Lokacin Wayoyin Kabad na PLC Ya Rage Sosai Tare da Toshewar Tashar Jirgin Kasa ta DIN Mai Fitarwa Mai Girma 5.08mm — Abin da OEMs na Masana'antu ke Samuwa a Ingantaccen Haɗawa
TL;DR
- Tubalan tashoshi masu toshewa na 5.08mm suna rage lokacin wayoyi a kowace haɗin kai daga daƙiƙa 45-90 (tashar sukurori ta gargajiya) zuwa daƙiƙa 15-25 — raguwar kashi 50-70% wanda ya haɗu zuwa sa'o'i 40-60 da aka adana a kowace kabad ɗin PLC idan aka ninka ta hanyar ƙarewar mutum 600-1,200.
- Masu haɗin da aka riga aka haɗa da pluggable suna kawar da kurakuran aikin wayoyi saboda an gyara maƙallin haɗin a matakin ƙera kayan haɗin maimakon a fassara shi ta hanyar mai ginin panel daga zane na wayoyi - rage ƙimar kurakuran wayoyi daga kusan 2-5 a kowace kabad zuwa kusan sifili.
- Sauya kayan aikin I/O daga filin ya ragu daga mintuna 45-105 zuwa ƙasa da mintuna 10 Idan aka yi amfani da masu haɗin da za a iya haɗawa da su - ƙwararren zai cire toshewar mahaɗin, ya canza module ɗin, sannan ya sake haɗa mahaɗin ɗaya da sifili.
Abubuwan Aiki na Wayoyin Tashar Sukurori na Gargajiya
A cikin kabad ɗin sarrafawa na PLC mai matsakaicin rikitarwa don injunan marufi, tsarin jigilar kaya, ko sarrafa injin ƙera allura, yawanci akwai ƙarewar waya 600-1,200. Kowace ƙarewa akan toshewar hanyar haɗi ta sukurori na gargajiya yana buƙatar: cire 8-10mm na rufi daga ƙarshen waya ta amfani da kayan aikin cirewa da aka daidaita, saka wayar da aka cire a cikin buɗewar tashar, matse sukurori zuwa ga ƙarfin juyi da aka ƙayyade (yawanci 0.5-0.8 Nm don waya 2.5mm² kamar yadda masana'anta suka ƙayyade), da kuma tabbatar da haɗin tare da gwajin ja bisa ga IEC 60947-7-1. Cikakken zagayen tabbatar da tsiri-saka-tighten-tabbatar yana ɗaukar daƙiƙa 45-90 a kowace waya ya danganta da ƙwarewar ma'aikacin, damar samun wurin ƙarshe a cikin kabad mai cike da kaya, da kuma ko hanyar sadarwa ta waya tana buƙatar ƙarin matakan sarrafa kebul. A matsakaici na daƙiƙa 60 a kowace haɗi da ƙarewa 800 a kowace kabad, aikin wayoyi kai tsaye kaɗai shine mintuna 800 - sama da awanni 13 a kowace kabad.
Wannan bai haɗa da lokacin da ake buƙata don fassara zane-zanen wayoyi da kuma taswirar su zuwa matsayin ƙarshe na zahiri ba. Zane-zanen wayoyi yana nuna haɗin ma'ana: "I0.0 → tashar X1:47." Dole ne ƙwararren masani ya gano tashar X1 a kan layin DIN, ya ƙidaya zuwa matsayi na 47 a jere na tashoshi masu kama da iri ɗaya 60-80, sannan ya saka waya madaidaiciya. A yawan tashoshi 60 a kowace mita na layin DIN, bambancin gani tsakanin tashar 47 da tashar 48 yana buƙatar mai da hankali kan kowace haɗi ɗaya. Matsakaicin kuskuren da ke ƙarƙashin yanayin samarwa - inda masu fasaha ke da kabad na wayoyi na awanni 7-8 a kowace aiki - shine kusan kurakurai 2-5 na wayoyi a kowace kabad a matsakaici, bisa ga ingancin bayanan shagon panel da na sake dubawa. Kowane kuskure yana ɗaukar mintuna 15-45 don ganowa da gyara yayin gwajin aiki, yana ƙara mintuna 30-225 na sake aiki a kowace kabad. Waɗannan kurakurai kusan gaba ɗaya aikin matakin taswirar hannu ne - yatsun ma'aikacin sun sauka akan waya madaidaiciya amma matsayin ƙarshe mara kyau - kuma ba za a iya kawar da su ta hanyar horo ko horo kawai ba.
