Dalilin Da Ya Sa GE Fanuc PLCs Ke Bacewa Daga Benayen Masana’antar Discrete
Mafi yawan masana’antar discrete na fuskantar wata matsala da ba a gani sosai. Tsofaffin GE Fanuc 90-30 da 90-70 PLCs ba sa iya biyan bukatun samarwa na zamani. GE ta daina bayar da goyon bayan fasaha na hukuma ga waɗannan dandamali a 2022. Yanzu kayan gyara suna ɗaukar makonni 12 zuwa 16 kafin a kawo su. Sakamakon haka, kuɗin kiyayewa na shekara-shekara ya ƙaru da kashi 40 cikin 100.
Waɗannan tsoffin na’urorin sarrafawa ba su da ɗakakkun tashoshin EtherNet/IP na asali. Sun dogara ne da tsohuwar sadarwar serial kaɗai. Saboda haka, ba za su iya aikawa da bayanan lokaci-zuwa-lokaci zuwa manyan tsarin sarrafa masana’antu ba. A cewar rahoton masana’antu na Rockwell Automation na 2025, sama da kashi 68 cikin 100 na masana’antar discrete na fuskantar tangarda saboda tsofaffin tsarin sarrafawa. Bugu da ƙari, kashi 37 cikin 100 na matsalolin tsayawar layi kwatsam ana gano su ne daga tsoffin GE Fanuc CPU modules. Ga masana’antar “smart factory”, yin ƙaura cikin natsuwa daga tsoffin PLC zuwa sabbi ba zaɓi ba ne kuma.
Asirin Haɗarin Sauya PLC Tsakanin Manyan Masu Kera Daban – Tabbatarwa Daga Bayanai na Fage
Ƙungiyoyin sarrafa kansu da dama suna rage kimar haɗarin sauya PLC daga iri ɗaya zuwa wani iri daban. Bayanai na filin aiki suna nuna cewa ladder logic na GE Fanuc ya bambanta da kashi 72 cikin 100 daga ƙa’idojin shirye-shiryen Allen-Bradley. Yin kwafe-ka-liƙa kai tsaye na logic sau da yawa yana haifar da kurakuran interlock. Waɗannan kurakuran na iya haddasa tsayawar gaggawa na layukan samarwa da ke aiki.
Bugu da ƙari, matakan ƙarfin wutar siginar analog ba su dace da juna sau da yawa. Wannan matsalar kaɗai ce ke haifar da kashi 18 cikin 100 na gazawar gyara bayan ƙaura. Sauya dukkan layi gaba ɗaya a lokaci ɗaya yawanci yana haifar da tsayawar samarwa na awanni 11 ga kowace bita. Mafi yawan masana’antar discrete ba za su iya jure irin waɗannan dogayen lokutan tsaiko ba. Har ila yau, saita sigogin hanyar sadarwa ba daidai ba na iya tarwatsa tsofaffin allon sa ido na SCADA. Sakamakon haka, waɗannan ɓoyayyun haɗurra na iya sa aikin ƙaura ya zama babbar matsalar kashe kuɗi cikin sauri.
Dalilin Da Ya Sa Allen-Bradley Ya Fi Sauran Alamu PLC Dacewa Don Wannan Ƙaura
Bayan shekaru 15 na aikin gyaran DCS da PLC kai tsaye, na fito da sahihan sakamako. Zaɓin alamar (brand) yana da tasiri kai tsaye ga nasarar aiki. Allen-Bradley PLCs suna ba da sauƙaƙƙen I/O mapping ga layukan taro na discrete idan aka kwatanta da Siemens. Haɗaɗɗen yarjejeniyar EtherNet/IP ta dace da yawancin tsarin hanyar sadarwar masana’anta ba tare da buƙatar manyan sauye-sauye ba.
Jerar CompactLogix tana rage jimillar kasafin gyara da kashi 14 cikin 100 idan aka kwatanta da masu sarrafawa na Siemens na matsakaicin matsayi. Bugu da ƙari, AB controllers suna tallafawa ayyukan hot backup. Wannan fasalin yana hana tsayawar samarwa kwatsam lokacin gazawar controller. A cikin masana’antar discrete, ikon sarrafa kuɗi da tabbatar da kwanciyar tsarin aiki suna fi muhimmanci fiye da siffofi masu rikitarwa fiye da kima. Saboda haka, Allen-Bradley yana ba da mafi kyawun daidaiton aiki, ƙima, da amincin aiki ga wannan takamaiman hanyar ƙaura.
Tsarin Ƙaura Na Matakai Hudu Don Ƙananan Lokutan Tsayawar Samarwa
Mun haɓaka wannan tsarin matakai huɗu ne daga ainihin ayyukan ƙaura 28 na GE Fanuc zuwa Allen-Bradley. Kowane mataki ya mayar da hankali ne kan rage tasirin da ake samu a samarwa.
