design of electric actuator to replace pneumatic tipping valve in

(1)

DESIGN OF ELECTRIC ACTUATOR TO REPLACE PNEUMATIC TIPPING VALVE IN CEMENT INDUSTRY

By

Abdullah Hawari 220151102

MASTER’S DEGREE In

Master of Mechanical Engineering Mechantronic Consentration

Faculty of Engineering and Information Technology

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

March 2017

(2)

By

Abdullah Hawari 220151102

MASTER’S DEGREE In

Master of Mechanical Engineering Mechantronic Consentration

Faculty of Engineering and Information Technology

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

March 2017

Revision after the Thesis Defense on 18^th February 2017

(3)

Page 2 of 48

Abdullah Hawari 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, 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.

(Abdullah Hawari S.T.)

____________________________________________

Student

Date

Approved by:

(Edi Sofyan, B.Eng., M.Eng., Ph.D)

____________________________________________

Thesis Advisor

Date

(Dr. Ir. Gembong Baskoro, M.Sc.)

____________________________________________

Dean of Faculty Date

(4)

Abdullah Hawari

DESIGN OF ELECTRIC ACTUATOR TO REPLACE PNEUMATIC TIPPING VALVE IN CEMENT INDUSTRY

By

Abdullah Hawari

Edi Sofyan, B.Eng., M.Eng., Ph.D, Advisor

SWISS GERMAN UNIVERSITY

In the modern industry efficiency is what the user looking for, by using a pneumatics in one of the most contanimated industry is risk and inefficient. Contamination is the highest contribution of failure in pneumatics system, because contamination surely cause a leak and 45% of pneumatics failure are caused by leaking. Contamination can also depends on the size of the contaminator the more small the size the more likely it to cut through the seals and cause a cut that makes the system will loss it’s pressure and force. Electric actuatos is a safer choice because no risk in cobtamination problem. To test the compatibility of the design of the electric actuator by using the 3D modelling software and Simulink to provide a movement result and compare it with the requirement from the pneumatics. From the simulation result, it was shown that the electric actuator could compete with the pneumatic actuator in response speed, but not in torque magnitude.

Keyword : Pneumatics, Electric Actuator, Simulink, 3D modeling

(5)

Page 4 of 48

Abdullah Hawari

(6)

Abdullah Hawari I dedicate this thesis for my family that support me and for Engineering department of PT.

Andalan Fluid Sistem.

(7)

Page 6 of 48

Abdullah Hawari

ACKNOWLEDGEMENTS

My gratitude for the one and only Allah SWT, for everything I have and will achieve in my life.

Also I want to thank you for all members that support me through all this :

1. My family, you are my support and motivation to me to finish this work

2. Edi Sofyan, as an advisor, I would not imagine doing this work without any of your help and advice

3. Batch 3 of Master of Mechanical Engineering, for sharing and supporting tough every thick and thin

4. Engineering Department of PT. AFS, for the compromise, understanding and support that help me to finish this project

(8)

Abdullah Hawari

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENT ... 7

LIST OF FIGURES ... 8

LIST OF TABLES ... 9

Chapter 1 INTRODUCTION ... 10

1.1. Background ... 10

1.2. Research Problems ... 12

1.3. Research Objectives ... 12

1.4. Scope of Study ... 12

1.5. Significance of Study ... 12

1.6. Research Questions ... 12

1.7. Hypothesis... 13

Chapter 2 . LITERATURE REVIEW ... 13

2.1. Pneumatic Actuator ... 13

2.2. Electric Actuator ... 14

2.3. Cement Industry ... 16

2.4 Simulink ... 18

2.5 System Requirement ... 18

2.6 Previous Study ... 21

Chapter 3 . RESEARCH METHODS ... 22

3.1 Introduction ... 22

3.2 Process Flow ... 22

3.2.3 Simulink model ... 28

3.3 Schedule of Thesis Study ... 32

Chapter 4 . RESULT AND DISCUSSION... 33

4.1 Dimension ... 33

4.2. Simulink ... 34

Chapter 5 CONCLUSION AND RECOMENDATION... 45

5.1 Conclusion ... 45

5.2 Recommendation ... 45

REFERENCES ... 46

(9)

Page 8 of 48

Abdullah Hawari LIST OF FIGURES

Figure 1.1 Seal failure from a dirt ... 10

Figure 1.2 Ideal condition with no leak ... 11

Figure 1.3 Leak ... 11

Figure 2.1 Pneumatic speed ... 19

Figure 2.2 Free body diagram of the system ... 19

Figure 3.1 Flowchart of the Thesis ... 23

Figure 3.2 Flowchart of the simulation ... 24

Figure 3.3 Rod... 25

Figure 3.4 Gear ... 25

Figure 3.5 Backrod ... 26

Figure 3.6 Wiper Seal ... 26

Figure 3.7 Tube ... 27

Figure 3.8 Electric Actuator (a) Retract (b) Full Stroke ... 27

Figure 3.9 Constraint in 3D Model ... 28

Figure 3.10 Simulink model of the Electric Actuator ... 29

Figure 3.11 Cylindrical joint block ... 30

Figure 3.12 Simulink to physical block parameter ... 30

Figure 3.13 Physical to Simulink block parameter ... 31

Figure 3.14 Model in the mat lab ... 31

Figure 4.1 Space available for the electric actuator ... 33

Figure 4.2 Graph of P vs. Distance ... 35

Figure 4.3 Graph of P vs. Velocity ... 36

Figure 4.4 Graph P vs. Acceleration ... 36

Figure 4.5 Graph P vs. Torque ... 37

Figure 4.6 Graph I vs. Distance ... 38

Figure 4.7 Graph I vs. Velocity... 38

Figure 4.8 Graph I vs. Acceleration ... 39

Figure 4.9 Graph I vs. Torque ... 39

Figure 4.10 Graph D vs. Distance ... 40

Figure 4.11 Graph D vs. Velocity ... 41

Figure 4.12 Graph D vs. Acceleration ... 41

Figure 4.13 Graph D vs. Torque ... 42

Figure 4.14 The all achievable requirement ... 43

Figure 4.15 Another tweak on PID ... 44

(10)

Abdullah Hawari LIST OF TABLES

Table 2-1 Design of the dust cover ... 21

Table 3-1 Thesis work Activity and Time ... 32

Table 4-1 Simulation result of adjusting P ... 35

Table 4-2 Simulation result by adjusting I ... 37

Table 4-3 Simulation result by adjusting D ... 40

Table 4-4 Choice of the PID Parameter ... 42