DWIYAKSA, DANAN (2025) RANCANG BANGUN SISTEM OTOMASI PENGISIAN DAN PENGHITUNGAN MASSA POLY ALUMINIUM CHLORIDE BERBASIS PLC PADA PT. XYZ. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
Indonesia, as a developing country, faces challenges in the industrial sector, particularly in the chemical filling process, which is still carried out manually. This manual filling method often leads to inaccuracies in the amount of PAC (Poly Aluminium Chloride) in liters. Various studies on IoT and microcontroller-based automated liquid filling systems have been conducted. This research aims to design an automated system for filling and measuring the mass of Poly Aluminium Chloride based on PLC technology at PT. XYZ, with Visual Studio serving as the interface to control the process. This system is expected to improve the accuracy of both the filling and the mass calculation of PAC. The system integrates various components to achieve precision and efficiency in chemical filling operations. The push-button start, controls within the Visual Studio application, and database inputs such as the target volume and current volume, along with flow meter data that measures fluid flow, are transmitted to the Mitsubishi PLC as the central controller. The PLC processes this data and forwards it to the Visual Studio application for further analysis and control, enabling the system to operate automatically in a coordinated manner between hardware and software. Components such as the ball valve automatically regulate fluid flow, the contactor delivers voltage to the pump motor, and both the PLC and database record the entire filling process in real time. With this integrated setup, the system effectively supports structured and automated PAC filling. Testing results demonstrate a significant improvement in the accuracy of the PAC filling process. In one test with a target volume of 23,942 liters, the system recorded an average error rate of only 0,0965%, or approximately 23,1 liters. This minimal deviation indicates that the system performs with high precision and consistency. The accuracy reflects the successful integration of the PLC, flow meter, and Visual Studio software in monitoring and controlling the process in real time. Keywords: Programmable Logic Controller, Flow Meter, Polyaluminium Chloride, Automated System, Ball valve, Contactor Indonesia, sebagai negara berkembang, menghadapi tantangan dalam sektor industri, terutama dalam proses pengisian bahan kimia yang masih dilakukan secara manual. Pengisian manual ini menyebabkan ketidakakuratan jumlah liter PAC. Berbagai penelitian mengenai sistem otomasi pengisian cairan berbasis IoT dan mikrokontroler telah dilakukan. Penelitian ini bertujuan merancang sistem otomasi pengisian dan penghitungan massa poly aluminium chloride berbasis PLC pada PT. XYZ, dengan Visual Studio sebagai antarmuka untuk mengontrol proses. Dengan sistem ini, diharapkan dapat meningkatkan akurasi pengisian dan perhitungan massa PAC. Sistem ini mengintegrasikan berbagai perangkat untuk mencapai efisiensi dan akurasi dalam pengisian bahan kimia. Push button start, tombol pada aplikasi Visual Studio, serta data dari database seperti target liter dan jumlah liter saat ini, termasuk data dari flow meter yang mengukur aliran fluida, semuanya dikirimkan ke PLC Mitsubishi sebagai pusat pengendali. PLC ini kemudian mengelola dan memproses data tersebut, meneruskannya ke aplikasi Visual Studio untuk dianalisis dan dikendalikan lebih lanjut, sehingga sistem berjalan secara otomatis dan terkoordinasi antara perangkat keras dan perangkat lunak. Komponen seperti ball valve akan membuka aliran fluida secara otomatis, contactor akan mengalirkan tegangan ke motor pompa, dan sistem PLC serta database akan mencatat seluruh proses pengisian secara real-time. Dengan integrasi yang baik, sistem ini mampu mendukung pengisian PAC secara otomatis, terstruktur, dan efisien. Hasil pengujian sistem otomasi ini menunjukkan peningkatan yang signifikan dalam hal akurasi pengisian cairan PAC. Pada salah satu pengujian dengan target pengisian sebesar 23.942 liter, sistem mencatat rata-rata tingkat kesalahan (error) hanya sebesar 0,0965% atau sekitar 23,1 liter. Nilai error yang sangat kecil ini menandakan bahwa sistem mampu menjalankan proses pengisian dengan presisi tinggi dan konsistensi yang baik. Akurasi tersebut mencerminkan keberhasilan integrasi antara PLC, flow meter, dan perangkat lunak Visual Studio dalam mengontrol dan memantau proses secara real-time. Kata Kunci: Programmable Logic Controller, Flow Meter, Polyaluminium Chloride, Sistem otomasi, Ball valve, Contactor
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