Mataki Na Ɗaya – Tsara Bayanai Biyu Cikin Rarrabawa da Kimanta Haɗari Tun Kafin Fara Aiki
Ƙungiyoyi dole su ware shirye-shiryen logic da zanennin wayoyi na zahiri daban-daban. Kada a taɓa haɗa su cikin tarin bayanai guda. A yi alamar duk siginar safety interlock dabam-dabam domin a guji rasa mahimman logic na kariya. Daga nan a ba kowace tashar maki na haɗarin ƙaura. Tashoshin da ke da haɗari mai yawa su samu fifiko a aikin debugging na “offline”.
Mataki Na Biyu – Offline Virtual Debugging Tare da Kwatankwacin Digital Twin
A gina samfuran digital twin na 1:1 don kwaikwayon duk matakan aiki na layi a wajen yanayin samarwa. Masana za su kammala cikakken tantancewar logic ba tare da taɓa na’urorin samarwa na ainihi ba. Wannan matakin yana kawar da kashi 95 cikin 100 na kurakuran logic kafin a fara sauya kayan aiki a wurin. Kada a taɓa tsallake wannan mataki don a ce ana ajiye lokaci.
Mataki Na Uku – Sauya Kayan Aiki a Hankali a Lokutan Daddare na Off-Peak
A gudanar da duk sauya kayan aiki a cikin taga gyaran dare na awa 6 da ake yi kowace rana. A maye gurbin tashoshi ɗaya bayan ɗaya maimakon a kwashe dukkan ƙabid na lokaci guda. Sauyawa da debugging na tashar guda na ɗaukar awa 1.5 zuwa 2.5 kawai. Wannan dabarar tana barin yawancin layi yana ci gaba da gudana a lokutan samarwa.
Mataki Na Hudu – Gudanar da Tsarin Biyu a Zafi (Hot Parallel Run) da Canja Iko a Hankali
A gudanar da tsohon GE Fanuc PLC da sabon AB PLC a lokaci guda na sa’o’i 96 ba tare da yankewa ba. A kwatanta bayanan na’urori masu auna sigina (sensor) na lokaci-zuwa-lokaci da martanin aiki tsakanin tsarin biyu. A fara sauya ikon sarrafawa a hankali ne kawai bayan an kai kashi 100 cikin 100 na daidaiton bayanan aiki. Wannan hanyar tana tabbatar da rashin kowanne tsayawar samarwa da ba a tsara ba.
Misalan Aiki Biyu na Gaskiya Tare da Cikakken Bayanai na Ayyukan Layi
Case 1 – Ƙaura na Layar Bugun Sassan Motoci (Automotive Parts Stamping Line)
Bayanan aikin: Layin stamping mai tashoshi 6 tare da GE Fanuc 90-30 PLC a matsayin babban controller. Jimillar I/O points sun kai 426. Kafin gyara, layin yana fama da tsayawar ba-zata guda shida a duk wata saboda tsohon kayan PLC. Kowane tsayawa yana haifar da asarar matsakaicin mintuna 45 na samarwa.
Magani na musamman: Masana sun zaɓi Allen-Bradley CompactLogix L30ER controller. Sun ci gaba da amfani da duk tsohon wiring na tsaro. An sake gina allon sa ido na SCADA ba tare da sauya na’urar kwamfutar sama ba. Ƙungiyar ta aiwatar da tsarin ƙaura na daddare a hankali tsawon darare 5.
Sakamakon ƙididdiga: Jimillar tasirin tsayawar samarwa da aka ƙididdige bai wuce awanni 4 ba. Yawan matsalolin ba-zata na wata-wata ya sauka daga guda 6 zuwa sifili. Kuɗin kiyayewa na shekara ya ragu da kashi 46 cikin 100, wanda ya ceci masana’antar dala $87,000 a shekara. Yanzu duk bayanan samarwa suna tashi zuwa tsarin MES na masana’anta kowane millisecond 200. Samuwar layi (line availability) ta tashi daga kashi 91.3 cikin 100 zuwa 99.1 cikin 100.
Case 2 – Ƙaura na Layar Taron Sarrafa Wayoyin Hannu (Consumer Electronics Assembly Discrete Line)
Bayanan aikin: Layin taron kwalliyar wayar hannu mai daidaito sosai wanda asali yake amfani da GE Fanuc VersaMax PLC tare da I/O points 284. Tsohon tsarin bai iya haɗuwa da tsarin tsara motsin AGV na bita ba. Wannan ƙuntatawa ta haifar da asarar kashi 7 cikin 100 na ingancin samarwa a kullum, daidai da asarar mintuna 210 na fitarwa a kowane shift.
Magani na musamman: Ƙungiyar ta zaɓi Allen-Bradley ControlLogix 5580 PLC mai ƙarfi. Sun inganta tsohon pulse control logic na motoci servo guda takwas. EtherNet/IP ta ba da damar haɗin kai ba tare da tangarda ba tsakanin PLC da dandamalin tsara motsin AGV. Jimillar ƙaura ta ɗauki night shifts guda uku ba tare da wata katsewa a lokutan yini ba.
