Manufar Anish Kapoor na sassaken Cloud Gate a Millennium Park na Chicago ita ce yana kama da ruwa mai kama da mercury, wanda ke nuna birnin da ke kewaye ba tare da wata matsala ba. Cimma wannan rashin matsala aiki ne na ƙauna.
"Abin da nake so in yi a Millennium Park shi ne in yi wani abu da zai dace da sararin samaniyar Chicago...don mutane su ga gajimare suna shawagi a ciki da kuma waɗannan gine-gine masu tsayi da ke nuna a cikin aikin. Sannan, Saboda siffarsa a ƙofar, mahalarta, masu sauraro, za su iya shiga wannan ɗaki mai zurfi, ta yadda yake yin abu ɗaya ga tunanin mutum kamar yadda waje na aikin yake yi ga tunanin abubuwan da ke kewaye da birnin." - Shahararren mai zane ɗan Birtaniya Anish Kapoor, mai sassaka Cloud Gate, mai sassaka Cloud Gate a duniya.
Idan aka duba yanayin kwanciyar hankali na wannan babban sassaka na bakin ƙarfe, yana da wuya a iya hasashen adadin ƙarfe da ƙarfin hali da ke ƙarƙashin samansa. Cloud Gate yana ɓoye labaran masu ƙera ƙarfe sama da 100, masu yankewa, masu walda, masu gyaran gashi, injiniyoyi, masu fasaha, masu gyaran ƙarfe, masu shigarwa, da manajoji—a tsawon shekaru biyar.
Da yawa suna aiki na ƙarin lokaci, suna yin aikin bita da tsakar dare, suna yin sansani a wurin, kuma suna aiki a yanayin zafi mai digiri 110 a cikin cikakken kayan Tyvek® da na'urorin numfashi na rabin abin rufe fuska. Wasu suna aiki a wurare daban-daban, suna rataye da bel ɗin kujera yayin da suke riƙe da kayan aiki kuma suna aiki a kan gangaren da ke zamewa. Komai yana tafiya kaɗan (kuma ya wuce gona da iri) don ya sa abin da ba zai yiwu ba ya yiwu.
Kamfanin masana'anta Performance Structures Inc. (PSI), Oakland, CA, da MTH, Villa Park, IL, ne ya yi wannan aikin. A bikin cika shekaru 120 da kafa kamfanin, MTH, yana ɗaya daga cikin tsofaffin 'yan kwangilar ƙirar ƙarfe da gilashi a yankin Chicago.
Bukatun da ake buƙata don cimma aikin za su yi amfani da fasahar aiwatar da fasaha, kirkire-kirkire, ƙwarewar injiniya da ƙwarewar masana'antu na kamfanonin biyu. Sun keɓance har ma sun gina kayan aiki don aikin.
Wasu daga cikin ƙalubalen aikin sun fito ne daga siffarsa mai lanƙwasa - digo ko maɓallin ciki mai juyewa - wasu kuma daga girmansa mai kyau. Kamfanoni biyu daban-daban ne suka gina sassaken a wurare daban-daban dubban mil nesa, wanda ke haifar da matsaloli game da sufuri da salon aiki. Akwai hanyoyi da yawa da dole ne a yi a fagen aiki suna da wahalar yi a yanayin shago, balle a fagen. Akwai matsala da yawa da ke tasowa kawai saboda ba a taɓa ƙirƙirar irin wannan tsari ba a da. Don haka, babu tunani, babu zane, babu taswirar hanya.
Ethan Silva na PSI yana da ƙwarewa sosai a fannin gina harsashi, da farko a jiragen ruwa sannan daga baya a wasu ayyukan fasaha, ya cancanci yin ayyukan gina harsashi na musamman. Anish Kapoor ya nemi waɗanda suka kammala karatun kimiyyar lissafi da fasaha su samar da ƙaramin samfurin.
"Don haka na yi samfurin mita 2 x 3, wani yanki mai lanƙwasa mai santsi, sai ya ce, 'Kai, kai kaɗai ne ka yi shi,' domin ya shafe shekaru biyu yana neman wanda zai yi shi," in ji Silva.
