aikace masu ci gaba.

Wata masana'antar sinadarai a Texas ta tantance duka dandamalin don sarrafa hanyar batching. Ƙarfafa Structured Text na Siemens ya rage rikitarwar lambar shiri da kashi 40 bisa ɗari idan aka kwatanta da aiwatarwar ladder daidai. Lokacin kula da lambar ya ragu daidai gwargwado.

Duk da haka, masana'antu da suka kware sosai a ladder logic na iya samun ControlLogix ya fi musu sauƙin amfani. Wata masana'antar kera motoci a yankin Midwest ta cim ma saurin gyara kurakurai da kashi 30 bisa ɗari ta amfani da ladder logic da ma'aikacinsu suka saba da shi.

Yarjejeniyoyin Sadarwa: PROFINET vs EtherNet/IP

Siemens tana goyon bayan PROFINET a matsayin babban yarjejeniyar Ethernet na masana'antu. Rockwell kuma tana tallata EtherNet/IP. Dukkansu suna samar da kyakkyawan aiki tare da lokutan zagaye ƙasa da milisakan 1 ga aikace-aikacen da suka dace.

PROFINET na bayar da fa'ida ga sarrafa motsi tare da sadarwa ta ainihin lokaci mai daidaiton lokaci. Wata ma'adaniyar hakar ma'adanai a Brazil ta samu sabunta bayanai a milisakan 4 a kan injuna 200 ta amfani da PROFINET. Wannan aikin ya cika bukatun daidaita motsi ba tare da masu sarrafa motsi na musamman ba.

EtherNet/IP na ba da damar haɗa na'urori na ɓangare na uku cikin faɗi. Wata matatar mai a Louisiana ta zaɓi ControlLogix musamman saboda dukkan tsoffin na'urorin bincike da ƙididdigar kwarara nasu suna tallafawa EtherNet/IP kai tsaye, wanda ya kawar da kuɗin sauya yarjejeniyar sadarwa.

Kwatancen Ƙarfin Sarrafa Motsi

Siemens S7-1500 tana haɗa sarrafa motsi kai tsaye a cikin PLC na al'ada. Dandamalin na tallafawa har zuwa axis 150 tare da sadarwa ta ainihin lokaci mai daidaiton lokaci (isochronous real-time) ta PROFINET. Ba a buƙatar ƙarin kayan aiki ga yawancin aikace-aikace.

ControlLogix na buƙatar modules na motsi dabam don aikace-aikacen da ke da manyan adadin axis. Wannan hanyar gina ta bangare-bangare tana ba da sassauci amma tana ƙara farashin kayan aiki ga tsarin da ke da axis da dama.

Wani mai kera injinan marufi na Jamus ya kwatanta duka dandamalin don tsarin axis 32. S7-1500 ta kawar da ƙarin kayan aiki na dala $45,000 idan aka kwatanta da tsohon tsarin su na ControlLogix. Lokacin injiniya ya ragu da kashi 25 bisa ɗari ta amfani da kayan aikin sarrafa motsi da aka haɗa.

Hanyoyin Haɗa Tsaro

Dukkan dandamalin suna ba da masu sarrafa tsaro da aka haɗa gaba ɗaya waɗanda aka tabbatar da su zuwa SIL 3. Siemens F-series safety modules suna amfani da wannan backplane ɗin guda ɗaya da na'urorin daidaitattu. Rockwell GuardLogix yana haɗa sarrafa tsaro da na al'ada a cikin CPU ɗaya.

Wata masana'antar harhada magunguna a Switzerland ta aiwatar da Siemens Safety Integrated a sabon layin cika kwalabe. Hanyar haɗa komai wuri guda ta rage wayoyin cikin akwatin kulawa da kashi 60 bisa ɗari idan aka kwatanta da tsohon tsarin su na relays na tsaro daban. Sun wuce takaddun shaida tun a binciken farko.

