Dalilin Da Ya Sa Wayoyi Ke Hana Sabunta Kayan Aiki Na Tsohuwa Tun Kafin A Fara
Tsofaffin layukan samarwa ba sa yawan samun ƙarin bututun waya ko tire na igiyoyi masu komai. Ƙara na’urorin firikwensin da ke da waya na tilasta injiniyoyi su buɗe bango, su huda kankare, su kuma tsayar da injuna na dogon lokaci. Sau da yawa, sabunta kwampreso guda yana buƙatar sabuwar igiya mai tsawon mita 150 zuwa 250. Kuɗin kayan aiki kaɗai yana tsakanin $1,500 zuwa $3,000 ga kowane abin hawa/asset. Aikin hannu kuma yana ƙara awanni 20 zuwa 30. Saboda haka, yawancin masana’antu suna jinkirta ayyukan sa ido kan yanayin aiki har su zama ba a taɓa aiwatar da su ba.
Na’urorin Firikwensin Mara Waya Sun Sauya Lissafin Sabuntawa Gaba ɗaya
Na’urorin firikwensin jijjiga masu amfani da baturi suna kawar da duk wata matsala da ta shafi igiyoyi. Ana ɗora raka’a guda kai tsaye a kan gidajen bearing ko jikin inji. Yana auna jijjiga a aƙsai uku tare da zafin jiki. Lokutan tura bayanai suna tsakanin minti 1 zuwa sa’o’i 8. Rayuwar baturi tana tsakanin shekaru 3 zuwa 5 a ƙarƙashin yanayin aiki na yau da kullum. Babu akwatunan rarraba (junction box). Babu lanƙwashe bututun waya (conduit). Babu yanke igiyar da aka keɓe (shielded cable). Na’urar firikwensin tana fara aiki ne kai tsaye bayan shigar da ita na mintuna 15.
Haɗa Bayanai Masu Mara Waya da Dandamalin Kula da Inji Na Yanzu
Ƙaramin “gateway” na cikin gida yana tattara duk bayanan karatun firikwensin da ke cikin radius na mita 200. Wannan gateway yana amfani da Modbus TCP, OPC UA, da MQTT. Kowace PLC ko DCS da ke goyon bayan waɗannan yarukan sadarwa na iya karɓar bayanan kai tsaye. Injiniyoyi suna ƙirƙirar “tags” don jimillar jijjiga, “acceleration envelope”, da zafin jiki. Matakan ƙararrawa suna tashi ta hanyar HMI na masana’antar da ake da shi tuni. Ba a buƙatar wani sabon software na sa ido dabam. Tsarin Siemens, Rockwell, Schneider, da Emerson duk suna aiki ne kai tsaye daga akwatin.
Jagorar Shigarwa: Daga Akwati Zuwa Aiki Cikakke a Wata Shift Ɗaya
Na farko, yi binciken rediyo. Yi yawo a yankin da na’urar gwaji ta hannu. Tabbatar da ƙarfin sigina yana sama da -70 dBm a kowane wuri da aka tsara don na’urar firikwensin.
Na biyu, ɗora kowane firikwensin. Tsaftace saman da isopropyl alcohol. Sanya siririn shafi na “couplant” ga ɗorawa da mannewa. Murɗa “stud mounts” zuwa 5 Nm.
Na uku, sanya gateway ɗin. Ɗora shi aƙalla mita 1 sama da ƙasa. Ajiye shi a nisan mita 2 daga “variable frequency drives”. Haɗa shi da cibiyar sadarwar masana’anta ta hanyar Ethernet.
Na huɗu, ware IDs na firikwensin. Yi amfani da kayan aikin saiti na wayar hannu. Duba kowane QR code. Haɗa firikwensin da takamaiman tashar gateway da sunan asset.
Na biyar, daidaita bayanai zuwa ƙwaƙwalwar PLC. Buɗe “tag database” na na’urar sarrafawa. Ƙirƙiri rijistar “32-bit floating point” don saurin motsi (velocity) da zafin jiki. Sanya yawan sabunta bayanai ya daidaita da muhimmancin inji.
Na shida, fayyace matakan faɗakarwa. Yi amfani da ISO 10816-3 a matsayin matakin farawa. Don motar 30 kW, saita matakin gargadi a 4.5 mm/s da haɗari a 7.1 mm/s.
Na bakwai, tabbatar da aiki. Gudanar da abin hawa/asset ɗin na minti 20. Kwatanta karatun mara waya da na’urar auna jijjiga mai ɗaukuwa. Bambancin da ake iya yarda da shi ya kasance ƙasa da ±2 cikin ɗari.
Nazarin Hali 1: Masana’antar Sinadarai Ta Kauce wa Lalacewar Mota Ta $180,000
Wata masana’antar sinadarai a Louisiana tana da motoci 16 na fan ɗin hasumiyar sanyaya. Babu ɗayansu da ke da kariyar jijjiga. Sabunta su da igiyoyi zai buƙaci sabuwar igiya mai tsawon mita 3,200. Kimar kuɗi ita ce $48,000. Tsayawar aiki zai haura awanni 80 a kan karshen makonni huɗu. Madadin haka, masana’antar ta kafa na’urorin firikwensin mara waya 16 da gateways guda biyu. Jimillar kuɗin kayayyaki ya kasance $12,500. Shigarwa ya ɗauki awa 6 a cikin shifts biyu. Bayan watanni takwas, firikwensin guda ya gano ƙaruwa da kashi 35 cikin ɗari a jijjiga mai mita mai yawan lokaci. Sashen gyara ya gano reshen fan ɗin ya fashe. Kuɗin musanya shi ya kasance $4,200. Kauce wa mummunar lalacewa ya ceci kimanin $180,000 na yiwuwar lalacewar kayan aiki da tsayawar aiki ba tare da shiri ba.
