Kurakuran wayoyi 7 da ke lalata amincin tsarin sarrafawa
Dalilin da ya sa ingancin wayoyi ke ƙayyade nasarar aikin sarrafa kansa
Kwandunan sarrafawa suna zama tsarin jijiyoyin jiki na cibiyar masana'antu na zamani. PLCs, DCS modules, da safety relays duk suna dogara da wayoyi marasa kuskure. Duk da haka, bayanan bincikenmu a fadin kwanduna 500+ sun nuna cewa kashi 68% suna ɗauke da aƙalla kuskure ɗaya mai tsanani na wayoyi. Waɗannan kurakuran suna haifar da gazawar lokaci-lokaci, lalacewar sigina, da lalacewar kayan aiki tun kafin lokaci. Saboda haka, fahimtar waɗannan tarkunan abu ne mai muhimmanci ga kowane ƙwararren automaton.
Kuskure na 1: Gudanar da igiyoyin wuta da igiyoyin sigina tare
Haɗa igiyoyin wutar AC da igiyoyin sigina masu ƙananan mataki a cikin hanya ɗaya ta waya ya ci gaba da zama mafi yawan take hakki. Masu duba suna samun wannan kuskuren a cikin 43% na kwanduna. Layukan AC suna haifar da filayen electromagnetic da ke haifar da hayaniya a cikin wayoyin sigina da ke makwabtaka. Wannan yana haifar da karkacewar analog da kuma tayar da siginar dijital na ƙarya.
Wani masana'antar sinadarai a Texas ta fuskanci karatun da ke canzawa-canzawa a kan na'urorin auna mataki 16. Masu bincike sun gano layukan mota 480V suna tafiya a gefen wayoyin thermocouple sama da ƙafafu shida. Ware igiyoyin zuwa hanyoyin waya daban-daban ya kawar da hayaniyar. Masana'antar ta dawo da $120,000 na samarwar shekara-shekara da ta rasa saboda ƙararar ƙarya.
Kiyaye akalla inci huɗu na tazara. Keta juna a kusurwar digiri 90 idan ya zama dole. Yi amfani da igiyoyi masu garkuwa don duk siginar analog.
Kuskure na 2: Haɗa garkuwa da ƙasa a ɓangarori biyu
Igiyoyin da aka yi musu garkuwa suna kare sigina ne kawai idan an kammala su yadda ya dace. Mafi yawan kuskure shi ne a haɗa garkuwa da ƙasa a ɓangarori biyu. Wannan yana ƙirƙirar ground loop da ke ƙara hayaniya fiye da abin da garkuwar ke hana shi.
Wani masana'antar abinci a California ta yi fama da gazawar shigar PLC marasa bayani na watanni. Masana suka riƙa maye gurbin kayayyaki akai-akai. Asalin matsalar: wayoyin garkuwa daga na'urori masu auna sigina 24 a filin an haɗa su da ƙasa a ƙarshen na'urar firikwensin da kuma ƙarshen PLC. Juya su zuwa grounding na wuri guda kaɗai ya magance duk gazawar cikin sa'o'i kaɗan.
A dakatar da garkuwa a ƙarshen na'urar sarrafawa kaɗai. Bar ƙarshen filin a keɓe. Don yanayi na musamman kamar thermocouples, bi ƙayyadaddun bayanan mai ƙera daidai yadda suka rubuta.
Kuskure na 3: Amfani da Wayar Rarraba Wuta da Ta Yi Ƙanƙanta
Raguwar wuta (voltage drop) tana haifar da abubuwan ban mamaki a cikin tsarin kula da injina. PLC power supplies suna buƙatar isasshen ƙarfin wuta a tashoshin shigarwarsu. Wayoyi da suka yi ƙanƙanta suna ƙara juriya wanda ke rage wuta ƙasa da matakin da aka yarda da shi a lokacin kololuwar ƙarfi (peak current).
Wata masana'antar taro a Ohio ta fuskanci saɓanin sake saiti na PLC a layuka biyu. Gwaje-gwaje sun nuna 22.8V a yanayin daidaitacce, yana raguwa zuwa 20.1V lokacin da duk fitattun (outputs) suka kunna. Waya 14 AWG mai tsawon ƙafa 75 ta haddasa raguwar da ta yi yawa. Sauya ta da 10 AWG ya dawo da aiki mai kwanciyar hankali.
Ku ƙididdige raguwar wuta (voltage drop) ga dukkan layukan wutar lantarki. Ku kiyaye raguwar a ƙasa da 3%. Ku yi la’akari da fadada tsarin a nan gaba lokacin zaɓar girman waya.
Kuskure na 4: Barin Sanya Ferrules a Kan Waya Mai Zare
Waya mai zare tana buƙatar ferrules don samun amintaccen haɗi a cikin screw terminals. Idan babu ferrules, zaren kan rabu, lamarin da ke haifar da sako-sakon haɗi da matsalolin da ke bayyana lokaci-lokaci. Masu bincike suna samun rashin ferrules a cikin 57% na allunan sarrafawa.