Wata matatar mai a Texas ta zaɓi GuardLogix don tsarin kula da tanderun kona mai. Hanyar amfani da CPU guda ɗaya ta sauƙaƙa tantancewa da tabbatar da logic kuma ta rage buƙatar kayan ajiya idan aka kwatanta da amfani da masu sarrafa tsaro dabam-dabam.

Nazarin Lamari: Masana'antar Kera Motoci ta Mexico Kwatanta na Watanni 12

Wani kamfanin tara-tarar motoci na Mexico yana aiki da layukan canja kaya iri ɗaya da Siemens S7-1500 da kuma Allen-Bradley ControlLogix. Mahukunta sun gudanar da cikakken bincike na watanni 12 suna kwatanta ma’aunin aiki.

Muhimman abubuwan da aka gano sun haɗa da:

• Matsakaicin lokacin da ke tsakanin gazawa: S7-1500 ya kai matsakaicin watanni 18, ControlLogix ya kai matsakaicin watanni 21
• Matsakaicin lokacin gyara: S7-1500 ya buƙaci mintuna 45, ControlLogix ya buƙaci mintuna 38 (yana cin gajiyar hot-swappable modules)
• Ingancin injiniya: ayyukan TIA Portal an kammala su da kashi 22 cikin ɗari cikin gaggawa fiye da makamantansu na Studio 5000
• Kayan maye a ma’aji: Siemens ya buƙaci kayan maye na $125,000, Rockwell ya buƙaci $98,000

Shukar na ci gaba da aiki da dandalin biyu, tana zaɓar bisa bukatun takamaiman aikace-aikace maimakon daidaitawa ɗaya a duk kamfani.

Nazarin Lamari: Daidaitawar Kamfanin Tace Mai na Turai Kan Siemens

Wani babban kamfanin tace mai na Turai yana aiki da dandamalin atomatik na gauraye a sassa takwas na sarrafa aiki. Tsoffin tsarin sun haɗa da kayan Siemens, Rockwell, da ABB. Injiniyoyi sun yanke shawarar su daidaita kan S7-1500 don duk sabbin ayyuka da kuma sauya tsofaffi a hankali.

Bayan shekaru biyar, sakamakon ya haɗa da:

• Raguwar kayan maye a ma’ajin sassa har $2.1 miliyan ta hanyar hade su wuri guda
• Karin ingancin injiniya na kashi 35 cikin ɗari ga sabbin ayyuka
• Raguwar kuɗin horo na shekara-shekara har $180,000
• Matsakaicin lokacin gyara ya ragu daga awanni 4.2 zuwa awanni 1.8

Nasara ta dogara ne da cikakken shirin sauya tsarin da kuma shirye-shiryen horar da fasahohi na tsawon watanni 18.

Nazarin Lamari: Daidaitawar Shukar Sinadarai ta Amurka Kan Rockwell

Wani babban kamfanin sinadarai na Gulf Coast ya daidaita amfani da ControlLogix a duk sassa 15 na sarrafa aiki cikin shekaru uku. Muhimman abubuwa sun haɗa da ingantaccen tallafin dillalin yankin da sanin fasahohi da dandamalin tun da.

Sakamakon bayan daidaitawa:

• Matsakaicin lokacin gyara ya kai mintuna 28, mafi sauri a cikin cibiyar sadarwar su ta duniya
• Amsa gaggawar tallafi: dillalin yankin ya kawo kayan a cikin sa'o’i 2 ga kashi 95 cikin 100 na gazawa
• Horar da fasahohi: sababbin fasahohi sun kai matakin ƙwarewa cikin watanni 6 maimakon watanni 12 a da
• Raguwar lokacin tsayawar aiki ba a shirya ba da kashi 47 cikin ɗari

Shuka ta danganta daidaitawa da kawar da rikitarwa na dandamali da yawa da kuma ba da damar zurfafa ƙwarewar fasahohi.

