Emerson da ABB: Yadda Haɗin Kai Tsakanin Samfuran Atomatik Ke Sauya Ayyukan Masana'antu
Masana'antun kere-kere a yau suna fuskantar buƙatar ƙarin inganci. Hakanan suna buƙatar rage kuɗaɗen aiki. Masana'antu da dama har yanzu suna dogaro da tsarin sarrafa kansa masu zaman kansu. Waɗannan tsarin da aka ware suna haifar da gibin bayanai. Hakanan suna haifar da cunkoson aiki. Sakamakon haka, jimillar aikin shuka gaba ɗaya yana raguwa.
Daga hangen injiniya, rabuwar tsarin atomatik (automation) tana haifar da maimaita gazawa. Masu sarrafawa daban-daban suna amfani da manyan hanyoyin sadarwa (protocols) daban. Kwamfutocin injiniyoyi suna aiki da fakitin software daban-daban. Ma'aikata suna yawan canzawa tsakanin HMI (Human-Machine Interfaces) da dama. Wannan rabuwar tana ɓata lokaci kuma tana jawo kuskure. Haɗin gwiwar samfura daban (cross-brand integration) ba zaɓi ba ne yanzu. Dole ne ne na kasuwanci.
Emerson da ABB: Amsar Haɗin Gwiwa ga Warewar Sassa a Masana'antu
Shugabanni biyu na masana'antu yanzu suna fuskantar wannan ƙalubale tare. Emerson tana kawo zurfin ƙwarewa a DCS (distributed control systems). ABB tana ba da fasahar PLC mai ci gaba da kuma ingantattun hanyoyin kariyar wutar lantarki. Haɗin gwiwarsu yana ƙirƙirar muhallin sarrafawa guda. Wannan muhallin yana tafiyar da duka sarrafa gauraye da na tsarin ci gaba ba tare da tangarɗa ba.
Bayanan fasaha: Yawancin masana'antu suna gudanar da ayyukan ci gaba (zafi, matsin lamba, gudu) da kuma ayyukan gauraye (marufi, rarrabuwa, tarawa). Tsarin gargajiya suna tilasta injiniyoyi su rika kula da matakan sarrafawa daban-daban. Emerson da ABB yanzu suna ba da hanyoyin haɗin da aka riga aka gwada. Wannan yana rage haɗarin aikin kuma yana gaggauta lokacin commissioning.
Haɗa PLC da DCS zuwa Tsarin Ayyuka Gauraye
PLC suna kwarewa wajen sarrafa na'urori masu saurin gaske (high-speed discrete control). Suna magance amsawa a matakin milisakan don dabarun mantiki da motsi. Tsarin DCS suna ƙwarewa a aikin sarrafa ci gaba (continuous process automation). Suna sarrafa kulawar madauwari (loop control), tsarin jere na batch, da sarrafa ƙararrawa. Yawancin masana'antu suna buƙatar duka biyun. Dandamalin DCS na Emerson suna haɗuwa cikin sauƙi da PLC na ABB ta OPC UA da EtherNet/IP.
Jagorar injiniya: Lokacin haɗa PLC na jerin ABB AC500 ko AC800 da tsarin Ovation ko DeltaV na Emerson, yi amfani da gama-garin hanyar canjin masana'antu (industrial switch fabric). Saita irin ɗaya samfurin bayanai a ɓangarorin biyu. Daidaita (map) alamomin I/O kai tsaye ba tare da matsakaitan gateways ba duk lokacin da zai yiwu. Wannan yana rage jinkiri (latency) zuwa ƙasa da milisakan 50. Hakanan yana kawar da wuraren gazawa guda ɗaya.
Wannan haɗin yana tallafawa ayyukan gauraye ba tare da ƙarin rikitarwa ba. Injiniyoyi suna samun wata hanya guda don sarrafa duk ayyukan kulawa. Daga ƙwarewar filin aiki, haɗa PLC da DCS cikin tsari guda na rage awannin aikin injiniya har zuwa kashi 20%. Hakanan yana kawar da kurakuran daidaita bayanai masu tsada tsakanin tsarin daban-daban.
Daidaita Bayanai: Ƙirƙirar Tushen Gaskiya Ɗaya
Rarrabuwar bayanai (data silos) har yanzu na ɗaya daga cikin manyan shingaye ga daidaitacciyar aikin masana’anta. Tsarukan Emerson da ABB suna daidaita bayanan ainihin lokaci a dukkan sassan masana’antar. Ma’aikata suna samun majiyar bayanai guda ɗaya mai dogaro don ma’aunin samarwa da lafiyar kadarori. Wannan gani a sarari yana rage kuskuren ɗan adam sosai. Haka kuma yana hanzarta yanke shawara a dakin samarwa.