Wata ma'adinan mai a Louisiana tana fuskantar matsalar gazawar na'urar auna kwarara (flow transmitter) kusan duk sati. Bincike ya nuna an saka igiyoyin layin zare kai tsaye cikin terminal blocks. A hankali, girgiza injuna tana karya jujjuyayyun zaren ɗaya bayan ɗaya. Sanya ferrules a kan dukkan ƙarshen waya 2,400 ya kawar da matsalar gaba ɗaya.
Yi amfani da ferrules a kan duk ƙarshen igiyoyin da aka yi da layukan zare. Zaɓi girman da ya dace da girman (gauge) ɗin waya. Yi crimp da kayan aikin da aka daidaita.
Kuskure na 5: Cikawar Wireway fiye da Kima da Lanƙwasawa Matuƙa
Tursasa wayoyi da yawa cikin wireway yana lalata rufin igiya kuma yana hana sauƙin binciken matsala. Cikawa fiye da kima kuma yana hana zafin jiki fita. NEC ta fayyace iyakar cika, amma saba wa wannan doka abu ne da ake yawan gani.
Wata masana'antar takarda a Mississippi ta fuskanci matsalolin drive da ake maimaitawa da aka gano sun samo asali ne daga igiyoyin encoder da suka lalace. Wireway ɗin sun cika zuwa 90% cikakken cika ƙarfin ya matse rufin waya, yana haifar da gajeriyar hanya. Sake tsara su ya rage cika zuwa 40%. Kurakuran drive sun ragu da 85%.
Kada ku wuce cika 50%. Ku kiyaye ƙaramin radius ɗin lanƙwasawa ga duk igiyoyi. Ku bar ɗan sako-sako don gyare-gyaren gaba.
Kuskure na 6: Rashin Lakabi ko Rashin Isasshen Lakabi a Kan Waya
Wuraren waya da ba su da lakabi suna mai da sauƙaƙen binciken matsala ya zama aikin leƙen asiri. Masu bincike suna gano gajerun lakabi ko rashin lakabi a cikin 72% na allunan sarrafawa. Rasit da suka ɓace suna ƙara tsawon lokacin dakatarwa kuma suna ƙara haɗarin kuskure.
Wani masana'antar magunguna a New Jersey ta shafe sa'o'i 14 tana bin diddigin haɗin waya guda mara kyau. Panel ɗin ya ƙunshi wayoyi 1,200 ba su da lakabi. Lakabi na daidai da ƙa'ida zai gano wayar a cikin ƴan mintoci kaɗan. Yanzu masana'antar tana wajabta yin lakabin heat\-shrink a kan kowane waya.
Yi lakabi a duka ƙarshen kowane waya. Yi amfani da lakabin heat\-shrink don dawwama. Hada lambar waya, nau'in sigina, da wurin da take nufa.
Kuskure na 7: Mummunan Hanyoyin Grounding da Bonding
Kurakuran grounding suna jawo matsaloli masu ɗan lokaci\-ɗan lokaci fiye da kowace irin kuskuren wayoyi. Mummunan grounding yana haifar da hayaniya (electrical noise), haɗarin tsaro, da lalata kayan aiki. Duk da haka, ana ba shi kulawa kaɗan fiye da sassan wayoyi masu ganuwa.
Wani dandali a Tekun Arewa (North Sea) ya fuskanci rushewar PLC ba a san dalili ba lokacin guguwa. Grounding na control panel ɗin an haɗa shi da ƙarfen ginin ta hanyar ƙusoshi masu tsatsa. An auna juriya 4.7 ohms maimakon 0.5 ohms da ake buƙata. Sanya sandar ƙasa ta musamman ya rage juriya zuwa 0.3 ohms. Rushewar ta daina gaba ɗaya.
Sanya sandunan ƙasa na musamman. Haɗa duk ƙasashe (grounds) zuwa wuri guda. Auna juriya duk shekara. Yi amfani da wayar kore/ja\-ja (green/yellow) kawai don grounding.
Nazarin Lamari: Oil Sands na Canada Ya Ajiye $4.2 Miliyan
Wani wurin hakar man fetur na oil sands a Canada ya aiwatar da shirin inganta aikin wayoyi bayan maimaituwar gazawa. Injiniyoyi sun duba panels 47 kuma suka rubuta take\-hakki 312. Sun fifita gyare\-gyaren ne bisa tasirin su ga tsaro.
Farashin shirin ya kai $180,000 a cikin watanni 18. Ribobin sun haɗa da raguwa 76% a lokutan tsayawar aiki da suka shafi control da kuma kawar da manyan kuskuren haɗari guda uku da aka kusa yi. Ƙarin samarwa ya kai jimillar $4.2 miliyan a shekara.