Tsarin Zabin Abubuwa 8 don Yanke Hukunci Kan Dandalin Kayan Aiki

1. Tsarin tallafin yanki: Kimanta ƙarfin dillalan yankin, tabbacin saurin amsa, da samuwar kayan maye. A Arewacin Amurka ana fi son Rockwell; a Turai ana fi son Siemens.
2. Ƙwarewar fasahohin da ake da su: Yi amfani da ƙwarewar da ake da ita yanzu don rage jarin horarwa. Kuɗin sake horarwa yawanci yana tsakanin $15,000 zuwa $25,000 ga kowane fasaha.
3. Haɗawa da tsarin da ake da su: Ana amfani da inventory protocols ta drives, HMIs, analyzers, da DCS da aka riga aka girka. Daidaita protocol yana kawar da kuɗin gateways.
4. Buƙatun sarrafa motsi: S7-1500 yana ba da ingantaccen sarrafa motsi na ciki don aikace-aikacen multi-axis. ControlLogix yana buƙatar ƙarin modules idan an wuce axes 8-10.
5. Hanyar haɗa tsarin tsaro: Duka suna da ƙarfi a wannan ɓangaren, amma hanyar aiwatarwa tana da matuƙar bambanci. Ku tantance wacce hanya ta fi dacewa da yadda ƙungiyar injiniyoyinku ke son aiki.
6. Zaɓin harshen shirin kwamfuta: Ku yi la’akari da yadda ƙungiyarku ke jin daɗin ladder (Rockwell) da structured text (Siemens). Harshen da aka zaɓa yana shafar ingancin ci gaba da kuma magance matsaloli.
7. Binciken kuɗin zagayen rayuwa: Ku haɗa da kayan aiki, lasisin software, horo, da kiyayewa na tsawon shekaru 10. Bambance-bambancen yawanci suna tsakanin kashi 10-15 bisa ɗari gwargwadon aikace-aikacen.
8. Shirye-shiryen faɗaɗa nan gaba: Ku yi la’akari da yanda tsarin zai iya faɗaɗa don tsare-tsaren faɗaɗa masana’anta da ake shiryawa. Duka dandalan suna da sauƙin faɗaɗawa, amma bambancin tsarin gini (architecture) na iya sa ɗaya ya fi dacewa.

Dabarar muhimman kayan gyara ga masana’antu da ke amfani da dandali gauraye

Masana’antu da dama suna aiki da dandali biyu lokaci guda a lokacin canji. Kula da adadin kayan ajiya na gyara da ya dace ga kowane dandali yana rage haɗarin tsayawar samarwa. Ƙungiyarmu tana riƙe da kayan aikin atomatik na darajar dala miliyan 16 a cikin manyan dakunan ajiya guda bakwai na yanki.

Muna ajiye sahihan kayan Siemens S7-1500 ciki har da CPUs (samfurorin 1511 zuwa 1518), na’urorin wutar lantarki, kayan shigarwa da fitarwa na dijital da analog (I/O modules), da masu sarrafa sadarwa. A lokaci guda kuma muna ajiye kayan Allen-Bradley ControlLogix ciki har da CPUs 1756-L7x da L8x, na’urorin wutar 1756, da duk nau’ikan kayan shigarwa da fitarwa (I/O modules).

Baya ga Siemens da Rockwell, muna ajiye kayayyakin Bently Nevada, GE Fanuc, Emerson, ABB, Schneider Electric, Honeywell, da Yokogawa. Sashen gaggawarmu na isarwa a kowane lokaci (24/7) yana tura kaya cikin awanni biyu bayan tabbatar da oda.

Hanyar sadarwar sufuri ta duniya da ke tallafawa dandali biyu

Tsayawar samarwa ba ya jira sarkar kayayyaki. Ƙawancenmu na sufuri yana ba da damar isar da kaya cikin gaggawa a duk faɗin duniya ko wane dandali kuke amfani da shi:

• DHL Express: Sabis na fifikon kasa da kasa da isarwa cikin awanni 24-48 zuwa manyan cibiyoyin masana’antu
• FedEx Priority Overnight: Isarwa ranar kasuwanci ta gaba a duk fadin Arewacin Amurka da Turai
• UPS Worldwide Expedited: Isar da kaya a lokacin da aka kayyade tare da cikakkiyar damar bin diddigin kaya
• Jigilar kaya ta jirgin sama: Zaɓi mai araha don manyan jigila tare da isarwa cikin kwanaki 3–5

