Ƙunshiyar Farashi da Ba a Gani ba na Hanyoyin Sadarwa marasa Kwanciyar Hankali tsakanin PLC da TSI a Masana’antun Zamani
Tsarin industrial automation suna dogaro ne da daidaitacciyar musayar bayanai a lokaci guda tsakanin na’urori da dama. Tsaron injinan juyawa yana dogaro gaba ɗaya da tsarin Bently Nevada TSI don auna girgiza da zafin jiki a ainihin lokaci. PLC na GE Fanuc ne ke kula da muhimmin tsarin sarrafa lissafi da tarawa bayanai a irin waɗannan tsare-tsare. Bayanai na masana’antu sun nuna cewa kashi 68% na gazawar kula da kayan aikin hasashen matsala (predictive maintenance) a masana’antar wutar zafi na fitowa ne daga matsalolin hanyoyin sadarwa. Ƙananan jinkirin watsawa (jitter) na iya jinkirta isar da muhimman bayanai, yayin da manyan katsewar sadarwa ke haifar da ƙararrawar ƙarya da tsayuwar aiki ba tare da an shirya ba. Bugu da ƙari, matsalolin da ke yanke-yanke suna cin kusan kashi 40% na lokutan aiki na masu gyara a wurin. Bincike mai ma’auni da nuni (targeted quantitative troubleshooting) yana kawar da bincike wofinti marar jagora, yana kuma hanzarta gano da gyara matsala.
Manyan Dalilai Hudu na Gazawar Sadarwa
Kididdigar gazawa a fagen aiki ta raba matsalolin PLC-TSI zuwa manyan rukuni hudu masu yawan faruwa. Matsalolin matakin “physical layer” suna da alhakin kashi 45% na dukkan al’amuran daidaituwar sadarwa da ta lalace. Rashin daidaito na sigogin “protocol” yana haifar da kashi 32% na matsalolin rashin watsawar bayanai na dindindin. Tsangwamar lantarki (EMI) da rashin daidaitaccen “grounding” suna haddasa kashi 15% na yanke-yanken sigina. Rashin dacewar nau’in “firmware” kuwa yana haifar da sauran kashi 8% na ɓoyayyun haɗurra. Duk da haka, yawancin matsalolin da ake samu a wurin aiki suna haɗa dalilai da dama lokaci guda. Saboda haka, bin tsarin tantance matsala daga kayan aiki (hardware) zuwa software a matakai-matakai yana ƙara ingancin gano matsala ƙwarai.
Binciken Matakin “Physical Layer” da Gyaran Kayan Aiki
Matsalolin “physical layer” suna bayyana ne cikin yanayi na bazata kuma suna yanke-yanke. Lalacewar rufin igiyoyin da aka kare da “shielding” har ta kai ƙasa da kashi 20% na kaurin asali yana jawo raguwa a ƙarfi da ingancin sigina a hankali. Sako-sakon matsewar sandunan haɗi na iya haifar da daskarewar bayanai na tsawon dakiku 2 zuwa 50 a lokuta marasa tsari. Modules CMM321 na GE Fanuc 90-30 PLC suna da matuƙar saurin kamuwa da matsalar rashin kyakkyawan hulɗa a muhallin da ke da girgiza sosai. Masu aikin fasaha dole ne su gwada juriya (resistance) na madauki na igiya su tabbatar yana ƙasa da 1.5Ω. Raba igiyoyin wutar lantarki da igiyoyin sigina da tazara sama da cm 30 yana rage tasirin EMI sosai. Gwaje-gwajen fage sun tabbatar da cewa maye gurbin tsofaffin igiyoyi yana rage yiwuwar matsalolin “physical layer” da kashi 90%. Fitilar alamar kore mai walƙiya cikin kwanciyar hankali na nuna cewa halin musayar bayanai (handshake) yana tafiya daidai.