Sakamakon ƙididdiga: Ingancin aikin layin samarwa ya ƙaru da kashi 8.2 cikin 100. Daidaiton matsayi na servo ya inganta daga ±0.1 mm zuwa ±0.03 mm. Adadin ɓarnar kaya ya ragu daga kashi 1.7 cikin 100 zuwa 0.9 cikin 100. Babu wani rugujewar shiri ko kuskure da ya faru cikin watanni 12 bayan ƙaura. Masana’antar ta dawo da duk jarin da ta saka a aikin ƙaura cikin watanni 8 ta hanyar ƙarin inganci.
Kurakuran Ƙaura da Aka Fi Yi da Dabarun Gujewa na Masana
Bayanan fage suna nuna cewa kashi 32 cikin 100 na ƙungiyoyi suna yin kwafe kai tsaye na tsohon logic ba tare da sake yin signal re-mapping ba. Wannan kuskure yana haifar da mu’amala mara kyau ga na’urorin pneumatic da servo a wurin aiki. Masana da dama kuma suna watsi da daidaita agogo (clock synchronization) tsakanin sabon PLC da tsohon tsarin DCS. Sakamakon haka, timestamps na bayanan samarwa suna rikicewa, abin da yake shafar nazarin bayanai masu yawa (big data) na gaba.
Shawarata ta asali tana da sauƙi. Kada a taɓa tsallake digital twin simulation domin a rage lokacin aikin gini. Offline debugging yana hana aukuwar manyan haɗurran tsaro da ba za a iya gyara su ba a kan layukan samarwa da ke aiki. Koyaushe a ware isasshen lokaci don tabbatarwa kafin kayan aiki su taɓa bene na masana’anta. A cikin ayyukanmu, digital twin simulation ta ƙara awanni 36 na shirin aiki kawai amma ta kawar da kashi 95 cikin 100 na kurakuran da ake samu a wurin.
Jigogin Masana’antu da Taƙaitaccen Taƙaitaccen Fasaha
Kasar kasuwar gyaran tsoffin PLC a duniya za ta ƙaru da kashi 12.7 cikin 100 a shekara daga 2026 zuwa 2030. Masana’antu da dama za su daina dogaro da hanyoyin canji ta gateway. Ana sa ran ƙaura kai tsaye daga alama zuwa wata alama daban za ta zama hanyar da aka fi so. Ƙaura ta matakai masu zafi (phased hot migration) za ta zama daidaitaccen tsarin aiki ga layukan samarwa da ke aiki.
Gina hanyar sadarwar masana’antu guda ɗaya (unified industrial network) dole ne ya kasance tare da sabunta sabon kayan PLC. Masu aikin sarrafa kansu dole su iya duka tsoffin tsarin shirye-shiryen PLC da sabbi. Waɗanda suka zuba jari a cikin ƙwarewar aiki tsakanin alamu daban-daban za su jagoranci sabon gagarumin salo na zamani da tsarowa na masana’antu. Bisa bayanan ayyukan da ake da su yanzu, matsakaicin lokacin dawowar jari (ROI) na wannan hanyar ƙaura yana tsakanin watanni 6 zuwa 14 gwargwadon girman layi.
Yanayin Aikace-aikace da Shawarwarin Magani
Wannan tsarin ƙaura yana dacewa kai tsaye da yanayi uku mafi yawan faruwa, tare da sakamakon ƙididdiga da aka tabbatar:
Samar da sassan motoci: Layukan stamping, welding, da painting da ke da haɗaɗɗun I/O points tsakanin 300 zuwa 1000. A yawanci ana samun ajiyar kuɗi na dala $65,000 zuwa $120,000 a shekara ga kowanne layi.
Taron kayan lantarki na 3C: Layukan daidaito mai yawa da ke buƙatar daidaiton matsayi na servo ƙasa da ±0.05 mm. Ingantuwar daidaito bayan ƙaura na kai matsakaicin riba ta 0.07 mm.
Samar da sassan makamashi na zamani: Layukan taron baturin module da pack da ke buƙatar bayanai na lokaci-zuwa-lokaci zuwa MES. Jinkirin tashi bayanai yana sauka daga daƙiƙa 2 zuwa ƙasa da millisecond 250.
Ga kowanne yanayi, a fara da digital twin simulation. Daga nan a aiwatar da sauya kayan aiki na daddare a hankali. A ƙarshe, a gudanar da tsarin biyu a lokaci guda na sa’o’i 96 kafin a yi cikakken sauya iko.
Rubutacce ta Song Mingyuan, injiniyan sarrafa kansa mai ƙwarewa a PLC, DCS da manyan alamu na sarrafa masana’antu na ƙasashen duniya ga aikace-aikacen petrochemical.
