By
Agus Purwanto 2-1752-046
MASTER’S DEGREE in
MASTER OF MECHANICAL ENGINEERING
FACULTY ELECTRICAL INFORMATION TECHNOLOGY OF MECHATRONIC CONCENTRATION
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 – Indonesia
Januari 2019
Agus Purwanto 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, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
[ AGUS PURWANTO ]
_____________________________________________
Student
Date
Approved by:
[ EDI SOFYAN B.Eng, M.Eng, Ph.D ( AERO ) ] _____________________________________________
Thesis Advisor
Date
[ Dr. Maula Hikmah Galinium ]
_____________________________________________
Dean
Date Revision after thesis defense, 31 Januari 2019
Agus Purwanto ABSTRACT
MASTER OF MECHANICAL ENGINEERING
FACULTY ELECTRICAL INFORMATION TECHNOLOGY OF MECHATRONIC CONCENTRATION
By
Agus Purwanto
Edi Sofyan B.Eng, M.Eng, Ph.D ( AERO ), Advisor Dr. Hanny J. Berchsman, Co-Advisor
SWISS GERMAN UNIVERSITY
This research analytical vibration bushing at around pin joint linkage arm at Rubber Curing Machine that could be WORN OUT that caused by friction. It’s caused by rotation and stress force of linkage arm when rubber mould closed. WORN OUT bushing at pin joint will make position pin joint unconcentric with inner diameter of bushing with outer diameter pin joint, it caused displacement on pair linkage arm ( left and right ) not equal. So it can be unbalanced stress force at paired linkage arm that would caused defect product by open mould. In this case anylitical do for proven vibration value correlation with WORN OUT bushing condition more accurate to knowed. This research do by measuring method characteristic of vibration around the link joint for approach predictive method by using accelerometer, niddle dial gauge and sound level sensor at near bushing in a good condition or vise versa. Vibration toke the data by using Accelero and plotted data by used IDE arduino. By monitored and plotted data vibration measurement with various sensors and ways, it would be proved that measuring vibration on axis Y and Z more accurate then to the other methode measurement of vibration using sound level and niddle dial gauge.
Keywords: Vibration, Predictive Maintenanance, Stress force, friction, Accelero and Gyro sensor.
Agus Purwanto
© Copyright 2019 by Agus Purwanto All rights reserved
Agus Purwanto DEDICATION
I dedicate this works for the future of the country Indonesia
and My belove Mother MULYANI, and my best family that I am very loved
Agus Purwanto ACKNOWLEDGEMENTS
Reseacher say thanks to :
Thank you to Allah SWT that have giving to me for good chance and good season to finished this research.
Sholawat and Salam always sending for The Best Human and Leader in The World Our Prophet Muhammad SAW that have been move human from the darkness in to shining world.
All Structure Management Organization PT. Gajah Tunggal Tbk that have been gave me chance and opportunity to finished my Master Mechanical Engineering.
Mr. Srijaya as Plant Head Factory Plant A, Mr. Yafeth Tri Setiabudi as Departemen Head Technical Bias Am-Tube and Tyre at PT. Gajah Tunggal Tbk plant A/C.
Mr. Marjono, Mr. Soleh and Instrument B/C/H/I Team at PT. Gajah Tunggal Tbk that have been support to finished this research by borrowed the tranducer load cell for this research.
My Beloved Mother Mulyani and My Parent in law Oom that have been always praying for me, loving me, strengthten me, always make me keep spirit, and kept fight for finished this thesis research.
My Beloved Father that have been meet Allah SWT, Alhamdulillah I am becoming one of Master Degree in structure family. I always hope he got the happiness show me from the heaven.
My Beloved Wife Yanti Mulyati and my two hero Fadhil and Faiq that always loving me, and supported every my step, and keep me strength when tired.
Mr. Dr. Edi Sofyan, B.Eng, M. Eng, PhD ( AERO ) as advisor and Mr. Hanny J.Bercshman as co Advisor that not only teach build this research but give motivated and suggestions for me to finished this research.
Agus Purwanto My Partners at the office as corps that gave colour, interchange sains and experience, and share happiness especially My Best Team Technical C Departement.
Commonly for Staff Office Production, Engineering Hary Mukti’s Team and a lot of people at Plant A/C PT. Gajah Tunggal Tbk
My Collagues as one batch in Pasca Sarjana Master of Mechanical Engineering Programme at Swiss German University especially Batch VI ( Faris, Widianto, Edmond, Andreas, Albert, Calvin, Fahmi ) and also my collagues Fahmi and Kuswana.
And also every hand that I don’t mentioned before that have been gave support and suggestion by abstract and reality, from the deep of my heart I’m say thank you very much, may Allah SWT will change giving to all of you with happiness and luckiness.
Sincerely yours Writer
Agus Purwanto TABLE OF CONTENTS
Page
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 8
LIST OF FIGURES ... Error! Bookmark not defined. LIST OF TABLES ... 10
CHAPTER 1 - INTRODUCTION ... 17
1.1 Background ... 17
1.2 Objectives ... 25
1.5. Research Questions ... 25
1.6. Hypothesis ... 25
CHAPTER 2 - LITERATURE REVIEW ... 27
2.1 Theoretical Perspectives ... 27
2.1.1. Accelero - Gyro Sensor. ... 27
2.1.2. MEMS Accelerometer Gyroscope Magnetometer. ... 28
2.1.3. Accelerometer. ... 33
2.1.4. Gyroscope. ... 34
2.1.5. Microcontroller ... 34
2.1.6. Visualisation Linkage Arm ( as miniature model curing rubber press ). ... 35
2.1.7. Simulation study Solidworks. ... 36
2.1.8. Simulation study Working Model 2D. ... 44
Agus Purwanto CHAPTER 3 – RESEARCH METHODS ... Error! Bookmark not defined.
