Optimalisasi Kendali Posisi dan Kecepatan Clamping Konektor Baterai Dengan Dual-Loop P-PI Controller Pada Mesin Press Welding

Yuliyanto, Kurniawan Dwi (2025) Optimalisasi Kendali Posisi dan Kecepatan Clamping Konektor Baterai Dengan Dual-Loop P-PI Controller Pada Mesin Press Welding. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses Press Welding merupakan tahap penting dalam produksi baterai untuk menyambungkan konektor antar sel. Pada salah satu lini produksi, ditemukan masalah splash yang menyebabkan tingkat reject sebesar 0,09% dan waktu siklus 21,5 detik, melebihi target 18 detik. Splash terjadi akibat overheating yang dipicu oleh ketidakstabilan diameter kontak serta ketiadaan kontrol posisi JAW Clamp yang presisi. Untuk mengatasi hal ini, sistem hidrolik digantikan dengan motor servo. Namun pada pengujian awal tanpa kontrol, pergerakan servo tidak stabil dan gagal mencapai setpoint secara konsisten. Kondisi ini menegaskan perlunya sistem kontrol yang mampu menjamin presisi dan kestabilan gerakan servo. Penelitian ini mengimplementasikan kontrol Dual-Loop P-PI, dengan kontroler P untuk posisi (outer loop) dan kontroler PI untuk kecepatan (inner loop). Parameter dituning menggunakan metode Ziegler-Nichols dan disempurnakan melalui fine-tuning manual berbasis pengujian. Hasil menunjukkan waktu clamping menurun dari 4 detik menjadi 2,29 detik (efisiensi 42,75%), diameter konektor stabil pada 6,01 mm (error ≈ 0 μm), dan tingkat reject menurun dari 0,07% menjadi 0,01%. Validasi model melalui Transfer Function Estimation (TFEST) menunjukkan kecocokan sebesar 88,49% pada loop kecepatan dan 94,65% pada loop posisi. Dengan demikian, kontrol Dual-Loop P-PI terbukti efektif dalam meningkatkan efisiensi waktu siklus, menjaga stabilitas diameter konektor, dan menurunkan tingkat reject pada proses Press Welding.
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The press welding process is a crucial stage in battery production to connect inter-cell Connectors. In one production line, a splash issue was identified, causing a 0.09% reject rate and a cycle time of 21.5 seconds—exceeding the target of 18 seconds. The splash was triggered by overheating due to unstable contact diameters and the absence of precise control over the JAW clamp position. To address this, the hydraulic system was replaced with a servo motor. However, initial baseline testing without control showed that servo movement was unstable and failed to consistently reach the defined position setpoints. This highlighted the need for a control system capable of ensuring movement precision and stability. This study implements a Dual-Loop P-PI control method, where a P-controller is used for position control (outer loop) and a PI-controller for speed control (inner loop). Controller parameters were tuned using the Ziegler-Nichols method and further refined through manual fine-tuning based on experimental results. Testing showed that clamping time decreased from 4 seconds to 2.29 seconds (a 42.75% improvement), the Connector diameter stabilized at 6.01 mm (error ≈ 0 μm), and the splash-induced reject rate decreased from 0.07% to 0.01%. Model validation using the Transfer Function Estimation (TFEST) method showed a fit of 88.49% for the speed loop and 94.65% for the position loop. Thus, the implementation of servo motor control using a Dual-Loop P-PI controller proves effective in improving cycle time efficiency, maintaining Connector diameter stability, and reducing product reject rates in the press welding process.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Press Welding, Motor Servo, Kontrol Posisi, Kontrol Kecepatan, Dual-Loop P-PI Controller. Press Welding, Servo Motor, Position Control, Speed Control, Dual-Loop P-PI Controller.
Subjects:	T Technology > T Technology (General) T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK3070 Automatic control T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK4055 Electric motor T Technology > TK Electrical engineering. Electronics Nuclear engineering > TK4660 Welding; Electric welding.
Divisions:	Faculty of Vocational > 36304-Automation Electronic Engineering
Depositing User:	Kurniawan Dwi Yuliyanto
Date Deposited:	04 Aug 2025 02:23
Last Modified:	04 Aug 2025 02:23
URI:	http://repository.its.ac.id/id/eprint/125544

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