Tsarin farko shine PSI ta ƙera da kuma gina sassaken gaba ɗaya, sannan ta aika da dukkan sassan zuwa kudu da Tekun Pacific, ta hanyar Panama Canal, arewa tare da Tekun Atlantika, da kuma tare da Tekun St. Lawrence zuwa tashar jiragen ruwa a Tafkin Michigan, a cewar Edward Uhlir, babban darektan Millennium Park Inc. A cewar sanarwar, wani tsarin jigilar kaya da aka tsara musamman zai jigilar shi zuwa Millennium Park. Takaitawar lokaci da aiki sun tilasta wa waɗannan tsare-tsaren su canza. Saboda haka, dole ne a haɗa bangarorin da aka lanƙwasa don jigilar kaya sannan a kai su Chicago, inda MTH za ta haɗa ƙananan gine-gine da manyan gine-gine, sannan ta haɗa bangarorin da babban ginin.
Kammalawa da goge walda na Cloud Gate don ganin sun yi kyau sosai yana ɗaya daga cikin mafi wahalar aikin shigarwa da haɗa kayan aiki. Tsarin matakai 12 ya ƙare da launin ruwan kasa mai haske kamar na goge kayan ado.
"Don haka mun yi aiki a kan wannan aikin na tsawon shekaru uku, muna yin waɗannan sassan," in ji Silva. "Aiki ne mai wahala. Yawancin lokacin ana ɓatar da shi ne wajen gano yadda ake yin sa da kuma tsara cikakkun bayanai; kun sani, kawai a kammala shi. Yadda muke amfani da fasahar kwamfuta da kuma aikin ƙarfe na zamani shine haɗakar fasahar kera da sararin samaniya."
Yana da wuya a yi wani abu mai girma da nauyi haka daidai gwargwado, in ji shi. Manyan faranti suna da faɗin ƙafa 7 da tsawon ƙafa 11 kuma suna da nauyin fam 1,500.
"Yin duk aikin CAD da ƙirƙirar ainihin zane-zanen shagon aikin a zahiri babban aiki ne a cikin kansa," in ji Silva. "Muna amfani da fasahar kwamfuta don auna faranti da kuma tantance siffarsu da lanƙwasa daidai don su dace daidai.
"Mun yi ƙirar kwamfuta sannan muka raba ta," in ji Silva. "Na yi amfani da gogewata da gina harsashi, kuma ina da wasu ra'ayoyi kan yadda zan raba siffofi don sa layukan su yi aiki don mu sami sakamako mafi kyau."
Wasu faranti murabba'i ne, wasu kuma siffar biredi ne. Yayin da suke kusa da canjin da aka yi, haka nan siffar biredi take, kuma girman canjin radial ɗin yake. A saman, suna da faɗi da girma.
Silva ya ce, "Babban ƙalubalen shine a samar da manyan layukan zuwa lanƙwasa daidai gwargwado. Ana yin hakan ta hanyar ƙirƙirar da ƙera tsarin haƙarƙari ga kowane faifai daidai gwargwado. Ta wannan hanyar za mu iya fayyace siffar kowanne faifai daidai."
Ana birgima allunan a kan na'urorin 3D waɗanda PSI ta tsara kuma ta ƙera musamman don birgima waɗannan allunan (duba Hoto na 1). "Kamar ɗan'uwa ne ga na'urorin rollers na Burtaniya. Muna birgima su ta amfani da dabara irin ta yadda ake yin fenders," in ji Silva. Lanƙwasa kowane faifan ta hanyar motsa shi baya da gaba a kan na'urorin rollers, daidaita matsin lamba akan na'urorin rollers har sai bangarorin sun kasance cikin inci 0.01 na girman da ake so. Babban daidaiton da ake buƙata yana sa ya yi wuya a samar da zanen gado cikin sauƙi, in ji shi.
