NOVANTO, HENDRA TRIA (2026) RANCANG BANGUN PROTOTYPE SISTEM OTOMASI PENYORTIRAN BENDA BERDASARKAN KETINGGIAN MENGGUNAKAN PROGRAMMABLE LOGIC CONTROLLER (PLC). S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
he implementation of automation technology in the industrial sector continues to advance as an effort to improve the efficiency, accuracy, and speed of production processes. One of the processes that requires an automated system is object sorting based on physical characteristics, particularly object height. This study aims to design, develop, and evaluate a prototype of an automated object sorting system based on object height using a Programmable Logic Controller (PLC) as the main controller. The variables observed in this study include object height as the system input, the sorting classification results based on height categories as the system output, and the number of successfully sorted objects recorded through a counting feature. The experiment was conducted using 10 test objects with different height variations selected through a purposive sampling technique, in which the samples were chosen according to predetermined characteristics relevant to the research objectives. The research employed the Research and Development (R&D) method with an experimental approach, while the collected data were analyzed using descriptive quantitative analysis based on the testing results of each system component and the overall system performance. The prototype was developed using an Omron CP1E PLC to control the DC conveyor motor, while an Arduino Mega 2560 was utilized to process data from the HC-SR04 ultrasonic sensor, the E18- D80NK photoelectric sensor, the counting sensor, and to control the servo motor as the sorting mechanism. The experimental results indicate that the proposed system is capable of detecting the presence of objects, measuring object height, classifying objects according to predefined height categories, directing them automatically to the appropriate sorting path, and counting the number of sorted objects in real time. These results demonstrate that the developed prototype performs effectively and can serve as an alternative educational platform as well as a reference for the future development of PLC-based automated object sorting systems for industrial applications. Keywords: Programmable Logic Controller (PLC), industrial automation, object sorting, ultrasonic sensor, counting. Penerapan teknologi otomasi pada sektor industri terus berkembang sebagai upaya meningkatkan efisiensi, ketelitian, dan kecepatan proses produksi. Salah satu proses yang memerlukan sistem otomatis adalah penyortiran benda berdasarkan karakteristik fisiknya, khususnya tinggi objek. Penelitian ini bertujuan untuk merancang, merealisasikan, dan mengevaluasi prototype sistem otomasi penyortiran benda berdasarkan ketinggian dengan memanfaatkan Programmable Logic Controller (PLC) sebagai pengendali utama. Variabel yang diamati dalam penelitian ini meliputi tinggi benda sebagai masukan sistem, hasil klasifikasi penyortiran berdasarkan kategori ketinggian sebagai keluaran sistem, serta jumlah benda yang berhasil disortir melalui fitur counting. Pengujian dilakukan terhadap 10 benda uji yang memiliki variasi tinggi berbeda dengan menggunakan teknik purposive sampling, yaitu pemilihan sampel berdasarkan karakteristik yang telah ditentukan sesuai kebutuhan penelitian. Metode penelitian yang diterapkan adalah Research and Development (R&D) dengan pendekatan eksperimen, sedangkan pengolahan data menggunakan metode analisis deskriptif kuantitatif berdasarkan hasil pengujian setiap komponen serta performa keseluruhan sistem. Prototype dibangun menggunakan PLC Omron CP1E untuk mengendalikan motor DC konveyor, sedangkan Arduino Mega 2560 dimanfaatkan sebagai pengolah data dari sensor ultrasonik HC-SR04, sensor fotoelektrik E18-D80NK, sensor counting, serta pengendali motor servo sebagai mekanisme penyortiran. Berdasarkan hasil pengujian, sistem mampu mendeteksi keberadaan benda, mengukur tinggi objek, mengelompokkan benda sesuai kategori yang telah ditentukan, mengarahkan benda ke jalur penyortiran secara otomatis, serta menghitung jumlah benda yang berhasil disortir secara real-time. Hasil tersebut menunjukkan bahwa prototype yang dikembangkan memiliki kinerja yang baik dan dapat dijadikan sebagai alternatif media pembelajaran maupun referensi dalam pengembangan sistem otomasi penyortiran berbasis PLC untuk aplikasi industri. Kata Kunci: Programmable Logic Controller (PLC), otomasi industri, penyortiran berdasarkan ketinggian, sensor ultrasonik, counting.
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