Ta yaya masu kula na gefen GE RXi Edge ke haɗa PLC da PC a cikin aikin sarrafa kansa?

Haɗa Sarrafawa da Lissafi: Sabon Tsari don Otomeshin Masana’antu

Gidajen samarwa na zamani suna fuskantar rikici na asali. PLC na gargajiya na aiwatar da ladder logic da daidaiton microsecond amma ba za su iya gudanar da nazari mai rikitarwa ba. Kwamfutocin masana’antu (Industrial PC) suna iya sarrafa bayanai amma ba su da lokacin aiki mai tabbatacce. Gudanar da waɗannan na’urori biyu a jere yana haifar da gibi a daidaita bayanai kuma yana ninka nauyin kiyayewa. GE PACSystems RXi Edge Controllers suna warware wannan rikicin ta hanyar haɗa injin sarrafa ainihin lokaci tare da muhallin kwamfuta na amfani na gama-gari a cikin akwati guda.

Tsarin Kayan Aiki: Fahimtar Tsarin Haɗaɗɗen Zane

RXi yana amfani da tsarin sarrafa kansa maras daidaito (asymmetric multiprocessing). Keɓantacciyar ƙwayar ARM Cortex tana kula da duba I/O mai tabbataccen lokaci da aiwatar da lissafi (logic). Mai sarrafa AMD Ryzen V1605B mai “quad-core” yana gudanar da aikace-aikacen Windows ko Linux. Babban hanyar haɗin ƙwaƙwalwa mai sauri (high-speed memory-mapped interface) tana haɗa waɗannan ɓangarorin biyu. Wannan ƙirar tana tabbatar da cewa zagayowar binciken PLC ba sa yankewa ko da lokacin da ɓangaren PC ke gudanar da aikin nazari mai nauyi.

Muhimman ƙayyadaddun kayan aiki ga injiniyoyi:

• Ƙwaƙwalwar tsarin ECC tana gyara kuskuren bit ɗaya ta atomatik, tana hana lalacewar bayanai
• SSD 128GB tare da algorithms na wear-leveling yana tsawaita rayuwar flash a yanayin da ake rubutu da yawa
• Tashoshi huɗu na Gigabit Ethernet masu keɓewa suna tallafawa hanyoyin sadarwa dabam-dabam don sarrafawa, IT, da tsaro
• Zafin aiki: 0°C zuwa 70°C ba tare da tilasta sanyaya ba
• Juriyar girgiza: 15G na 11ms, juriyar rawar jiki: 3G a 10-500Hz

Daga hangen injiniya, ECC RAM tana da matuƙar mahimmanci. Muhallin masana’antu na fuskantar canje-canjen wutar lantarki da tsangwamar lantarki (EMI). Sauyawar bit ɗaya kawai a cikin PID loop na iya sa bawul ya buɗe ba daidai ba. ECC tana hana irin wannan yanayin gazawa.

Haɗin Kai na Yarjejeniyoyi: Haɗawa da Tsofaffin Fieldbus

RXi na ƙunshe da direbobin asali (native drivers) don hanyoyin sadarwar masana’antu da dama. Wannan yana kawar da na’urorin “protocol gateway” da ke ƙara jinkiri da kuma ƙarin wuraren gazawa.

Shawarwarin daidaitawa: Raba kowane yarjejeniya zuwa nasa tashar Ethernet ɗin da aka ware. Wannan yana raba zirga-zirgar sarrafawa daga zirga-zirgar IT. Guguwar watsawa (broadcast storm) a kan hanyar sadarwar ofis ba za ta shafi ainihin lokacin duba I/O ba.

Jagorar Shigarwa: Mafi Kyawun Dabarun Injiniya

Shigar da na'ura yadda ya kamata yana hana gazawar a filin aiki. Bi waɗannan hanyoyin aiki daidai yadda aka bayar.

Muhimmin bayanin tsaro: Jira daƙiƙa 60 bayan cire wutar lantarki kafin buɗe kowace akwati. Capacitors na ciki suna riƙe da wuta mai haɗari. Yi amfani da multimeter don tabbatar da cewa babu wuta kafin taɓa tarminal.

