Kendali Posisi Nozzle Menggunakan Motor Servo Pada Mesin Adjustment Acid Filling Menggunakan Metode PID

Wahono, Abdul Hafid (2024) Kendali Posisi Nozzle Menggunakan Motor Servo Pada Mesin Adjustment Acid Filling Menggunakan Metode PID. Diploma thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT GS Battery, sebagai pemimpin dalam industri manufaktur aki, menghadapi tantangan dalam meningkatkan efisiensi produksi, khususnya terkait proses pengisian air asam dalam mesin adjustment acid filling. Mesin ini menggunakan motor induksi 3 fasa dan lead screw untuk kendali posisi nozzle. Mesin ini memiliki permasalahan ketidakseimbangan frame nozzle dan jarak antar gigi piringan gear sebagai encoder eksternal yang tidak memenuhi spesifikasi atau kebutuhan yang diperlukan untuk mencapai hasil yang akurat dan konsisten dalam operasi mesin. Hal ini mengakibatkan akurasi pengisian yang rendah dan frekuensi kejadian minor stoppages yang tinggi. Data monitoring menunjukkan bahwa selama tujuh hari pada tahun 2023, minor stoppages mencapai 628 menit dengan frekuensi 1507 kali, mengakibatkan kehilangan waktu produksi 10 jam 50 menit dalam 7 hari dan mempengaruhi pencapaian rencana produksi tahunan. Untuk mengatasi masalah ini, dilakukan improvement dengan mengganti motor induksi dengan motor servo yang dilengkapi encoder internal, memperbaiki frame nozzle agar center of gravity, dan mengganti lead screw dengan ball screw yang lebih tahan lama. Hasil dari improvement ini menunjukkan peningkatan akurasi kendali posisi nozzle secara signifikan. Sebelum perbaikan, rata-rata error kendali posisi nozzle mencapai 11,40% untuk baterai B19/B20, 11,02% untuk baterai D23, dan 14,81% untuk baterai D26/D31. Setelah perbaikan, error rata-rata turun menjadi 3,44%, 3,61%, dan 2,67% masing-masing untuk tipe baterai tersebut. Penambahan kontrol PID lebih lanjut menurunkan error rata-rata menjadi 1,51%, 1,17%, dan 1,12%. Efisiensi produksi meningkat sebesar 99,47%, dengan minor stoppages berkurang secara drastis dari 628 menit menjadi hanya 3 menit dengan frekuensi 8 kali. Improvement ini berhasil mengurangi Minor stoppages dan meningkatkan produktivitas pada proses produksi baterai AMB (automotive battery).
=============================================================================================================================PT GS Battery, a leader in the battery manufacturing industry, faces challenges in improving production efficiency, particularly concerning the acid filling process in the adjustment acid filling machine. This machine uses a 3-phase induction motor and lead screw for nozzle position control. The machine suffers from issues such as the imbalance of the nozzle frame and the gear tooth spacing of the external encoder, which do not meet the specifications or requirements needed to achieve accurate and consistent results in machine operation. This results in low filling accuracy and a high frequency of minor stoppages. Monitoring data shows that during seven days in 2023, minor stoppages totaled 628 minutes with a frequency of 1507 occurrences, leading to a production time loss of 10 hours and 50 minutes over the week and impacting the achievement of the annual production plan. To address these issues, improvements were made by replacing the induction motor with a servo motor equipped with an internal encoder, adjusting the nozzle frame to be center of gravity, and replacing the lead screw with a more durable ball screw. These improvements led to a significant increase in nozzle position control accuracy. Before the improvements, the average position control error was 11,40% for B19/B20 batteries, 11,02% for D23 batteries, and 14,81% for D26/D31 batteries. After the improvements, the average error decreased to 3,44%, 3,61%, and 2,67% for these battery types, respectively. Further addition of PID control reduced the average error to 1,51%, 1,17%, and 1,12%. Production efficiency increased by 99,47%, with minor stoppages drastically reduced from 628 minutes to just 3 minutes with a frequency of 8 occurrences. These improvements successfully reduced minor stoppages and enhanced productivity in the AMB (automotive battery) production process.

Item Type:	Thesis (Diploma)
Uncontrolled Keywords:	Efisiensi Waktu, Kontrol PID, Motor Servo, Proses Pengisian Air Asam, Acid Filling Process, PID Control, Servo Motor, Time Efficiency.
Subjects:	T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK3070 Automatic control T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK4055 Electric motor
Divisions:	Faculty of Vocational > 36304-Automation Electronic Engineering
Depositing User:	Abdul Hafid Wahono
Date Deposited:	21 Aug 2024 02:56
Last Modified:	21 Aug 2024 02:56
URI:	http://repository.its.ac.id/id/eprint/115484

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