Dean Faculty of Engineering and Information Technology Date (3)Michelle Steffi Gunawan CRANE RAIL MEASRUEMENT TOOL – RAIL ROVER By Michelle Steffi Gunawan Edi Sofyan, B

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By

Michelle Steffi Gunawan 2-1652-004

MASTER’S DEGREE in

MASTER OF MECHANICAL ENGINEERING ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

February 2018

Revision after the Thesis Defense on 15^th February 2018

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Michelle Steffi Gunawan 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.

Michelle Steffi Gunawan

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Student Date

Approved by:

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

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Thesis Advisor Date

Dena Hendriana, B. Sc., SM., Sc.D

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Thesis Co-Advisor Date

Dr. Irvan S. Kartawiria, ST., MSc.

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Dean Faculty of Engineering and Information Technology Date

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Michelle Steffi Gunawan CRANE RAIL MEASRUEMENT TOOL –

RAIL ROVER

By

Edi Sofyan, B. Eng., M. Eng., Ph.D, Advisor Dena Hendriana, B. Sc., SM., Sc.D, Co-Advisor

SWISS GERMAN UNIVERSITY

Overhead crane, consists of hoist, girder, end carriage, festoon system, conductor, runway and rail, has been widely used in industrial and structural field to lift heavy material from one location to another. Straight crane rail is one of the major factors that influence the crane to travel and run smoothly. Measuring crane rail is the main problem that occurs since a long time ago with various methods. In this project, designing a tool for measuring crane rail (Rail Rover) is set as the main objective. There are some existing tools from research teams and companies that has been built to achieve the crane rail measurement. This project used optical instruments, such as laser sensor and photodiodes as the main aiding component to realize the objective. Arduino, rotary encoder, counter meter and other mechanical components are other essential parts that helps finish the design. There are some analyses has been done, like the possibility of laser light is not perpendicular to photodiode board, the stability of DC motor, selected laser sensor accuracy, and the simple simulation result of data reading of photodiode through Arduino. In conclusion, the design of Rail Rover is applicable for crane rail elevation measurement with some improvements needed.

Keywords: Crane, Crane Rail Measurement, Rail Rover, Crane Rail Elevation

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Michelle Steffi Gunawan DEDICATION

I dedicate this project to the company I worked PT. Primacipta Megah Jaya, the university I loved Swiss German University, and my country whom I honored

Indonesia.

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Michelle Steffi Gunawan ACKNOWLEDGEMENTS

I wish to express my gratitude to our God who gives me strength, diligence and wisdom that aid me a lot in working my project. To my family who understand my condition and despair, thank you for raising my spirit again to struggle and finish this project.

Special thanks to Mr. Frans Ransatar Nababan as company manager that gave me the idea and inspiration for the topic, also helps me much on the progress. I would like to say thank you to my advisor Edi Sofyan, B.Eng., M.Eng., Ph.D. and my co-advisor Dena Hendriana B.Sc., SM., Sc.D., also Swiss German University and other lecturers for helping me and giving me time and opportunities to design, evaluate and analyse this particular topic. Finally, the last thankfulness is for the company and project team that provide time, knowledge and experience that has been shared with me so that I can finish the project.

I have found out that for these years, there are curriculum and particular subjects are very helpful in analysing the issue of this thesis project. Although not all knowledge on each subject is used, they have been considered and analysed whether they can be utilized in the thesis.

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Michelle Steffi Gunawan TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENTS ... 7

LIST OF FIGURES ... 9

LIST OF TABLES ... 12

CHAPTER 1 - INTRODUCTION ... 13

1.1. Background ... 13

1.2. Research Problem ... 16

1.3. Research Objectives ... 16

1.4. Significance of Studies ... 17

1.5. Research Questions ... 17

1.6. Hypothesis ... 17

1.7. Limitation ... 18

CHAPTER 2 - LITERATURE REVIEW ... 19

2.1 Crane Rail ... 19

2.2 Previous Studies ... 24

2.2.1 Crane Rail Measurement Tool ... 24

2.2.2 Crane Rail Measurement Method ... 28

2.3 Measurement Tool Components... 30

2.3.1 Sensors ... 30

2.3.2 Actuators ... 31

2.3.3 Other Components ... 32

CHAPTER 3 – RESEARCH METHODS ... 34

3.1 Design Justification ... 34

3.2 Materials and Equipment ... 37

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3.2.2 Rotary Encoder and Counter Meter... 39

3.2.3 Laser Sensor ... 42

3.2.4 Photodiodes ... 47

3.2.5 Other Electrical Components ... 48

3.2.6 Arduino ... 52

3.3 Design Calculation and Parameter ... 54

3.4 Data Processing System ... 59

3.5 Analytical Method ... 63

3.5.1 AC Motor Simulation ... 63

3.5.2 Laser Accuracy Testing ... 65

3.5.3 Photodiodes Reading Simulation Method ... 69

CHAPTER 4 – RESULTS AND DISCUSSIONS... 71

4.1 Initial Evaluation and Testing Results ... 71

4.1.1 AC Motor Simulation ... 71

4.1.2 Rail Rover Drawbacks ... 73

4.1.3 Laser Accuracy Testing Results ... 74

4.1.4 Photodiodes Reading Simulation Results ... 75

4.2 Rail Rover Discussion ... 78

4.3 Rail Rover Analysis ... 79

4.3.1 Systematic Error ... 79

4.3.2 Analysis of Data Taken by Rail Rover ... 80

CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 81

5.1 Conclusions ... 81

5.2 Recommendations ... 82

GLOSSARY ... 85

REFERENCES ... 87

CURRICULUM VITAE ... 90

APPENDIX ... 91