Muhallin Shirye-shirye: Aiki da PACEdge da CODESYS

RXi na tallafawa muhallai biyu na ci gaba. PACEdge na samar da kayan aikin asali na GE tare da ɗakunan karatu (libraries) da aka gina tuni don nazarin bayanai a gefen na’ura (edge analytics). CODESYS na bayar da bin ƙa’idar IEC 61131-3 ga ƙungiyoyin da suke ƙaura daga wasu samfuran PLC. Duka muhallan suna raba injin lokaci guda ɗaya, don haka halayen shirin suna zama ɗaya ko wanne zaɓi aka yi.

Ga injiniyoyin da suka sabo da wannan dandali, ku fara da wannan tsarin aiki:

1. Ƙirƙiri sabon aiki a cikin PACEdge Workbench
2. Saita kayan aiki daga kundin na’ura (zaɓi samfurin RXi-EP-1605B)
3. Daidaita adireshin I/O na jiki zuwa sunayen canje-canje
4. Rubuta dabarun iko ta amfani da jadawalin ladder ko structured text
5. Tura zuwa mai kula ta hanyar Ethernet ta amfani da kayan aikin tura shiri (deployment tool)
6. Yi amfani da sa ido na kan layi don kallon ƙimomin canje-canje a lokaci-na-ainihi

Kuskure gama-gari: mantawa da saita fifikon zagayowar bincike (scan cycle). Don madaukai masu matuƙar muhimmanci ga lokaci (ƙasa da ms 10), ka sanya fifiko 1. Don ayyuka da ba su da tsananin muhimmanci kamar rajistar bayanai, fifiko 5 yana aiki da kyau. Mai tsara lokuta (scheduler) koyaushe yana aiwatar da ayyuka masu fifiko mafi girma da farko.

Ayyuka na Lokaci-na-Ainihi: Ma’aunai da auna tabbataccen lokaci (determinism)

Injiniyoyi suna bukatar lambobi masu ƙarfi. RXi na bayar da aiki mai tabbacin lokaci a ƙarƙashin yanayi mafi muni.

Sakamakon gwaji daga masu gwaji masu zaman kansu:

• Jinkirin daga shigar dijital zuwa fitarwa: microseconds 250 (na kowa), microseconds 500 mafi yawa
• Jit ɗin aiwatar da zagayowar PID: ± microseconds 15 a cikin sa’o’i 24
• Lokacin zagayowar Ethernet don bytes 1000: milliseconds 1.2 a lokacin da CPU ke aiki %100
• Lokacin amsa katsewa: microseconds 75 daga gefen tashi na sigina zuwa farkon aikin

Wadannan lambobi sun ninka aikin PLC na daidaitaccen mataki sau uku. Babban abin da ke ba da damar haka shi ne tushe na lokaci-na-ainihi da aka keɓe. Binciken bayanai a gefen PC ba zai iya toshe gudanar da iko ba, ko da yawan amfani da CPU ya kai kashi nawa.

Binciken Harka 1: Inganta Layin Tattara Motoci

Wani kamfanin ƙera motoci na Detroit yana aiki da tashoshin taro goma sha biyu. A asali, kowane tasha yana da PLC dabam don sarrafa conveyor da kuma PC na masana'antu don tattara bayanan inganci. Daidaita bayanai tsakanin na'urorin yana amfani da OPC DA ta hanyar Ethernet. Jinkirin da aka saba samu yana tsakanin milliseconds 150 zuwa 250.

Ƙungiyar injiniyoyi ta maye gurbin na'urori 24 da masu sarrafawa RXi goma sha biyu. Kowane RXi yana gudanar da dabarar conveyor a kan ainihin-kwaikwayo na lokaci (real-time core) kuma yana gudanar da nazarin inganci a kan ainihin PC. Raba bayanai yana faruwa ne ta ƙwaƙwalwar ciki, wanda ya kawar da jinkirin hanyar sadarwa gaba ɗaya.