3.1. Materials and Equipment. ... Error! Bookmark not defined.
3.1.1. Accelero and Gyro sensor. ... Error! Bookmark not defined.
3.1.2. Microcontroller ATMega ... Error! Bookmark not defined.
3.1.3. Arduino IDE ... Error! Bookmark not defined.
3.1.4. Solidwork simulation ... Error! Bookmark not defined.
3.1.5. Simulation with 2D Working Model. ... Error! Bookmark not defined.
CHAPTER 4 – RESULTS AND DISCUSSIONS ... Error! Bookmark not defined.
4.1. Initial Evaluation ... Error! Bookmark not defined.
4.2. Data Analysis ... Error! Bookmark not defined.
4.2.1. Theoritical Calculation ... Error! Bookmark not defined.
4.2.2. Actual data from the accelerometer sensor. ... Error! Bookmark not defined.
4.2.3. Simulation External Load using Cadcam software.Error! Bookmark not defined.
4.2.4. Simulation using 2D Working Model Software. Error! Bookmark not defined.
4.2.4.1. Analytical simulation acceleration good bushing conditionError! Bookmark not defined.
4.2.4.2. Analytical WORN OUT Bushing Condition .. Error! Bookmark not defined.
CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONSError! Bookmark
not defined.
5.1. Conclusions ... Error! Bookmark not defined.
5.2. Recommendations ... Error! Bookmark not defined.
GLOSSARY ... Error! Bookmark not defined.
REFERENCES ... Error! Bookmark not defined.
CURRICULUM VITAE ... Error! Bookmark not defined.
Agus Purwanto TABLE OF CONTENTS
Page DEDICATION ... Error! Bookmark not defined.
ACKNOWLEDGEMENTS ... Error! Bookmark not defined.
TABLE OF CONTENTS ... 10 LIST OF FIGURES ... 12 LIST OF TABLES ... 15 CHAPTER 1 - INTRODUCTION ... Error! Bookmark not defined.
1.1 Background ... Error! Bookmark not defined.
1.2 Objectives ... Error! Bookmark not defined.
1.5. Research Questions ... Error! Bookmark not defined.
1.6. Hypothesis ... Error! Bookmark not defined.
1.7. Research Limitation. ... Error! Bookmark not defined.
CHAPTER 2 - LITERATURE REVIEW ... Error! Bookmark not defined.
2.1 Theoretical Perspectives ... Error! Bookmark not defined.
2.1.1. Accelero - Gyro Sensor. ... Error! Bookmark not defined.
2.1.2. MEMS Accelerometer Gyroscope Magnetometer.Error! Bookmark not defined.
2.1.3. Accelerometer. ... Error! Bookmark not defined.
2.1.4. Gyroscope. ... Error! Bookmark not defined.
Agus Purwanto 2.1.6. Visualisation Linkage Arm ( as miniature model curing rubber press ). ... Error!
Bookmark not defined.
2.1.7. Simulation study Solidworks. ... Error! Bookmark not defined.
2.1.8. Simulation study Working Model 2D. ... Error! Bookmark not defined.
CHAPTER 3 – RESEARCH METHODS ... 46
3.1. Materials and Equipment. ... 46
3.1.1. Accelero and Gyro sensor. ... 46
3.1.2. Microcontroller ATMega ... 47
3.1.3. Arduino IDE ... 48
3.1.4. Solidwork simulation ... 49
3.1.5. Simulation with 2D Working Model. ... 49
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 53
4.1. Initial Evaluation ... 53
4.2. Data Analysis ... 53
4.2.1. Theoritical Calculation ... 53
4.2.2. Actual data by used accelero and sound sensor. ... 55
4.2.4. Simulation using 2D Working Model Software. ... 60
4.2.4.1. Analytical Good bushing condition. ... 61
4.2.4.2. Analytical Worn out bushing condition. ... 61
4.2.4.2. Actual data accelero from simulated 2D Working Model. ... 63
4.2.4.3. Actual data displacement nidle dial gauge linkage arm. ... 68
4.2.3. Simulation External Load using Cadcam software. ... 70
CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 72
5.1. Conclusions ... 72
Agus Purwanto REFERENCES ... 76 CURRICULUM VITAE ... 79
LIST OF FIGURES
Figures Page
1. Figure.1.1. Flow Process Diagram ... 14 2. Figure.1.2. Defective Rubber Product by Open Mould (a), and zooming
Image view defective of rubber product have burry (b) ……….17 3. Figure.1.3. Fish Bone Diagram show Potential Caused Defective Rubber Open Mould coming from ...……….………....18 4. Figure.1.4. Graph of Pareto Chart based on potential caused defect …………...22 5. Figure.2.1. MEMS Accelerometer Gyroscope Magnetometer ( left ) ………...….26 6. Picrure.2.2. Board Modul Accelero Gyro Sensor ITG/MPU ………...….. 27 7. Figure.2.3. Accelero working principle ……….... 28 8. Figure. 2.4. Schematic Block Diagram Accellero ( ADLX345 ) ………..….… 29 9. Figure.2.5. Board Modul GY-80……….…………29 10. Figure 2.6. Schematic MEM Confguration on Accelerometer ……… 30 11. Figure.2.7. Schematic Wiring Diagram Board Microcontroler and Board Accelero
and gyro modul ……… ……….…33 12. Figure.2.8. Schematic Wiring Diagram Board Microcontroler and Board Accelero
and gyro modul ………...………...…….35 13. Figure.2.9. Arduino Mega Microcontroler Board………36 13. Figure.2.10. Real measurement stress force using niddle dial gauge, planning