Daidaita Sigogin “Protocol” da Tsari Don Kawar da Rashin Daidaito
Sigogin “protocol” da aka ɗaura da juna na daidaito su ne ginshiƙin kwanciyar hankali a sadarwa. Mafi yawan matsaloli na tasowa ne daga rashin daidaiton saitin gudun watsawa (baud rate). Tsarin Bently 3500 TSI na asali yana amfani da 19200 baud, yayin da tsofaffin PLC na GE Fanuc akai-akai ke amfani da 9600 baud. Rashin daidaiton baud rate yana haifar da gazawar fassara bayanan “data frame” kashi 100%. Daidaita tsari yana buƙatar bit 8 na bayanai, bit 1 na tsayawa (stop bit), da even parity don cika ka’idojin IEEE. Saita adireshin tashoshi (station addressing) na musamman yana hana rikicin IP a hanyoyin sadarwa na multi-drop. Daidaita “calibration” bisa ƙa’ida yana magance kashi 92% na matsalolin da suka danganci “protocol”. Yin ajiyar sigogi akai-akai yana hana maimaita kuskuren saitawa yayin aikin kulawa.
Daidaidaitaccen “Grounding” da Hana Tsangwamar EMI
Rashin daidaitaccen “grounding” shi ne mafi yawan ɓoyayyen tushen matsala da ake yi watsi da shi. Filayen lantarki na masana’anta suna haifar da ƙarfin wuta na banza (stray induced voltage) 30–50V a kan igiyoyi marasa kariya. Raba “grounding grid” ɗaya guda ga na’urori da dama yana haifar da bambancin ƙarfin wuta 0.5–1.2V a tsakaninsu. Wannan ƙaramin bambanci na iya lalata siginar TSI mai matuƙar daidaito. Dole ne a sami “grounding grid” mai zaman kansa da aka keɓe musamman, wadda juriya ɗinta ya kasance ƙasa da 4Ω. Haɗa dukkan sassan ƙarfe a matsayin matakin daidaita ƙarfin wuta ɗaya (equipotential bonding) a cikin kabad ɗin ƙarfe yana kawar da tsangwamar ƙananan ɓoyayyun ƙwarara (stray current). Binciken “grounding” na shekara-shekara yana hana haɗurran da suka shafi tsufa da lalacewar tsarin. Ingantacciyar kariya daga EMI na daidaita sahihancin watsawar bayanai har zuwa kashi 99.8%.
Ra’ayin Kwararre: Matsalolin Masana’antu da Sabbin Hanyoyi
Bayan shekaru 15 na aikin daidaita tsarin a wuraren samar da wutar lantarki da na Petrochemical, na gano mahimman matsalolin da ke damun masana’antu. Yawancin masana’antu suna aiki da tsare-tsaren da suka haɗu, inda ake amfani da tsofaffin PLC na GE Fanuc tare da sabbin tsarin Bently Nevada TSI. Haɗa na’urori na zamani daban-daban yana haifar da ɓoyayyun matsalolin rashin dacewar “firmware”. Kimanin kashi 60% na masana’antun wuta masu matsakaicin tsufa ba sa yin cikakken binciken daidaiton “firmware”. Wannan sakaci yana kaiwa ga rugujewar sadarwa lokaci-lokaci duk bayan watanni 3–6. Saboda haka, daidaita “firmware” kafin aikin kulawa ya kamata ya zama tsarin doka. Masana’antu na gaba za su rungumi ƙayyadaddun ka’idojin sadarwar IoT guda ɗaya da za su sauƙaƙa haɗa na’urori tare da rage gazawar da ke faruwa tsakanin samfuran kamfanoni daban-daban.
