MODIFIKASI SISTEM CARCASS STITCHER PADA MESIN BUILDING MENGGUNAKAN PLC SIEMENS SIMATIC S7-300

PRAKOSO, GALUH PURBO (2020) MODIFIKASI SISTEM CARCASS STITCHER PADA MESIN BUILDING MENGGUNAKAN PLC SIEMENS SIMATIC S7-300. S1 thesis, Universitas Mercu Buana.

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Abstract

Carcass stitching process is a process in which carcass in the form of combination of materials such as sidewall, innerliner, nylon chafer, steel chafer, and bodyply are pressurized using carcass stitcher with the help of a pneumatic system. Carcass stitcher will move horizontally from the inside of the carcass into the outside of the carcass. Each product size has a different carcass width. The current system cannot detect certain parts of the carcass where the carcass stitcher must pause (holding) to ensure that the part has been pressed properly. In addition, the amount of air compressed pressure on the carcass stitcher has the same value because it only uses a regulator. And also the speed of the carcass stitcher when moving has a constant value. This can cause product defects that are indicated to occur in carcass stitching process such as BLP (Blown Ply), BPW (Bodyply Waving), CFC (Chafer or Cord Convolved), and THO (Turn Up Height Out). In addition, there will be a production delay when changing product size or shifting because the drum setter must check and rearrange the position of the carcass stitcher sensor. In order to overcome this problem, it is necessary to do a system modification on the carcass stitcher section by adding a linear position transducer to detect the position of the carcass sticher, adding an inverter speed reference to control the speed of the carcass stitcher while moving, and also adding an electro-pneumatic regulator to set the amount of air compressed on the carcass stitcher. The addition of process parameters is used as a carcass stitching process control. Siemens Simatic S7-300 PLC is used as a control system with ladder diagram programming language and statement list created through Simatic Manager Step7 software. The results of this research concluded that the modification of carcass stitcher system can run well with 100% accuracy and 0% error. The set up time is reduced to 5.96 minutes or decreased by. 47.3%. This result can reduce production delay so it can increase production output by one greentire per shift. As well as the defects that indicated to occur in carcass stitching process decreased by 44.6%. Keywords : Carcass Stitcher, Defect, PLC Siemens, Set Up Time Proses carcass stitching adalah suatu proses dimana carcass yang berupa gabungan dari material sidewall, innerliner, nylon chafer, steel chafer, dan bodyply diberi tekanan menggunakan carcass stitcher dengan bantuan sistem pneumatik. Carcass stitcher akan bergerak secara horizontal dari bagian dalam carcass menuju bagian luar carcass. Masing-masing size produk memiliki lebar carcass yang berbeda-beda. Sistem saat ini tidak dapat mendeteksi bagian-bagian tertentu dari carcass dimana carcass stitcher harus berhenti sejenak (holding) untuk memastikan bagian tersebut telah ditekan dengan baik. Selain itu, besaran tekanan angin pada carcass stitcher memiliki nilai yang sama karena hanya menggunakan sebuah regulator saja. Dan juga kecepatan carcass stitcher saat bergerak memiliki nilai yang konstan. Hal ini dapat menyebabkan terjadinya defect produk yang terindikasi terjadi di proses carcass stitching seperti BLP (Blown Ply), BPW (Bodyply Waving), CFC (Chafer or Cord Convolved), dan THO (Turn Up Height Out). Selain itu, akan terjadinya delay produksi saat pergantian size produk atau pergantian shift karena drum setter harus mengecek dan mengatur ulang posisi sensor carcass stitcher. Untuk dapat mengatasi masalah tersebut perlu dilakukan sebuah modifikasi sistem pada bagian carcass stitcher dengan cara menambah linear position transducer untuk mendeteksi posisi carcass sticher, menambah inverter speed reference sebagai pengatur kecepatan carcass stitcher saat bergerak, dan juga menambah electro-pneumatic regulator sebagai pengatur besaran tekanan angin pada carcass stitcher. Penambahan parameter proses digunakan sebagai kendali proses carcass stitching. PLC Siemens Simatic S7-300 digunakan sebagai sistem kontrol dengan bahasa pemrograman ladder diagram dan statement list yang dibuat melalui software Simatic Manager Step7. Hasil dari penelitian ini menyimpulkan bahwa modifikasi sistem carcass stitcher dapat berjalan dengan baik dibuktikan dengan nilai akurasi keberhasilan 100% dan error 0%. Set up time berkurang menjadi 5,96 menit atau turun sebesar. 47,3%. Hasil ini dapat mengurangi delay produksi sehingga dapat meningkatkan output produksi sebanyak satu greentire per shiftnya. Serta defect-defect yang terindikasi terjadi di proses carcass stitching mengalami penurunan sebesar 44,6%. Kata kunci : Carcass Stitcher, Defect, PLC Siemens, Set Up Tim

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