Jerin Abubuwan Dubawa 10 na Ingancin Wayoyin Control Panel
- Tabbatar rabuwar kebul na wuta da na sigina ta cika ƙayyadaddun bayanai
- Tabbatar cewa an gamaƙe garkuwa (shields) a ƙarshen gefe guda kawai
- Lissafa raguwar ƙarfin wuta (voltage drop) ga dukkan da'irorin wutar lantarki
- Duba yadda aka saka ferrule a kan wayoyi masu igiyoyi da yawa (stranded)
- Auna kaso na cikar wireway (manufa <50%)
- Duba duk lakabi don tabbatar da su a bayyane suke kuma suna dawwama
- Gwada juriya ta ƙasa a babban bus (manufa ≤1 ohm)
- Tabbatar da bin ƙa'ida ta radius na lanƙwasa wayoyi
- Rubuta duk abubuwan da suka kau daidai da zane-zanen ƙira
- Yi duba da na'urar gano zafi (thermal scan) yayin cikakken nauyi
Muhimman Sassan Ajiyar Kaya da Sufuri: Abokin haɗin gwiwar ku na awa 24/7
Ko mafi kyawun haɗa wayoyi ba zai iya hana duk gazawar kayan aiki ba. Hasken walƙiya, tashin wuta, da tsufa a ƙarshe suna lalata kayayyaki. Samun kayan maye cikin gaggawa yana rage lokacin tsayawar aiki. Muna da kayayyakin ajiya sama da $15M+ na Allen-Bradley, Bently Nevada, GE Fanuc, Emerson, ABB, Siemens, Schneider Electric, Honeywell, Triconex, da Yokogawa. Sashenmu na gaggawa na 24/7 yana tura kaya cikin sa'o'i 2 ta DHL Express, FedEx Priority, da UPS Worldwide Expedited.
Misalin Amfani: Jigilar gaggawa ta terminal block zuwa Chile
Wani ma'adinan jan ƙarfe a Chile ya fuskanci gobara a cikin wani kwamitin sarrafawa, wadda ta lalata block ɗin haɗin wayoyi 48. Lokacin isarwa na al'ada shi ne makonni huɗu. Ma'adinan yana fuskantar asarar $2.8 million a rana saboda dakatar da samarwa. Mun samo terminal blocks na Phoenix Contact daga ma'ajinmu na Miami cikin awa ɗaya. Jigilarsa ta tashi ta FedEx Priority kuma ta isa Santiago washegari. An kammala sake haɗa wayoyi cikin awanni 48, wanda ya ceci sama da $11.2 million.
Tambayoyi da Ake Yawan Yi (FAQ)
-
Sau nawa ya kamata mu duba wayoyin cikin kwamitin sarrafawa?
Muna ba da shawarar cikakken bincike aƙalla sau ɗaya a shekara. Muhalli masu tsanani na iya buƙatar dubawa sau biyu a shekara. Yin ɗaukar zafin jiki (thermal scanning) duk bayan watanni shida yana gano matsalolin haɗin wayoyi tun suna tasowa. -
Mene ne lokacin dawowar ku na gaggawa wajen samar da kayan maye?
Sashen aikawanmu na 24/7 yana tura kaya cikin sa'o'i 2. Isarwa: awa 24 zuwa Arewacin Amurka/Turai, awa 48 zuwa Asiya/ Gabas ta Tsakiya, awa 72 a duniya gaba ɗaya ta DHL/FedEx/UPS. -
Waɗanne nau'ikan alamomin atomatik (automation brands) kuke ajiyewa don sassan kwamitocin sarrafawa?
Muna ajiye Allen-Bradley, Bently Nevada, GE Fanuc, Emerson, ABB, Siemens, Schneider, Honeywell, Triconex, Yokogawa, da sauran su. Yawancin kaya suna tashi a rana guda.
Hasashen marubuci: Shekaru 18 na ƙwarewa wajen duba kwamitocin sarrafawa
Na duba fiye da kwamitocin sarrafawa 500 a fadin nahiyoyi biyar. Mafi kyawun kwamitoci suna da abubuwa uku gama gari: tsarawa cikin cikakken kulawa, bin ƙa'idoji ƙaƙƙarfan, da cikakkiyar takardun bayani. Ina ba da shawarar matakai uku: a rika yin binciken shekara-shekara ta amfani da jerin abubuwan dubawa na daidaitacce, a ɗauki hotunan duk kwamitoci kowace shekara domin kwatantawa, kuma a rika horar da ma'aikatan fasaha kan ingantattun dabarun ɗaure wayoyi duk shekara. Tozarta gazawa guda ɗaya kaɗai da aka hana ta faruwa na iya halatta shekaru na ƙoƙarin kariya. Ku yi haɗin gwiwa da mai ba da sabis na sufuri da ajiya (logistics) na awanni 24/7 da ke ajiye ainihin kayan haɗi domin tabbatar da saurin dawowa da aiki idan matsala ta taso.