Sai mai walda ya haɗa kwararar da aka haɗa zuwa tsarin haƙarƙarin ciki. "A ganina, kwararar da aka haɗa hanya ce mai kyau ta ƙirƙirar walda mai tsari a cikin bakin ƙarfe," in ji Silva. "Yana ba ku walda masu inganci tare da mai da hankali sosai kan samarwa kuma yana da kyau."
An yi amfani da hannu wajen niƙa dukkan saman allon don a gyara su daidai da girman inci dubu ɗaya da ake so domin su haɗu (duba Hoto na 2). Duba girman da kayan aikin aunawa daidai da laser. A ƙarshe, an goge farantin zuwa madubi kuma an rufe shi da fim mai kariya.
An gina kusan kashi ɗaya bisa uku na bangarorin, tare da tushe da tsarin ciki, a cikin taron gwaji kafin a jigilar bangarorin daga Auckland (duba Hoto na 3 da 4). Mun tsara tsarin gefen kuma muka yi wasu dinki a kan wasu ƙananan allunan don haɗa su wuri ɗaya. "Don haka lokacin da muka haɗa su a Chicago, mun san zai dace," in ji Silva.
Zafin jiki, lokaci da girgizar babbar mota na iya sa zanen da aka naɗe ya sassauta. Ba wai kawai an ƙera ragar da aka yi da ribbed grating ba ne don ƙara tauri na allon, har ma don kiyaye siffar allon yayin jigilar kaya.
Saboda haka, tare da ragar ƙarfafawa a ciki, ana yin maganin zafi da sanyaya farantin don rage matsin lamba na abu. Don ƙara hana lalacewa a lokacin wucewa, ana yin katako ga kowane farantin, wanda daga nan ake ɗora shi a kan kwantena, kusan huɗu a lokaci guda.
Daga nan aka ɗora kwantena a cikin kayayyakin da ba a gama ba, kusan huɗu a lokaci guda, aka aika su zuwa Chicago tare da ma'aikatan PSI don shigarwa tare da ma'aikatan MTH. Ɗaya shine mutumin jigilar kaya wanda ke daidaita jigilar kaya, ɗayan kuma shine mai kula da fannin fasaha. Yana aiki tare da ma'aikatan MTH kowace rana kuma yana taimakawa wajen haɓaka sabbin fasahohi idan ana buƙata. "Tabbas ya kasance muhimmin ɓangare na tsarin," in ji Silva.
Lyle Hill, shugaban MTH, ya ce da farko an ba MTH Industries aikin ɗaure sassaken da ke cikin ƙasa da kuma sanya babban ginin, sannan a haɗa zanen gado da shi da kuma ba da yashi da gogewa na ƙarshe, bisa ga jagorancin fasaha na PSI. Kammala sassaken yana nufin daidaito tsakanin fasaha da aiki; ka'ida da gaskiya; lokacin da ake buƙata da lokacin da aka tsara.
Lou Cerny, mataimakin shugaban injiniya da manajan ayyuka na MTH, ya ce abin da ya fi burge shi game da aikin shine keɓancewarsa. "Gaskiya ne, akwai abubuwa da ke faruwa a kan wannan aikin da ba a taɓa yin sa ba a da, ko kuma ba a taɓa yin la'akari da shi ba a da," in ji Cerny.
Amma yin aiki a kan aikin farko yana buƙatar ƙwarewa mai sassauƙa a wurin aiki don fuskantar ƙalubalen da ba a zata ba da kuma amsa tambayoyin da ke tasowa yayin da aiki ke ci gaba:
Ta yaya za a sanya bangarori 128 na bakin karfe masu girman mota zuwa wani babban gini na dindindin yayin da ake sarrafa su da safar hannu na yara? Ta yaya za a yi walda babban wake mai siffar baka ba tare da dogaro da shi ba? Ta yaya za a shiga walda ba tare da iya walda daga ciki ba? Ta yaya za a cimma cikakkiyar kammalawar madubi don walda na bakin karfe a cikin yanayin filin? Me zai faru idan walƙiya ta buge shi?