Tsarin da Za a Iya Fitar da Shi: Karewa a Riga, Ba a Kabad ba
Bulogin tashoshi masu haɗawa suna canza tsarin wayoyi na asali daga ƙarewa a cikin kabad zuwa ƙarewa a kan abin ɗaurewa. Maimakon kawo wayoyi daban-daban cikin kabad da kuma ƙarewa kowannensu zuwa matsayinsa na ƙarshe a kan layin DIN, mai ginin panel yana karɓar igiyoyin waya da aka riga aka haɗa tare da masu haɗin da za a iya haɗawa da su waɗanda aka riga aka ƙare a kan ƙarshen waya. Toshewar mahaɗin - filogi mai matsayi 2-24 tare da tsayin 5.08mm - yana haɗuwa da kan layi mai tsayayye da aka ɗora akan layin DIN. Aikin mai ginin kabad yana canzawa daga ƙarewa guda 800 zuwa haɗa tubalan mahaɗi 20-40 da aka riga aka haɗa a cikin kanun su da suka dace.
Wannan wani tsari ne na musamman na haɗa kayan aiki tare da tasirin da ya wuce tanadin aiki kai tsaye. Ana ɗaga aikin wayoyi masu inganci, waɗanda ke da sauƙin kuskure zuwa matakin kera kayan aiki, inda za a iya yin sa a kan benci a ƙarƙashin ingantaccen yanayi na haske, tare da samun damar shiga fuskokin masu haɗawa ba tare da wata matsala ba, kuma - a zahiri - tare da kayan aikin gwajin kayan aiki na atomatik wanda ke tabbatar da kowane haɗi don ci gaba, daidaita aikin fil, da juriyar rufi kafin jigilar kayan aiki zuwa shagon kayan aiki. Tsarin gwajin kayan aiki ta amfani da Cirris ko makamancin haka na'urar gwaji ta atomatik zai iya tabbatar da haɗuwar mahaɗin matsayi 50 cikin ƙasa da daƙiƙa 30 kuma ya samar da rahoton gwaji wanda ke aiki a matsayin shaida mai inganci don dubawa na shagon kayan aiki. Canjin ya kasance daga amincewa da hankalin ma'aikacin zuwa amincewa da ma'aunin kayan aikin gwaji na haƙiƙa.
Tanadin lokaci yana da matuƙar muhimmanci kuma an rubuta shi sosai a cikin ginin panel na masana'antu. Toshe mai haɗawa tare da wayoyi 12 da aka riga aka gama yana toshewa cikin kan layin DIN nasa cikin daƙiƙa 5-10 - lokacin da ake buƙata don daidaita mai haɗawa da kan, tura shi har sai shafin kullewa ya shiga tare da dannawa mai ji, kuma a gani ya tabbatar da cikakken shigarwa ta hanyar duba cewa fuskar mai haɗawa tana da fuskar kan. Toshewar tashar sukurori ta gargajiya mai matsayi 12 tana buƙatar mintuna 12-18 don ƙarewa a cikin kabad. Hanyar toshewa tana rage wannan zuwa ƙasa da daƙiƙa 30 don aikin gefen kabad - raguwar fiye da kashi 95% a cikin aikin gefen kabad ga waɗannan haɗin 12. A cikin kabad mai haɗin 800 tare da masu haɗin da za a iya haɗawa, lokacin wayar gefen kabad yana raguwa daga awanni 13+ zuwa kimanin awanni 2-3. Lokacin haɗa kayan haɗin da aka ƙare, wanda aka yi a benci, yana ƙara awanni 4-6, don raguwar net na 35-45% a cikin jimlar aikin wayoyi.