Yadda yake aiki ta fuskar fasaha: Tsarukan biyu suna raba ƙimomin sigogin aiki masu ɗauke da lokaci (timestamped process values) ta amfani da tushen lokaci guda (NTP ko PTP). Masu adana tarihi (historians) na kamfanoni biyu suna taruwa su zama tafkin bayanai guda (data lake). Jerin ƙararrawa da abubuwan da suka faru (events) suna haɗuwa a matakin HMI. Wata masana’antar sinadarai da ta yi amfani da wannan hanya ta rage sulhu daidaita bayanai da hannu da kashi 90%. Shugabannin canjin ma’aikata yanzu suna gano abubuwan banmamaki a cikin daƙiƙu, ba sa’o’i ba.
Lura ga injiniya: Koyaushe tabbatar cewa duka tsarin suna goyon bayan irin waɗannan bayanan martabar OPC UA ɗaya. Emerson yawanci yana amfani da UA-Methods don sarrafa umarni. ABB kuma tana dogara da UA-Variables don musayar bayanai. Takardar ƙayyadadden “companion specification” mai kyau tana warware waɗannan bambance-bambancen tun kafin a kaddamar da tsarin.
Tsinkayar Kula da Na’urori ta Hanyar Haɗaɗɗen Nazarin Bayanai
Tsayawar aiki ba da gangan ba yana jawo wa masana’antu asarar kuɗaɗe biliyoyi a kowace shekara. Kayan aikin sa ido kan kadarorin Emerson suna auna lafiyar kayan aiki ba kakkautawa. Hasashen bayanai na ABB yana sarrafa waɗannan bayanan don gano tsarin lalacewa. Tare, suna gano matsalolin da ka iya tasowa kafin samarwa ta tsaya.
Bayani na fasaha dalla-dalla: AMS Device Manager na Emerson yana tattara bayanan girgiza, zafi, da alamar bawul. Wannan bayanin ana turawa zuwa dandalin hasashen bayanai na ABB Ability. ABB tana amfani da samfuran koyo na na’ura (machine learning) da aka horar da su da tarihihin lokutan lalacewa. Idan samfurin ya gano abin da bai dace ba, sai ya aika da gargaɗin kula da na’ura kai tsaye zuwa allon ma’aikacin Emerson. Ƙungiyoyin kula da na’urori sai su ɗauki mataki tun da wuri. Suna kare kadarori maimakon jiran su lalace sannan su yi gyara.
Wani masana’antar sassan motoci ta rage tsayawar aiki ba da gangan ba da kashi 18% a cikin watanni shida ta amfani da wannan hanyar haɗin gwiwa. Muhimmin abu shi ne saita sahihan matakan faɗakarwa a cikin watanni biyu na farko na aikin haɗin gwiwa.
Ribobin Dorewa daga Hadaɗɗen Tsarin Sarrafawa
A yau, masu ƙera kaya suna fifita dorewa tare da ingantacciyar samarwa. Hadaɗɗen tsarin Emerson da ABB yana inganta amfani da makamashi ta atomatik. Dabara a cikin daidaita sarrafawa mai wayo tana rage ɓarna. Haka kuma tana rage sawun carbon.
Aiwatarwa a aikace: Tsarin kariyar wutar lantarki na ABB da na’urar sarrafa juyawar mota (variable frequency drives) suna ba da rahoton amfani da makamashi a ainihin lokaci. DCS na Emerson yana amfani da waɗannan bayanan don daidaita saitunan tsarin aiki ta atomatik. Alal misali, tsarin na iya jinkirta fara jerin aiki da ba su da matuƙar muhimmanci a lokacin kololuwar buƙata. Haka kuma zai iya rage aikin famfunan gefe idan buƙatar gudana ta ragu.
Masana’antu suna ganin auna tanadin kuɗi a fannoni na wutar lantarki da sauran kayan amfani. Saboda haka, dorewa tana zama abin da ke taimakawa rage kuɗi, ba nauyin bin ƙa’ida kawai ba. A masana’antu masu yawan amfani da makamashi kamar ƙarafa ko sinadarai, wannan haɗin gwiwa yawanci yana samar da tanadin makamashi na kusan 8–12% ba tare da sabunta manyan injuna ba.
Dalilin da ya sa Haɗin Gwiwar Samfuran Kamfanoni Daban-Daban Shi ne Gaba
Haɗin gwiwar samfuran kamfanoni daban-daban ba salo ba ne kawai. Yana da buƙatar faɗaɗa aiki (scalability necessity). Masana’antu da dama suna aiki da muhallin masu kaya daban-daban. Saboda haka, daidaiton aiki da haɗin kai tsakanin samfuran ya zama muhimmi don ci gaba. Emerson da ABB sun kafa misali na mafita na atomatik masu buɗe hanya (open) kuma masu iya aiki tare (interoperable).
Shawarwarin dabaru ga injiniyoyi: Lokacin zaɓar sababbin tsarin sarrafawa, koyaushe ku tambayi masu kaya tambayoyi huɗu:
- Tsarinku yana goyon bayan haɗin OPC UA kai tsaye (native OPC UA integration) da alamar da muke da ita a yanzu?