Sakamakon da ake iya aunawa bayan watanni shida:

• Amsar madauki na sarrafawa: ta inganta daga 200ms zuwa 15ms (raguwa 93%)
• Ƙimar jarin kayan aiki: ta ragu da 35% (an ajiye dala $84,000)
• Tsayawar samarwa: an rage da 28% (daga awanni 42 zuwa awanni 30 a wata)
• Ingancin layin: ya ƙaru da 22% (daga 71% zuwa 86.6% OEE)
• Awannin kiyayewa: an ajiye awa 120 a kowane wata ta hanyar kawar da matsalar binciken PC

Daga mahangar injiniya, lokacin amsa na 15ms ya ba da wata sabuwar dama. Layin yanzu yana gudanar da auna ƙarfin juyi (torque) kai tsaye yayin matse sukurori. A da, jinkirin 200ms yana nufin gyaran torque yana faruwa ne bayan an riga an daidaita sukurin.

Binciken lamari na 2: Kula da kiyayewa ta hasashe ga reactor na sinadarai

Wata masana'antar sinadarai a Houston tana amfani da na'urorin auna sigina 450 a duk fadin layukan reactor guda uku. DCS ɗin da ake da shi yana tattara bayanai duk bayan daƙiƙa biyar amma baya yin bincike a gida. Ana tura bayanai zuwa uwar garken tsakiya don sarrafawa. Gano abin da ya saba da al'ada yana ɗaukar mintuna 30 zuwa 45, wanda ya yi jinkiri sosai don ɗaukar matakin kariya tun da wuri.

Masana'antar ta girka masu sarrafawa RXi guda biyar, ɗaya a kowane yankin reactor. Kowane mai sarrafawa yana gudanar da ƙaramin samfurin hanyar sadarwar jijiyoyi (neural network) don gano abin da ya saba da al'ada. Samfurin yana sarrafa duk bayanan na'urorin aƙalla sau ɗaya a kowane daƙiƙa. Ana samun sakamako a ƙasa da milliseconds 50.

Sakamakon da ake iya aunawa cikin watanni goma sha biyu:

• Tsayawar masana'anta ba tare da shiri ba: an rage da 40% (daga awanni 312 zuwa awanni 187 a shekara)
• Hasashen gargadi na gaba: sahihanci 93%, ƙimar kuskuren ƙarya 2%
• Gano matsala tun kafin ta tsananta: an kama matsalolin lalacewar ƙarfe guda uku makonni biyu kafin gazawar da ta yi tsanani
• Tasirin kuɗi: ajiyar dala $270,000 a shekara daga gyare-gyare da asarar samarwa
• An guje wa yiwuwar wani lamari: asarar dala $1.2 million na lalacewar kayan aiki da tsaftace muhalli

Aikin sarrafa bayanai na gida na RXi ya kasance mai matuƙar muhimmanci. Nazarin uwar garken tsakiya bai iya gano jinkirin lalacewar ƙarfe ba saboda katsewar cibiyar sadarwa na lokaci-lokaci yana sa a rasa bayanai. Ajiyar bayanai na gida a kan kowane RXi ya tabbatar da cikakkiyar daidaiton bayanai.

Binciken lamari na 3: Bin doka na jerin_batches a masana'antar abinci da abin sha

Wani masana'antar abin sha a Chicago tana samar da nau'ikan jiragen samarwa 120 a kullum. Kowace jirgi na buƙatar rajistar zafin jiki, matsin lamba, da pH don bin ka'idojin FDA. Tsofaffin tsarin suna amfani da PLC don sarrafawa da kuma PC dabam don yin rijista. Ma'aikata suna kwafe bayanai da hannu daga allon PC zuwa takardun bin doka. Kuskure ya kai 15%.

Masana’antar ta tura masu kula RXi guda shida. Kowane na’ura na aiwatar da jerin ayyukan batch da lokaci guda yana rikodin dukkan canje-canjen aikin (process variables) zuwa ma’adanar bayanai ta SQLite. Uwar garken yanar gizo na gida a cikin RXi yana ƙirƙirar rahotannin bin ƙa’ida a lokacin da ake buƙata.