Kawar da Kuskure Ta Hanyar Gyaran Pinout
Mafi mahimmancin fa'idar tubalan tashar da za a iya haɗawa ba lallai bane ta hanyar tanadin aiki — shine kusan kawar da kurakuran aikin wayoyi. Lokacin da mai kera kayan haɗin ke gina mahaɗi mai matsayi 12 tare da wayoyi a matsayi na 1 zuwa 12, an gyara fil ɗin a zahiri. Mai ginin panel ba zai iya saka waya mara kyau a matsayi na 7 ba saboda wayar matsayi na 7 ta riga ta ƙare a cikin mahaɗin a matsayi na 7 kuma ba za a iya motsa ta ba tare da yankewa da sake ƙarewa ba. Abinda kawai aka yi a cikin kabad shine haɗa mahaɗin a cikin kanun da ya dace, wanda aka yiwa alama da mai gano mahaɗin (misali, "X101") wanda ya dace da zane-zanen wayoyi da lakabin zahiri akan jikin mahaɗin gefen kayan haɗin.
Wannan sauyi daga tabbatarwa ta kowace waya zuwa tabbatarwa ta kowace mahaɗi yana canza bayanin gano kurakurai. A cikin kabad na gargajiya mai waya mai maki-zuwa-maki, dole ne a duba kowace haɗin 800 daban-daban bisa ga zane-zanen wayoyi - tsarin tabbatarwa yana buƙatar awanni 4-6 kuma yana ƙarƙashin ƙimar kuskuren ɗan adam iri ɗaya da wayoyi na asali. Tare da masu haɗin da za a iya haɗawa, tabbatarwar ta rage zuwa: (1) tabbatar da cewa an gwada igiyar ci gaba da pinout a masana'antar kayan haɗin kuma rahoton gwajin yana samuwa, kuma (2) tabbatar da cewa kowace toshe mai haɗawa tana cikin kanun da ya dace ta hanyar duba lakabin da ido akan zane na tsarin kabad. Mataki na 2 yana ɗaukar mintuna 10-15 ga masu haɗin 30. Jimlar aikin tabbatarwa ya ragu daga awanni 4-6 zuwa ƙasa da awa ɗaya. Yawan kuskuren wayoyi ya ragu daga 2-5 kowace kabad zuwa kusan sifili saboda mai haɗin yana tilasta pinout - babu shawarar mai aiki game da wace waya take zuwa inda, kawai daidaiton gani tsakanin lakabi biyu.
The UL 508A mizani ga allunan sarrafa masana'antu da kuma IEC 61439 don haɗakar na'urorin sauya wutar lantarki masu ƙarancin wutar lantarki da na'urorin sarrafawa, fasahar haɗin da za a iya haɗawa da ita tana nufin hanyar inganta ingancin wayoyi na masana'anta. UL 508A ta musamman tana ba da damar haɗa masu haɗawa da za a iya haɗawa da ita azaman hanyar wayoyi masu karɓuwa muddin an jera mahaɗin don aikace-aikacen kuma ƙimar wutar lantarki/hawa suna cikin ƙayyadaddun ƙayyadaddun masana'antar mahaɗin.
Sabis na Fili: Inda ROI ke Yawaita
Tanadin lokacin haɗawa yana tabbatar da ɗaukar tubalan tashar da za a iya haɗawa a shagon panel; tanadin sabis na filin shine inda ROI ke hanzarta fiye da hujjar siyan farko. Lokacin da na'urar I/O ta gaza a cikin kabad ɗin PLC da aka haɗa da tashoshin sukurori na gargajiya, tsarin hidimar filin yana ɗaukar lokaci mai tsawo: ɗaukar hoto ko yiwa kowace waya da aka haɗa da na'urar da ta gaza lakabi (minti 10-30, ya danganta da yawan waya da ingancin lakabin da ke akwai), cire duk wayoyi 20-40 na mutum ɗaya (minti 5-15), cire na'urar da ta gaza kuma shigar da madadin (minti 5-10), sake dakatar da duk wayoyi zuwa tashoshin da suka dace akan na'urar maye gurbin yayin da ake nuni ga hoton ko lakabin da aka ɗauka a mataki na 1 (minti 20-45), kuma tabbatar da kowace haɗi (minti 5-10). Jimlar lokacin da ya wuce: mintuna 45-105 na ƙwararrun ma'aikata, wanda injin samarwa baya aiki.