Wata ma’adinan hakar ma’adinai a Indonesia ta samu gaggawar CPU ControlLogix 1756-L83E cikin awa 16 a lokacin katsewar aiki mai tsanani. Wata masana’antar sinadarai a Jamus ta samu gaggawar CPU S7-1500 cikin awa 14. Duka isar da kayayyakin biyu sun hana asarar samarwa mai darajar miliyoyin daloli.

Tallafin fasaha daga ƙwararrun masana da ke aiki da dandamali da yawa

Ƙungiyar tallafinmu ta ƙunshi injiniyoyi da aka tabbatar da cancantarsu a dandalin Siemens da Rockwell. Kowane memba na ƙungiyar yana da akalla shekaru 12 na ƙwarewa da waɗannan tsarin biyu a fannoni daban-daban na masana’antu.

Wani abokin ciniki a Thailand ya buƙaci taimako wajen sauya tsohon shirin ControlLogix zuwa S7-1500 don faɗaɗa masana’anta. Injiniyanmu ya jagorance su ta nesa wajen sauya lissafin mantiki da saita sigogin yarjejeniya (protocol). Sabuwar tsarin ta daidaita da kayan aikin da ke akwai cikin kwanaki biyu.

Muna ba da tallafin waya na awa 24/7 don gaggawa. Tambayoyin fasaha na al’ada suna samun amsa cikin awanni biyu na ranakun kasuwanci. Duk tallafi ya haɗa da taimakon gano matsala ta nesa kyauta ga lokutan gaggawa.

Hasashen marubuci: Shekaru 22 na ƙwarewa da dandamali da dama

A duk tsawon aikina na ƙera tsarin da ke amfani da dandalin Siemens da Rockwell a nahiyoyi biyar, na lura da irin salon al’amura iri ɗaya. Babu ɗaya daga cikin dandalan da ya fi kowa a kowane yanayi. Zabin da ya fi dacewa ya dogara kacokan ne da yanayinku na musamman.

Ina ba da shawarar matakai uku na musamman ga wuraren aiki da ke fuskantar wannan shawarar:

• Yi gudanar da aikin gwaji na farko (pilot project) da kowace dandali kafin ku ɗaure kanku da daidaitawa ɗaya tak. Gwajin ainihin aiki a masana’anta yana bayyana matsalolin da duba takardun ƙayyadaddun bayanai kan rasa.
• Ku haɗa masu gyaran na’urori (maintenance technicians) cikin tsarin zaɓe. Kwarewar su ta yau da kullum wajen warware matsala tana da tasiri kai tsaye a kan kuɗin dogon lokaci.
• Ku riƙe kayan gyara na dabaru ga duka dandamali idan kuna aiki da tarin na’urori gauraye. Kuɗin rike ajiyar nau’i biyu ya rabu ƙwarai idan aka kwatanta da asarar kuɗin tsayawar masana’anta na dogon lokaci.

Dandali da aka zaɓa da kyau yana iya yi maka aiki lafiya tsawon shekaru masu yawa. Muhimmin abu shi ne a daidaita ƙarfinsa da takamaiman bukatun aikace-aikacenka maimakon bin son yankin da ba tare da nazari ba.

Hanyoyin Gaba: Haɗuwa da Daidaitattun Ƙa’idoji

Duka Siemens da Rockwell suna ci gaba da matsawa zuwa ga daidaitattun ƙa’idojin masana’antu. Amfani da OPC UA da PROFINET yana ƙaruwa a duka dandamalin. Sadarwar Ethernet tana rage katanga na bambancin yarukan sadarwa (protocols).