Cerny ya ce, alamar farko da ke nuna cewa wannan aiki zai zama aiki mai matuƙar wahala ita ce lokacin da aka fara ginawa da kuma sanya kayan aikin da nauyinsu ya kai fam 30,000. Tsarin ƙarfe da ke tallafawa sassaken.
Duk da cewa ƙarfe mai cike da zinc da PSI ta samar don haɗa tushen ginin abu ne mai sauƙin ƙerawa, wurin ginin yana da rabin saman gidan cin abinci da rabi kuma a saman wurin ajiye motoci, kowannensu a tsayi daban-daban.
"Don haka tsarin ginin yana da ɗan kama da na roba kuma yana da rauni," in ji Cerny. "Inda muka sanya yawancin wannan ƙarfe, har ma a farkon aikin farantin da kansa, dole ne mu sa crane ɗin ya tuƙa zuwa rami mai tsawon ƙafa 5."
Cerny ya ce sun yi amfani da tsarin makalewa mai matuƙar inganci, gami da tsarin ɗaukar kaya na injiniya, irin na nau'in kayan da ake amfani da su a haƙar kwal, da kuma wasu ankare-kanen sinadarai. Da zarar an gyara tsarin ƙarfe a cikin siminti, ya zama dole a gina babban gini wanda za a haɗa harsashin.
"Mun fara shigar da tsarin truss ta amfani da manyan zoben O-ring guda biyu da aka ƙera na bakin ƙarfe 304—ɗaya a ƙarshen arewa na ginin da kuma ɗaya a ƙarshen kudu," in ji Cerny (duba Hoto na 3). Ana riƙe zoben tare ta hanyar trusses na bututu masu ratsawa. An gina ƙaramin firam ɗin zobe a sassa kuma an ɗaure shi a wuri ta amfani da GMAW da madaurin walda da madaurin walda.
"Don haka akwai babban babban gini wanda babu wanda ya taɓa gani; kawai don tsarin gini ne," in ji Cerny.
Duk da ƙoƙarin da aka yi na tsara, ƙera, ƙera da kuma shigar da duk abubuwan da ake buƙata don aikin Auckland, wannan sassaka ba a taɓa yin irinsa ba kuma fasa sabbin hanyoyi koyaushe yana zuwa da ƙuraje da ƙaiƙayi. Haka nan, haɗa ra'ayin masana'antu na wani kamfani da na wani ba abu ne mai sauƙi ba kamar wuce sandar. Bugu da ƙari, nisan da ke tsakanin wurare ya haifar da jinkirin isar da kaya, wanda ya sa wasu masana'antu a wurin suka zama masu ma'ana.
"Yayin da aka tsara hanyoyin haɗawa da walda a gaba a Oakland, yanayin wurin ya buƙaci ƙwarewa mai dacewa daga kowa," in ji Silva. "Kuma ma'aikatan ƙungiyar kwadago suna da kyau ƙwarai."
A cikin watannin farko na farko, tsarin yau da kullun na MTH shine tantance abin da aikin ranar ya ƙunsa da kuma yadda ya fi kyau a ƙera wasu daga cikin abubuwan da za a gina ƙarƙashin firam ɗin, da kuma wasu struts, "masu ɗaukar girgiza," hannaye, fikafikai, da fil. Sandunan pogo suna buƙatar ƙirƙirar tsarin siding na ɗan lokaci, in ji Er.
"Tsarin ƙira ne da kera kayayyaki a kan lokaci domin ci gaba da tafiya da kuma kai su wurin da sauri. Muna ɓatar da lokaci mai tsawo muna tantance abin da muke da shi, muna sake fasalin da kuma sake fasalin wasu lokuta, sannan mu ƙera sassan da ake buƙata."
"A zahiri, za mu sami abubuwa 10 a ranar Talata da za mu kawo a wurin ranar Laraba," in ji Hill. "Akwai ƙarin lokaci da yawa da kuma ayyukan shago da yawa da aka yi a tsakiyar dare."