Tare da masu haɗin da za a iya haɗawa da su, hanyar za ta ruguje zuwa: cire toshewar toshewar haɗin daga ɓangaren da ya gaza (daƙiƙa 5), cire ɓangaren da ya gaza sannan a shigar da wanda ya maye gurbin (daƙiƙa 5-10), sannan a haɗa toshewar haɗin a cikin ɓangaren maye gurbin (daƙiƙa 5). An katse wayoyin sifili. Ana sake dakatar da wayoyin sifili. Haɗin sifili yana buƙatar tabbatarwa saboda mahaɗin ɗaya da wayoyi iri ɗaya a cikin matsayi ɗaya na fil yanzu an haɗa shi cikin ɓangaren maye gurbin iri ɗaya. Jimlar lokacin - ƙasa da mintuna 10, wanda maye gurbin ɓangaren injin da sake farawa na PLC ya mamaye - raguwa ne da kashi 80-90% daga tsarin gargajiya. A cikin masana'antu inda lokacin dakatarwar injin ke kashe dala 500-5,000 a kowace awa (layukan haɗa motoci, marufi na abinci da abin sha, masana'antar magunguna, ƙera semiconductor), bambancin tsakanin gyaran minti 90 da gyaran minti 10 yana adana dala 650-7,500 a cikin farashin dakatarwar kowane ɓangaren I/O. A tsawon shekaru 10-15 na aikin injin tare da maye gurbin na'urorin I/O guda 3-6, tanadin sabis na filin kawai zai iya wuce ƙarin farashin tubalan tashar da za a iya haɗawa da ninki 3-5.
Tattalin Arzikin Kuɗin Haɗin Kai
A matakin kayan aiki, tubalin da aka yi amfani da shi wajen haɗa bututun ...
Duk da haka, farashin kayan aiki abu ɗaya ne kawai. Matsakaicin nauyin ma'aikata na haɗa kayan aiki a Arewacin Amurka ko Yammacin Turai shine USD 35-55 a kowace awa. Tanadin aiki a kowace haɗi - kimanin daƙiƙa 30-50 - yana fassara zuwa USD 0.29-0.76 a kowace haɗi a waɗannan ƙimar. Ta amfani da matsakaicin maki na kowane fanni, ƙimar kayan aikin USD 0.75 za a daidaita ta da USD 0.50 a cikin tanadin aiki, wanda ke barin ƙimar kuɗi ta dala 0.25 a kowane matsayi - ko USD 200 akan kabad mai matsayi 800. Lokacin da aka haɗa da tanadin sabis na filin, rage lokacin gwaji na aiki, da kuma kawar da da'awar wayoyi na garanti, jimlar farashin mallakar yana canzawa sosai don fifita masu haɗin da za a iya haɗawa a shekara ta 1-2 na aikin filin.
Tambayoyin da Ake Yawan Yi
Menene ƙimar da ake da ita a yanzu don tubalan tashoshi masu iya haɗawa da 5.08mm?
An ƙididdige tubalan tashar da za a iya haɗa su da pitch 5.08mm don 12-16A a 300V ga ƙa'idodin IEC 61984 da UL 1059, ta amfani da waya 0.5-2.5mm² (20-14 AWG). Wannan ya ƙunshi mafi yawan siginar PLC I/O - shigarwar dijital (5-15mA a 24VDC), fitarwar dijital (0.5-2A a 24VDC ko 120VAC), da siginar analog (4-20mA ko 0-10V). Haɗin wutar lantarki mafi girma kamar masu haɗa motar, kayan wutar lantarki, da da'irar hita sama da 16A ya kamata su yi amfani da manyan masu haɗin kai (7.5mm ko 10.16mm) ko tubalan tashar wutar lantarki ta gargajiya. An ƙera ma'aunin 5.08mm musamman don daidaita tazarar tashoshi akan na'urorin PLC I/O daga manyan masana'antun ciki har da Siemens S7, Allen-Bradley ControlLogix, da jerin Mitsubishi MELSEC, wanda hakan ya sa ya zama ma'aunin da aka saba amfani da shi don wayoyi na PLC I/O a duk duniya.