Ingantattun abubuwan da aka rubuta:

• Lokacin fitar da rahoton bin ƙa’ida (compliance reporting): ya ragu da 50% (daga awanni 4 zuwa awanni 2 a kowace rana)
• Kurakuran shigar da bayanai: sun ragu da 33% (daga 15% zuwa 10% na batches)
• Kunna takardun bin diddigi (audit trail) ta atomatik: 90% ana ƙirƙirawa ta atomatik, daga 20% a baya
• Sakamakon binciken FDA: babu wani abin da aka samu, idan aka kwatanta da abubuwa uku da aka samu a baya
• Lokacin horar da ma’aikaci: ya ragu daga kwanaki 3 zuwa rana 1

Babban fa’ida na fasaha ita ce haɗaɗɗen bayanai (integrated database). A baya, PLC da PC suna sadarwa ta Modbus, wanda zai iya wuce rajista 125 ne kawai a kowace mu’amala. Sau da yawa bayanan batch suna yankewa. Taswirar ƙwaƙwalwa ta ciki ta RXi ta kawar da wannan cikas ɗin gaba ɗaya.

Nazarin Lamura na 4: Inganta Amfanin Makamashi a Masana’antar Tace Karafa

Wani gidan tace karfe a Pittsburgh yana gudanar da tanɗuna masu anneling guda takwas. Kowace tanda tana cin megawatt 2.5 a lokacin kololuwa. Tsarin kula da ake amfani da shi a baya yana riƙe zafin jiki ta amfani da sauƙaƙen ON/OFF control. Asarar makamashi ta yi yawa amma ba za a iya auna ta da kayan auna da ake da su ba.

Masana’antar tacewa ta saka masu kula RXi guda takwas, ɗaya a kowane tanda. Kowane mai kula yana gudanar da algoridim ɗin model predictive control wanda ke daidaita matakin kunna wuta bisa jinkirin dumama (thermal inertia). Algoridim ɗin ya koya mafi kyawun saurin hawa zafi (ramp rates) a cikin makonni biyu na aiki.

Sakamakon da aka auna bayan aiwatarwa:

• Dakatarwar wutar tanda ba tare da shiri ba: ta ragu da 45% (daga 22 zuwa 12 al’amura a shekara)
• Amfanin makamashi a kowane ton: ya ragu da 12% (daga 125 kWh zuwa 110 kWh)
• Ajiyar makamashi na shekara-shekara: $340,000 a farashin $0.08 kowane kWh
• Lokacin samun bayanai (data uptime): 99.5% ko da a lokacin katsewar hanyar sadarwar masana’anta
• Canjin zafin jiki: ya ragu daga ±15°C zuwa ±4°C

Ikon RXi na gudanar da nazari a gida (local analytics) ya kasance muhimmi. Algoridim ɗin model predictive control yana buƙatar sabunta bayanai kowane millisecond 100. Ingantawa ta girgije (cloud-based optimization) za ta ƙara millisecond 500 zuwa 1000 na jinkiri, wanda zai sa algoridim ɗin ya zama marar inganci.

Jagorar Fasaha Mai Zurfi: Tura Containers da Edge Analytics

RXi tana tallafawa Docker containers a kan asalin PC ɗinta. Wannan yana ba da damar sauƙaƙan yada nazari (portable analytics deployment). Injiniyoyi za su iya haɓaka samfuran Python ko C++ a kan kwamfutoci, su tattara su a matsayin containers, sannan su tura su zuwa kowace RXi ba tare da sake haɗa lamba (recompilation) ba.