Wani masana’antar kera motoci a Jamus yanzu tana haɗa masu kula da Siemens da Rockwell a layin samarwa guda ɗaya ta amfani da sadarwar OPC UA. Kowanne dandali yana sarrafa aikace-aikacen da suka fi dacewa da ƙarfinsa yayin da suke raba bayanai ba tare da tangarda ba. Wannan tsarin gauraye na iya wakiltar abin da manyan masana’antu za su riƙa yi a nan gaba.

Yayin da ƙa’idoji ke haɗuwa, zaɓin dandamali zai ƙara dogaro da saurin aiki da ya dace da aikace-aikace maimakon batun dacewar sadarwa. Injiniyoyi za su sami ‘yanci mafi girma wajen zaɓar kayan aiki mafi dacewa ga kowane aiki.

Tambayoyi da ake yawan yi

Q: Mene ne lokacin amsa gaggawa naku don sassan Siemens da Rockwell?
A: Sabis ɗin jigilar gaggawa namu na 24/7 yana tashi cikin awanni biyu bayan tabbatar da oda. Lokutan isarwa suna bambanta da wuri: awa 24 zuwa Arewacin Amurka da Turai, awa 48 zuwa Asiya-Pacific da ƙasashen Gabas ta Tsakiya, da awa 72 a duniya gaba ɗaya. Muna amfani da DHL Express, FedEx Priority, da UPS Worldwide Expedited gwargwadon wurinku da gaggawar bukata. Duk jigilar kaya tana zuwa da cikakken bin diddigi (tracking) da tallafin takardun kwastan.

Q: Kuna da kayan gyaran S7-1500 da ControlLogix a ajiya don a tura su nan da nan?
A: Eh, muna riƙe da cikakken ajiya na duka dandamalin biyu. Ajiyar Siemens ya haɗa da CPUs na S7-1500 (samfuran 1511, 1513, 1515, 1516, 1517, 1518), power supplies, modules na dijital da analog I/O, da communication processors. Ajiyar Rockwell ya haɗa da CPUs na ControlLogix 1756-L7x da L8x, 1756 power supplies, da duk nau’o’in I/O modules. Dakunan ajiyarmu a Houston, Miami, Rotterdam, Singapore, da Dubai suna tabbatar da samun kaya a yankuna don tura su cikin gaggawa.

Q: Waɗanne wasu nau’o’in na’urorin sarrafa kansa kuke tallafawa banda Siemens da Rockwell?
A: Muna da kaya kuma muna tallafawa kayayyakin Bently Nevada, GE Fanuc, Emerson, ABB, Schneider Electric, Honeywell, da Yokogawa. Ƙwarewarmu a kan nau’o’in iri-iri tana taimaka wa abokan ciniki su kula da muhalli mai masana’antu daga masana’antu daban-daban ta hanyar samun wuri guda na kayan gyara da tallafin fasaha. Yawancin kayayyaki na tashi ranar da aka yi oda daga ajiyar yanki tare da samun taimakon gaggawa na sa’o’i 24/7.

Kammalawa

Siemens S7-1500 da Allen-Bradley ControlLogix duka suna wakiltar manyan dandamalin PLC na duniya. S7-1500 ta fi ƙwarewa a haɗa injiniyanci a wuri guda, motion control, da ginin tallafin Turai. ControlLogix tana kan gaba wajen ƙarfaffen kayan aiki, tallafi a Arewacin Amurka, da saba wa masu fasaha. Babu ɗaya daga cikin dandamalin da ya fi ɗaya a kowane yanayi. Zaɓi mafi dacewa ya dogara ne da tallafin yankinku, ƙwarewar da ake da ita a yanzu, da bukatun aikace-aikace. Haɗa zaɓin dandalinku da ingantaccen shirin kayan gyara (spare parts) da tallafin dabarun sufuri na sa’o’i 24/7 yana tabbatar da samun tsarin kula da masana’anta a kowane lokaci. Ku yi haɗin gwiwa da mai ba da sabis da ke samar da ainihin kayan duka dandamalin, injiniyoyin da suka ƙware a dandamali da dama, da kuma iyawar isar da kaya cikin gaggawa a duniya. Ci gaban samarwarku ya dogara da waɗannan zaɓukan.