Ta yaya tubalan tashoshi masu haɗawa ke aiki a ƙarƙashin yanayin girgizar masana'antu?
Idan aka ƙayyade shi da kyau tare da makullin kullewa mai haɗawa, masu haɗin da za a iya haɗawa suna aiki da aminci a ƙarƙashin yanayin girgiza na masana'antu na yau da kullun. Babban bayanin shine tsarin riƙe mahaɗin - nemi masu haɗin tare da makullin kulle mai kyau wanda ke ba da dannawa mai ji akan cikakken sakawa, maimakon riƙewa da dacewa da gogayya. Jerin PCT na J-Guang yana amfani da ƙirar makulli biyu tare da ƙarfin riƙewa wanda ya wuce 80N, an gwada kowace IEC 60068-2-6 Gwajin girgiza a 10-500 Hz tare da girman motsi na 0.35mm. Don yanayin girgiza mai tsanani kamar kayan aikin haƙar ma'adinai, ɗakunan injinan ruwa, da kayan birgima na jirgin ƙasa, masu haɗin sukurori-flange tare da riƙe sukurori na injiniya zuwa kan kai suna ba da ƙarin tsaro fiye da madaidaicin makullin kullewa. A cikin shekaru 14 na bayanan filin a cikin tushen da muka shigar, ba mu yi rikodin gazawar filin guda ɗaya da ya haifar da katsewar mahaɗi a ƙarƙashin yanayin aiki na masana'antu na yau da kullun ba lokacin da aka ƙayyade samfurin makullin kulle daidai kuma aka shigar da shi.
Menene mafi ƙarancin adadin oda don saitunan haɗin haɗin al'ada?
Ana samun daidaitattun masu haɗin haɗin matsayi 2-24 masu ƙarfin 5.08mm daga hannun jari ba tare da ƙaramin adadin oda ba - ana iya yin odar raka'a ɗaya don yin gwaji da kimantawa na gwaji. Tsarin musamman tare da takamaiman haɗakar ƙidayar fil, lambar launi ta aiki (misali, shuɗi don siginar DC, ja don AC, rawaya don da'irori na aminci), ko lakabin gano mahaɗin da aka riga aka buga yawanci suna ɗauke da MOQs na guda 500-1,000 tare da lokutan jagora na makonni 4-6. Ga OEMs waɗanda ke daidaita kan takamaiman tsarin mahaɗi a cikin layin samfur gaba ɗaya, farashin kayan aikin haɗa kayan aiki na musamman yawanci ana rage shi a cikin kabad 500-1,000 na farko, kuma daidaiton lakabi a cikin dukkan kabad a cikin filin yana sauƙaƙa takardun sabis na filin da sarrafa kayan gyara.
Za a iya sake haɗa kabad ɗin da ke da sukurori da masu haɗin da za a iya haɗawa da su?
Gyaran wani ɓangare yana yiwuwa amma yana buƙatar kimanta injiniya. Idan kabad ɗin da ke akwai yana amfani da daidaitaccen hawa layin DIN, ana iya ɗora kanun toshe na tashar da za a iya haɗawa a kan layin guda ɗaya. Duk da haka, za a buƙaci a sake dakatar da wayoyi da ke akwai tare da matosai masu haɗawa masu haɗawa - wanda a zahiri yana sake haɗa kabad ɗin. Gyaran ya fi dacewa lokacin da aka riga aka tsara kabad ɗin don babban sake haɗawa (misali, yayin haɓaka tsarin sarrafawa daga tsohuwar ƙarni na PLC). Don sabbin gina kabad, hanyar haɗa igiyoyin waya da aka bayyana a sama tana ba da cikakken fa'idodi. Ga kabad ɗin da ke akwai, ƙimar haɓakawa ita ce mafi girman tanadin lokacin sabis na filin a nan gaba lokacin da kayan I/O ke buƙatar maye gurbinsu, tunda an riga an sami aikin wayoyi na farko. Muna ba da shawarar kimanta gyarawa akan kabad-da-kabad bisa ga tsawon lokacin sabis da ake tsammani da ƙimar gazawar module I/O na tarihi don wannan takamaiman samfurin kayan aiki.