Ayyukan kwantena (container workflow) don tsinkayar kiyayewa (predictive maintenance):

1. Tattara bayanan girgiza da zafin jiki daga zagayowar injin 100
2. Horaz daidaitaccen samfurin isolation forest ta amfani da scikit-learn a kan na’urar ci gaba (development PC)
3. Kunshi samfurin (model) da rubutun inference a matsayin Docker container
4. Aika container zuwa RXi ta hanyar PACEdge container registry
5. Saita container ɗin ya karanta bayanan I/O ta hanyar memory-mapped interface
6. Saita lokacin inference zuwa milisekondi 100 don kimanta abubuwan da suka saba (anomaly scoring) a ainihin-lokaci

Lura game da aiki: Container yana gudana a cikin namespace dabam daga real-time control kernel. Ko da idan container ya karye saboda cinye ƙwaƙwalwa gaba ɗaya, PLC logic tana ci gaba da aiki ba tare da yankewa ba. Wannan warewar muhimmin fasalin tsaro ne.

Tambayoyi da ake yawan yi daga tawagogin injiniyoyi

Mene ne mafi muni scan time idan ana gudanar da manyan nazarin bayanai (heavy analytics)?

Core na ainihin-lokaci (real-time core) yana tabbatar da mafi girman scan time na milisekondi 10 ko da kuwa nauyin aikin core na PC. Idan core na PC ya kai kashi 100% na amfani, ayyukan kulawa (control tasks) suna ci gaba ba tare da yankewa ba. Wannan halayyar deterministic ana tilasta ta ne a matakin kayan aiki ta hanyar ƙwaƙwalwar da aka ware da tashoshin ƙwaƙwalwa na musamman da rarrabuwar core (core isolation).

Ta yaya zan gudanar da sabunta firmware ba tare da dakatar da samarwa ba?

RXi yana goyon bayan bangarorin firmware masu maimaituwa (redundant firmware partitions). Sauke sabuwar firmware zuwa ɓangaren da ba ya aiki yayin da controller ke ci gaba da gudanar da lambar samarwa. Shirya warm restart a lokacin lokacin da aka tsara a dakatar da aiki. Controller ɗin zai tashi daga sabon ɓangaren a cikin ƙasa da daƙiƙa 30. Idan matsala ta taso, za ka iya koma zuwa tsohon ɓangaren ba tare da sake shirin na’urar ba.

Zan iya amfani da RXi a matsayin soft PLC don ayyukan sauya tsofaffin tsarin (legacy migration projects)?

I, za a iya. Muhallin PACEdge ya haɗa da kayan aikin juyawa (conversion tools) don Rockwell Logix 5000, Siemens Step 7, da GE Proficy. Yawancin ladder logic ana juyawa ta atomatik. Ga umarni masu rikitarwa kamar compute blocks, ana buƙatar duba da hannu. Ka sa ran nasarar juyawa ta atomatik kashi 80% zuwa 90% ga yawancin shirye-shirye.

Taƙaitaccen bayanin fasaha: Me yasa wannan tsari yake da muhimmanci

The GE PACSystems RXi Edge Controller yana magance wata matsala da ta daɗe tana takura injiniyoyin kula (control engineers) tsawon shekaru da dama. Yana ba da daidaitaccen lokaci (deterministic timing) na PLC mai ƙarfi tare da sassaucin ƙididdiga na PC na masana’antu cikin na’ura guda. Bayanai daga filin (field data) na masana’antar mota, sinadarai, abinci, da ƙarafa sun tabbatar da manyan ribobi: rage kuɗin jari da 35%, rage tsayawar aiki ba zato ba tsammani da 40%, da saurin martanin kula da tsarin sama da 93%.

Ga tawagogin injiniyoyi da ke shirin haɓakawa a nan gaba, RXi na ba da ingantacciyar hanya zuwa gaba. Yana haɗuwa da fieldbus da aka riga aka girka, yana goyon bayan harsunan ma'aunin IEC 61131-3, kuma yana gudanar da nazarin bayanai a cikin kwantena (containerized analytics) don aikace-aikacen AI. Canjin daga tsarin PLC da PC daban-daban zuwa haɗaɗɗun masu kula na gefen cibiyar (unified edge controllers) ne zai ayyana sarrafa masana'antu (industrial automation) a cikin shekaru goma masu zuwa.