Nazarin Hali 2: Masana’antar Sarrafa Abinci Ta Rage Tsayawar Aiki da Kashi 70 Cikin Dari
Wata masana’antar abinci a yankin Midwest tana da “screw conveyors” 24 da “bucket elevators”. Yawan lalacewar bearings yana jawo tsayawar samarwa duk bayan makonni uku. An ga cewa saka idon aiki da igiyoyi ya yi tsada sosai. Masana’antar ta shigar da na’urorin firikwensin jijjiga mara waya 24 da gateways guda uku. Jimillar kuɗin aikin ya kasance $18,000. An yi shigarwa ne yayin aikin yau da kullum. Babu tsayawar samarwa. A cikin shekarar da ta biyo baya, tsarin ya gano bearings huɗu da ke nuna ƙaruwa a juyin jijjiga. Ana maye gurbinsu ne a lokacin jadawalin tsaftacewa (sanitation windows). Tsayawar aiki ba tare da shiri ba ya ragu daga awanni 45 a shekara zuwa awanni 14 a shekara. Ajiya na shekara-shekara ya haura $90,000.
Abin da Masanan Dorewar Aiki Ke Faɗi Game da Sa Ido Mara Waya
Na’urorin jin jijjiga mara waya sun bunƙasa ƙwarai a cikin shekaru uku da suka gabata. Fargabar farko game da ɓacewar bayanai da rayuwar baturi ta kusan shuɗewa. Tsarukan zamani suna cin ma adadin isar bayanai na kashi 99.9 cikin ɗari a yawancin muhallin masana’antu. Ayyukan da suka fi nasara sukan fara ne da muhimman kayan juyawa. Pumps, fans, da motoci ƙasa da 500 kW suna ba da dawowar jari cikin sauri. Injiniyoyi yakamata su guji gateways masu takaitaccen mai ƙera guda ɗaya. Yarukan buɗe-baki kamar MQTT da OPC UA suna tabbatar da dacewa da tsarin gaba. Hanyar tana da bayyani: Mara waya bai zama zaɓi na biyu ba yanzu. Yana zama tsohon mataki na asali ga sabunta kayan aiki na tsohuwa.
Maganganun Aiki Ga Manyan Yanayin Masana’antu
Yanayi 1 – Assets marasa wayoyi da ke akwai: Yi amfani da na’urorin firikwensin mara waya masu amfani da baturin lithium na shekaru 5. Ba a buƙatar tsarin wutar lantarki.
Yanayi 2 – Binciken dorewar aiki na wucin gadi: Kafa na’urorin firikwensin mara waya masu ɗorawa da maganiti na tsawon kwanaki 30 zuwa 60. Tara bayanan tushe. Sannan ka sake amfani da su a kan wasu assets.
Yanayi 3 – Wurare masu nisa ko na waje: Zaɓi na’urorin firikwensin da ke da ƙimar IP67 ko IP68. Yi amfani da “cellular gateway” don tura bayanai kai tsaye zuwa dashboards na PLC da ke cikin “cloud”.
Yanayi 4 – Yankuna masu haɗari: Zaɓi samfuran da aka tabbatar da ATEX Zone 1 ko Class I Division 1. Ci gaba da bin ƙa’ida ba tare da tsadar na’urorin kariyar “intrinsic safety barriers” ba.
Tambayoyi da Ake Yawan Yi
1. Shin na’urorin firikwensin mara waya na iya wucewa da sigina ta cikin akwatunan ƙarfe?
Rashin ƙarfi na sigina (attenuation) yana ƙaruwa ta cikin ƙarfe mai kauri. Shigar da gateway ɗin da “line-of-sight” zuwa na’urorin firikwensin duk lokacin da ya yiwu. Idan akwatunan ƙarfe ba za a iya guje musu ba, yi amfani da eriya (antenna) mai nisa da aka ɗora a wajen akwatin.
2. Me ke faruwa idan gateway ta rasa wuta?
Na’urorin firikwensin suna ci gaba da aunawa kuma suna adana bayanai a cikinsu. Kowane firikwensin na iya ajiye bayanai har zuwa auna 10,000. Lokacin da wuta ta dawo, gateway tana karɓo duk bayanan da suka ɓace ta atomatik.
3. Shin na’urorin firikwensin mara waya suna aiki da tsofaffin PLC kamar SLC 500 ko PLC-5?
Eh, muddin PLC ɗin na goyon bayan Modbus TCP ta Ethernet. Tsofaffin na’urorin sarrafawa sau da yawa suna buƙatar na’urar juyawa daga Modbus TCP zuwa Modbus RTU. Yawancin gateways suna haɗa wannan aikin a cikinsu.