- Za mu iya raba gine-ginen sunayen injiniya (engineering namespace) ɗaya a dandalin biyu?
- Mene ne mafi girman ƙimar musayar tag ba tare da ƙarin kayan aiki ba?
- Kuna samar da samfuran haɗin da aka riga aka gwada (pre-tested integration templates) don manyan yanayin amfani?
Masu ƙera kaya ya kamata su fifita tsarin da ba su da takamaiman mai kaya (vendor-agnostic systems). Wannan hanyar tana tabbatar da sassauci na dogon lokaci kuma tana kare jarin kuɗaɗen kayan aiki. Ku guji kullewa a tsarin mallakar mai kaya (proprietary lock-in) duk inda zai yiwu.
Sakamakon Aiki a Gaskiya: Ma’aunin Ayyukan Tsarin Haɗaɗɗe
Teburin da ke ƙasa yana takaita manyan ci gaban ayyuka da aka lura da su a wuraren aiwatarwa da dama da suka yi amfani da haɗin gwiwar masana’antu Emerson-ABB.
| Ma’auni | Kafin Haɗa Tsarin | Bayan Emerson+ABB | Ci gaba |
|---|---|---|---|
| Lokacin Zagaye (layin mota) | Matsayin farko (Baseline) | -10% | Raguwar kashi 10% |
| Ingancin Samfuri (ƙimar lahani) | Matsayin farko (Baseline) | -15% | Ci gaba da kashi 15% |
| Lokacin Tsayawar Aiki Marasa Shirya | Matsayin farko (Baseline) | -18% (watanni 6) | Raguwar kashi 18% |
| Amfanin Makamashi (HVAC + dumama) | Matsayin farko (Baseline) | -9% | Ajiyar kuɗi 9% |
| Ayyukan Injiniyoyi (sabuwar haɗa layi) | Tsari na rabuwa na gargajiya (Standard separate) | Shared namespace ɗaya | Har zuwa kashi 20% ƙasa |
Shari’ar Aikace-aikace: Shukar Kera Kayan Sassan Motoci
Wani babban kamfani na ƙera sassan motoci na duniya ya fuskanci ƙalubalen inganci. Shukar ta na aiki da layuka daban-daban: bita fenti (paint shop, ci gaba da aiwatarwa) da taro (assembly, lissafin sarrafa na’ura mai rabuwa-discrete logic). Tsofaffin tsarin ba su iya raba bayanan inganci na ainihi (real-time) ba. Shukar ta haɗa Ovation DCS na Emerson da AC500 PLC na ABB. Sakamako ya bayyana cikin watanni uku.
- Lokutan zagaye (cycle times) sun ragu da kashi 10%
- Ingancin samfur ya ƙaru da kashi 15%
- Lokutan tsayawar aiki marasa shiri sun ragu da kashi 18% cikin watanni shida
- Kudin makamashi ya ragu da kashi 9% ta hanyar inganta sarrafa HVAC da dumamar tsarin aiki
Abin ɗauka na fasaha: Ƙungiyar injiniyoyi ta gina rumbun bayanan tag ɗaya da ke da maki gama-gari 2,500. Sun yi amfani da OPC UA tare da tsaro mai amfani da takardar shaidar. Ba a buƙaci kowace irin lambar al’ada (custom code) ba. Dukkan haɗa-haɗar ta ɗauki makonni takwas, ciki har da gwajin karɓar masana’anta (factory acceptance testing).
Wannan shari’ar ta tabbatar da cewa haɗin gwiwa tsakanin samfuran kamfanoni daban-daban (cross-brand synergy) yana kawo canje-canje masu auna su a aikin yau da kullum da kuɗaɗe.
Takaitaccen Jagora ga Injiniya: Jerin abubuwan dubawa na Haɗawa (Integration Checklist)
- Tabbatar da jituwa tsakanin bayanan martabar OPC UA (OPC UA profiles) (Emerson UA-Methods vs ABB UA-Variables)
- Kafa tushen lokaci guda ɗaya (NTP/PTP) don daidaita timestamps
- Tsara tsarin raba tag ɗaya (shared tag namespace) tare da burin jinkiri (latency) na mafi yawanci ms 50
- Saita matakan iyakar faɗakarwar predictive maintenance yayin haɗin gwaji na farko (joint commissioning) (watanni 2 na matakin bincike)
- Gwada tsaro mai amfani da takardar shaidar (certificate-based security) kafin cikakken aiwatarwa
- Yi amfani da na'urorin sauya sigina na masana’antu masu sarrafawa (managed switches) tare da rarrabe VLAN don zirga-zirgar sarrafa na’ura
An rubuta shi ne ta Fang Zekai, ƙwararren injiniya mai mai da hankali kan sarrafa ayyuka ta atomatik da tsarin kulawa ga abokan ciniki na duniya a bangaren man fetur & iskar gas.
