LATIEF, AHMAD NUR (2026) PERANCANGAN SIMULASI KONVEYOR PEMILAH BARANG BERDASARKAN JENIS DAN WARNA BENDA BERBASIS PROGRAMMABLE LOGIC CONTROLLER (PLC) DENGAN FACTORY I/O. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The development of industrial automation demands the implementation of efficient, accurate, and reliable control systems, especially in the process of moving and sorting goods. One system widely used in the manufacturing industry is an automatic sorting conveyor based on a Programmable Logic Controller (PLC). However, direct implementation in a real system requires large costs and is high risk if a design error occurs. Therefore, a simulation medium is needed as a means of testing and validating the system before its physical implementation. This study aims to design and test a simulation system for an automatic sorting conveyor based on PLC that is capable of sorting objects based on color and material type. The system was developed using CX-Programmer as PLC programming software, Factory I/O as a three-dimensional conveyor simulation, and OPC Server as a realtime data communication medium. The research variables include input in the form of color sensors and inductive proximity sensors, the process in the form of PLC control logic, and output in the form of a sorting actuator (pivot arm) and object classification results. The research method used is a simulation experiment with 20 test objects consisting of variations of blue, green, metal materials, and reject objects, which are tested repeatedly under the same working conditions. The test results show that the system is able to detect and sort all test objects according to the specified characteristics without any sorting errors. The actuators work according to the control logic sequence and respond to sensor signals in a timely manner. In addition, communication between the PLC and Factory I/O via the OPC Server runs stably and synchronously so that the monitoring and control process can be carried out in real-time. Based on the test results, the accuracy level of the sorting system reaches 100%. Thus, it can be concluded that the designed goods sorting conveyor simulation system has worked according to the expected working principles and has the potential to be implemented in goods sorting conveyor systems in industrial environments with adjustments to the mechanical aspects and sensor calibration. Keywords: Programmable Logic Controller, Sorting Conveyor, Factory I/O, Industrial Automation, HMI Perkembangan otomasi industri menuntut penerapan sistem pengendalian yang efisien, akurat, dan andal, khususnya pada proses pemindahan dan pemilahan barang. Salah satu sistem yang banyak digunakan di industri manufaktur adalah konveyor pemilah otomatis berbasis Programmable Logic Controller (PLC). Namun, penerapan langsung pada sistem nyata memerlukan biaya besar dan berisiko tinggi apabila terjadi kesalahan desain. Oleh karena itu, diperlukan media simulasi sebagai sarana pengujian dan validasi sistem sebelum diimplementasikan secara fisik. Penelitian ini bertujuan untuk merancang dan menguji sistem simulasi konveyor pemilah barang otomatis berbasis PLC yang mampu melakukan pemilahan benda berdasarkan warna dan jenis material. Sistem dikembangkan menggunakan CX-Programmer sebagai perangkat lunak pemrograman PLC, Factory I/O sebagai simulasi konveyor tiga dimensi, serta OPC Server sebagai media komunikasi data secara real-time. Variabel penelitian meliputi input berupa sensor warna dan sensor proximity induktif, proses berupa logika kontrol PLC, serta output berupa aktuator pemilah (pivot arm) dan hasil klasifikasi benda. Metode penelitian yang digunakan adalah eksperimen simulasi dengan 20 benda uji yang terdiri dari variasi warna biru, hijau, material logam, dan benda reject, yang diuji secara berulang pada kondisi kerja yang sama. Hasil pengujian menunjukkan bahwa sistem mampu mendeteksi dan memilah seluruh benda uji sesuai dengan karakteristik yang ditentukan tanpa kesalahan pemilahan. Aktuator bekerja sesuai urutan logika kontrol dan merespons sinyal sensor secara tepat waktu. Selain itu, komunikasi antara PLC dan Factory I/O melalui OPC Server berjalan stabil dan sinkron sehingga proses monitoring dan pengendalian dapat dilakukan secara realtime. Berdasarkan hasil pengujian, tingkat akurasi sistem pemilahan mencapai 100%. Dengan demikian, dapat disimpulkan bahwa sistem simulasi konveyor pemilah barang yang dirancang telah bekerja sesuai prinsip kerja yang diharapkan dan memiliki potensi untuk diimplementasikan pada sistem konveyor pemilah barang di lingkungan industri dengan penyesuaian pada aspek mekanik dan kalibrasi sensor. Kata Kunci : PLC, Konveyor Pemilah, Factory I/O, Sistem Otomasi, HMI
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