Setiawan, Aji Yusuf Saputra (2026) Perancangan Ulang dan Optimasi Wheel Hub Plug and Play pada Mobil Urban Ethanol Nogogeni ITS Team. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Pengembangan kendaraan hemat energi menuntut sistem mekanis yang tidak hanya ringan dan kuat, tetapi juga mudah dirawat dan dirakit. Mobil Urban Ethanol Nogogeni ITS Team masih menghadapi permasalahan pada sistem wheel hub, khususnya pada proses bongkar pasang roda yang memerlukan waktu lama akibat desain yang kompleks dan jumlah komponen yang relatif banyak. Kondisi ini berpotensi meningkatkan waktu perawatan serta risiko kesalahan perakitan. Oleh karena itu, penelitian ini bertujuan untuk melakukan perancangan ulang dan optimasi wheel hub plug and play agar lebih sederhana, efisien dalam perakitan, serta tetap memenuhi persyaratan kekuatan struktural. Metode Design for Assembly (DFA) diterapkan untuk mengevaluasi dan mengurangi jumlah komponen serta waktu perakitan, sedangkan metode Finite Element Analysis (FEA) digunakan untuk menganalisis kekuatan struktur wheel hub terhadap pembebanan akselerasi, deselerasi, dan gaya lateral. Parameter yang dianalisis meliputi distribusi tegangan von mises, deformasi, faktor keamanan, serta proses konvergensi mesh. Hasil penelitian menunjukkan bahwa penerapan metode DFA berhasil meningkatkan efisiensi perakitan dari 38,6% menjadi 43,1%, mereduksi waktu perakitan dari 54,45 detik menjadi 13,93 detik untuk setiap rodanya.. Penambahan massa akibat implementasi komponen baru hanya sebesar 3,62% pada material Al 6061-T6 dan 3,76% pada material Al 7075-T6 dari masa eksisting. Hasil simulasi FEA pada kondisi akselerasi, deselerasi, dan lateral menunjukkan bahwa seluruh nilai tegangan Von Mises maksimum berada di bawah tegangan ijin material sehingga komponen dinyatakan aman terhadap seluruh skenario pembebanan. Berdasarkan perbandingan dua material yang digunakan, Al 6061-T6 dipilih sebagai material terbaik karena mampu memenuhi seluruh kriteria kekuatan struktur dengan penambahan massa yang lebih rendah dibandingkan Al 7075-T6. Dengan demikian, desain wheel hub plug and play yang diusulkan mampu meningkatkan efisiensi proses perakitan, mempermudah perawatan, mempertahankan keamanan struktur, serta layak diterapkan pada Mobil Urban Ethanol Nogogeni ITS Team untuk mendukung pengembangan kendaraan hemat energi. =====================================================================================================================================
The development of energy-efficient vehicles requires mechanical systems that are not only lightweight and structurally strong but also easy to assemble and maintain. The Urban Ethanol vehicle developed by the Nogogeni ITS Team still faces challenges in its wheel hub system, particularly during the wheel assembly and disassembly process, which requires considerable time due to its complex design and the relatively large number of components. This condition increases maintenance time and the risk of human error during reassembly. Therefore, this study aims to redesign and optimize the plug-and-play wheel hub to achieve a simpler design, improve assembly efficiency, and maintain adequate structural strength. This research employed the Design for Assembly (DFA) and Finite Element Analysis (FEA) methods. The DFA method was applied to evaluate and reduce the number of components as well as the assembly time, while FEA was conducted to analyze the structural performance of the wheel hub under acceleration, deceleration, and lateral loading conditions. The evaluated parameters included the von Mises stress distribution, total deformation, safety factor, and mesh convergence. The results showed that the implementation of the DFA method successfully improved the assembly efficiency from 38.6% to 43.1% and reduced the assembly time from 54.45 seconds to 13.93 seconds for each wheel. The additional mass introduced by the redesigned components was only 3.62% for Aluminium 6061-T6 and 3.76% for Aluminium 7075-T6 compared with the existing design. Furthermore, the FEA results under acceleration, deceleration, and lateral loading conditions indicated that the maximum von Mises stress in all loading scenarios remained below the allowable stress of the selected materials, confirming that the proposed design satisfies the structural safety requirements. Based on the comparison of the two candidate materials, Al 6061-T6 was selected as the most suitable material because it fulfilled all structural design criteria while resulting in a lower mass increase than Al 7075-T6. Therefore, the proposed plug-and-play wheel hub design is capable of improving assembly efficiency, simplifying maintenance procedures, maintaining structural integrity, and is considered suitable for implementation in the Nogogeni ITS Team Urban Ethanol vehicle to support the development of energy-efficient vehicles.
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