Misalin Bincike na Aiki 1: Sa-Idon Injin Turbine na Masana’antar Wutar Zafi
Wata masana’antar wutar zafi mai ƙarfin 300MW ta girka GE Fanuc 90-30 PLC tare da Bently Nevada 3500/92 TSI. Tsarin ya kan yi daskarewar bayanai na tsawon dakiku 2–15, sau 8–12 a kowace rana. Ba a iya aika bayanan girgiza da zafin jiki a ci gaba, lamarin da ya jefa sahihin aikin injin cikin haɗari.
Bincike ya tabbatar da cewa akwai matsaloli uku da suka haɗu: rashin daidaiton baud rate (PLC na 9600, TSI na 19200), amfani da “grounding” ɗaya tare da juriya 1.1Ω, da kuma matsalolin dacewa na “firmware” V4.0 na PLC. Maganin ya haɗa da daidaita dukkan sigogi zuwa 19200 baud, yanayin 8E1; girka tsarin “grounding” mai zaman kansa da ke da juriya 3.2Ω; da sabunta “firmware” zuwa sigar V5.6 mai kwanciyar hankali. Gwajin matsa lamba na sa’o’i 96 ya tabbatar da zamanantar daidaiton tsarin.
Sakamako: Sauyin matsala ya koma sifili. Yawan nasarar watsawar bayanai ya tashi daga kashi 82% zuwa 99.97%. Masana’antar ta rage kuɗin aikin ma’aikata na shekara da kashi 22% tare da guje wa tsayuwar aiki guda biyu da ba a shirya ba.
Misalin Bincike na Aiki 2: Yanke-Yanken Sadarwa a Babban Injin Matsin Lantarki na Masana’antar Sinadarai
Babban injin matsin zafi mai juyawa (centrifugal compressor) a wata masana’antar sinadarai ya yi amfani da GE Fanuc RX7i PLC tare da ƙa’idojin sa-ido na Bently 3500/40. Ana samun ɗan gajeren yanke sadarwa sau 3–5 a kowane mako, wanda ke tayar da ƙararrawa marasa inganci da katse injin ba tare da buƙata ba, yana shafar samarwa.
Bincike ya gano cewa an shimfiɗa igiyoyin sigina a layi ɗaya da igiyoyin wutar lantarki masu ƙarfin gaske, da tazara na cm 10 kacal, wanda ya haifar da matsanancin EMI. Tsofaffin “terminal block” sun nuna juriya 0.8Ω a wurin hulɗa. Maganin ya haɗa da sake tsara hanyar igiyoyi zuwa tazara 35 cm, maye gurbin dukkan “terminal”, ƙara “shielding grounding”, tare da kafa duba juriya na kowane mako.
Sakamako: An kawar da dukkan matsalolin yanke-yanke. Yawan ƙararrawar ƙarya da ke katse injin ya ragu da kashi 100%. Layin ya cimma kwanaki 180 na aikin da ba a sami wata matsalar tsayuwa ba, abin da ya ƙara jimillar inganci da kashi 6.5%.
Shawarwari na Aiki ga Injiniyoyi
Injiniyoyin da ke fuskantar irin waɗannan matsalolin PLC-TSI ya kamata su yi amfani da tsarin gano matsala mai tsari. A fara da tabbatar da matakin “physical layer” ta hanyar duba lafiyar igiyoyi, ƙarfafa haɗin sandunan da'ira, da auna juriya na “grounding”. A ci gaba da tabbatar da daidaiton “protocol” ta hanyar daidaita baud rate, tsarin bayanai, da adireshin na’urori a dukkan bangarorin. A magance EMI ta hanyar ware igiyoyi yadda ya kamata da kuma amfani da “shielding”. A ƙarshe, a tabbatar da dacewar “firmware” sannan a rubuta dukkan saituna. Wannan tsarin da aka tsara yana rage lokacin neman matsala tare da ƙara yawan samun nasarar gyara daga gwaji na farko.
Rubutawa daga Fang Zekai, injiniya ƙwararre da ke mai da hankali kan sarrafa matakai da tsarin kulawa ga abokan cinikin man fetur da iskar gas a duniya.
