Nicholas Susanto
DESIGN AND CONSTRUCTION OF
RAJAWALI (THE FLYING CONDOR RIDE) WORKING MODEL
By Nicholas Susanto
A Bachelor’s Thesis
Submitted to the Faculty of Engineering MECHATRONICS DEPARTMENT
in partial fulfillment of the requirements for the Degree of
BACHELOR OF SCIENCES
WITH A MAJOR IN MECHATRONICS ENGINEERING
SWISS GERMAN UNIVERSITY Edutown-BSD City 15339
Island of Java, Indonesia www.sgu.ac.id
July 2010
Revision after thesis defense on August 12th 2010
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, not material which to a substantial extent has been accepted for the award of may other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
_______________________________________ ________________
Nicholas Susanto Date
Approved by:
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Ir. Arko, Ph.D - Advisor Date
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Nicholas Susanto ABSTRACT
DESIGN AND CONSTRUCTION OF
RAJAWALI (THE FLYING CONDOR RIDE) WORKING MODEL
By Nicholas Susanto
SWISS GERMAN UNIVERSITY Bumi Serpong Damai Ir. Arko, Ph.D, Advisor
The purpose of this thesis is to design and construct a working model of “Rajawali” Ride in Dunia Fantasi, or also known as Condor Ride. Designing a working model of this ride requires learning and applying mechatronical approach involving mechanical, electrical and programming aspects. The movement mechanism of this model is controlled by seven geared DC motors and some others supporting mechanism. All motors and movement sequence are controlled by a microcontroller. Finally, the whole system is integrated and observed to show that the overall working model resembles the real Rajawali ride. Additionally, this model can be used for edutainment, education, learning and entertainment purposes, which as it shows the basic physical sciences in real life.
Keywords: Rajawali, edutainment, mechatronics, mechanism, physical sciences
DEDICATION
I dedicate this thesis to God, my family, my lecturers and my friends.
Nicholas Susanto ACKNOWLEDGMENTS
Firstly the author wishes to thank God for the completion of this thesis. The author also wants to express the biggest gratitude to his family for their helps, support, and encouragement during this thesis work. This thesis work would not be possibly done without their help .
The author wishes to express gratitude to Ir. Arko, Ph.D for his helps and advises during this thesis work and this report writing. The help of Mr. Cepi Mohammad Hanafi S.S.T., SGU staff and colleagues have also been very important in this thesis.
The author also thanks to PT. Jaticy Jayasuba which has manufactured the mechanical parts.
Special gratitude will be given to Mr. Donny Jacobus who helped the author to communicate with the workshops in Legok, Tangerang.
The author also thanks to the people of Dunia Fantasi Engineering Department for their support and help during this thesis work.
The author would like to say gratitude to all his friends for the help and support during this thesis report writing. The togetherness during this thesis report writing shall be remembered forever.
Last but not least, special thanks will be given to Ingelia Levina for supporting the author in doing this thesis. Her continuous support gives the author a fighting spirit so this thesis can be finished in time.
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 4
ACKNOWLEDGMENTS ... 5
CHAPTER 1 – INTRODUCTION ... 13
1.1. Background ... 13
1.2. Thesis Purpose ... 14
1.3. Thesis Scope ... 14
1.4. Problem Identification ... 14
1.5. Thesis Limitation ... 14
1.6. Thesis Structure ... 15
CHAPTER 2 – LITERATURE REVIEW ... 16
2.1. Introduction ... 16
2.2. History of Rajawali ... 16
2.2.1 The Condor Ride ... 16
2.2.2 Flying Condor in Dunia Fantasi ... 16
2.3 Centripetal Acceleration ... 18
2.4. Brief Explanation About The Other Thesis Work ... 20
CHAPTER 3 – METHODOLOGY ... 22
3.1. Work Breakdown Structure ... 22
3.2. Global System Overview ... 22
3.3. Mechanical System Design ... 24
3.3.1. Subsystem Division ... 25
3.3.2. Base Plate Subsystem ... 26
Nicholas Susanto
3.3.5.3 Bearing ... 32
3.3.5.4 Gear Mechanism for Blade Subsystem ... 32
3.3.5.5 Slip ring ... 32
3.3.5.6 Carbon Brush Housing ... 33
3.3.5.7 Motor M3 Mounting ... 33
3.3.5.8. Blade ... 34
3.3.6. Gondola Subsystem ... 35
3.3.6.1. Gondola Holder ... 35
3.3.6.2. Gondola Hanger ... 35
3.3.6.3. Gondola Connector ... 36
3.3.6.4. Gondola ... 36
3.3.6.5. Motor M4, M5, M6, and M7 Mounting ... 37
3.3.6.6. Gear Mechanism for Gondola Subsystem ... 37
3.4. Electrical System Design ... 38
3.4.1. Power Supply ... 38
3.4.2. Actuators ... 39
3.4.3. Motor Driver ... 42
3.4.3.1. Relay Board 12 V / 10A ... 42
3.4.3.2. EMS H-Bridge 2A ... 42
3.4.4. Limit Switch... 44
3.4.5. Push Buttons ... 45
3.4.6 Positioning Measurement System ... 45
3.5. Microcontroller Programming ... 46
3.5.1. Microcontroller and Programming Language ... 46
3.5.2. Programming Flowchart ... 47
3.5.3 H-Bridge Interfacing with Microcontroller ... 49
3.5.4 I/O List ... 50
CHAPTER 4 – RESULT & DISCUSSION... 51
4.1. Introduction ... 51
4.2. Mechanical Result ... 51
4.3. Gear Ratio Calculation ... 59
4.4. Slip Ring Wiring Strategy ... 60
4.5. Swing Angle Analysis... 62
model can now counted with the formula: ... 63
4.6. Centripetal Force Analysis ... 63
4.7. Assembled Electrical System ... 64
4.8. DC Geared Motor Torque Testing ... 64
4.9. Pulse Width Modulation ... 69
CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 70
5.1. Conclusion ... 70
5.2. Recommendation ... 70
GLOSSARY ... 71
REFERENCES ... 73
APPENDIX A: Technical Drawing ... 75
APPENDIX B: Data Sheet ... 99
APPENDIX C- Program list ... 122
APPENDIX D: Bill of Material ... 126
CURRICULUM VITAE ... 127