"Kusan kashi 75 cikin 100 na abubuwan dakatar da allon an ƙera su ne ko kuma an gyara su a fagen," in ji Cerny. "Sau da yawa, mun ƙirƙiro rana ta awanni 24. Zan kasance a shago har zuwa ƙarfe 2, 3 na safe, kuma zan koma gida in yi wanka, in ɗauko da ƙarfe 5:30 na safe, amma har yanzu ina jika."
Tsarin dakatarwa na wucin gadi na MTH don haɗa gidan ya ƙunshi maɓuɓɓugan ruwa, struts da kebul. Duk haɗin da ke tsakanin faranti ana ɗaure su na ɗan lokaci. "Don haka dukkan tsarin an haɗa shi ta hanyar injiniya, an rataye shi daga ciki, tare da trusses 304," in ji Cerny.
Sun fara da kumbon da ke ƙasan sassaken omhalus - "cibiya ta maɓallin ciki". An rataye kumbon daga cikin sandunan ta amfani da tsarin tallafi na wucin gadi mai maki huɗu wanda ya ƙunshi rataye, kebul da maɓuɓɓugan ruwa. Cerny ya ce kumbon yana ba da "ba da karɓa" yayin da ake ƙara allunan ruwa. Sannan ana sake daidaita maɓuɓɓugan ruwa bisa ga nauyin da kowanne faranti ya ƙara don taimakawa wajen daidaita dukkan sassaken.
Kowanne daga cikin allunan 168 yana da nasa tsarin tallafin bazara mai maki huɗu don haka ana tallafa masa daban-daban lokacin da yake wurin. "Ba a fifita kowace haɗin gwiwa ba saboda an haɗa waɗannan haɗin gwiwa don cimma gibin 0/0," in ji Cerny. "Idan allo ya buga allon da ke ƙasa da shi, zai iya haifar da buckling da sauran matsaloli."
A matsayin shaida ga daidaiton aikin PSI, haɗawar tana da kyau sosai tare da ƙananan gibi. "PSI ta yi aiki mai kyau na yin bangarorin," in ji Cerny. "Ina ba su duk yabo domin a ƙarshe, ya dace sosai. Shigarwar tana da kyau sosai, wanda hakan yayi kyau a gare ni. Muna magana ne, a zahiri dubun inci ɗaya. An sanya farantin a kai Akwai gefen rufe tare."
"Lokacin da suka gama haɗa kayan, mutane da yawa suna tunanin an gama," in ji Silva, ba wai kawai saboda ɗinkin sun yi tsauri ba, har ma saboda sassan da aka haɗa gaba ɗaya, da kuma faranti masu kyau na madubi, sun zo don nuna yanayin da ke kewaye da shi. Amma ana iya ganin ɗinkin duwawu, ruwa mai kama da mercury ba shi da ɗinki. Bugu da ƙari, dole ne a haɗa sassaken gaba ɗaya don kiyaye ingancin tsarinsa ga tsararraki masu zuwa, in ji Silva.
Dole ne a dakatar da kammala Cloud Gate a lokacin babban buɗe wurin shakatawa a kaka ta 2004, don haka omhalus ya zama GTAW kai tsaye, kuma hakan ya ci gaba har tsawon watanni kaɗan.
"Kuna iya ganin ƙananan tabo masu launin ruwan kasa, waɗanda sune haɗin haɗin TIG a kusa da ginin gaba ɗaya," in ji Cerny. "Mun fara sake gina tantuna a watan Janairu."
Silva ya ce, "Babban ƙalubalen masana'antu na gaba a wannan aikin shine a yi walda ba tare da rasa daidaiton siffar da aka yi ba saboda lalacewar walda."
Cerny ya ce walda ta plasma tana ba da ƙarfi da tauri da ake buƙata ba tare da wata matsala ga zanen ba. Haɗin helium na argon/2% yana aiki mafi kyau wajen rage gurɓatawa da haɓaka haɗuwa.
Masu walda suna amfani da dabarun walda na plasma ta hanyar amfani da hanyoyin samar da wutar lantarki na Thermal Arc® da kuma haɗa tarakta da tocila na musamman waɗanda PSI ta ƙirƙira kuma ta yi amfani da su.