Giovanni Firdaus Putra Student Date Approved by: Edward Boris P

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By

Giovanni Firdaus Putra 11601047

BACHELOR’S DEGREE in

MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

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

June 2020

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Giovanni Firdaus Putra Revised After the Thesis Defense on

8^th July 2020

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Giovanni Firdaus Putra 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.

Giovanni Firdaus Putra

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Student Date

Approved by:

Edward Boris P. Manurung, M.Eng.

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Thesis Advisor Date

Leonard P. Rusli, M.Sc., Ph.D.

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Thesis Co-Advisor Date

Dr. Maulahikmah Galinium, S.Kom., M.Sc.

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Dean Date

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Giovanni Firdaus Putra ABSTRACT

Electric Oven Development For Wafer Stick Machine

By

Edward Boris P. Manurung, M.Eng., Advisor Leonard P. Rusli, M.Sc., Ph.D., Co-Advisor

SWISS GERMAN UNIVERSITY

Research in the field of automation still needed to make an improvement in this field.

While the wafer stick machine can fully operate, the gas system for the burner can be improved by either increasing its efficiency or finding new alternative of heat source for the oven on the machine. In this research, the possibility of using electric heater as a main heat source on the oven will be the main topic of this research. In addition, the PID control will be use to maintain the stability temperature of the system. The test will be using smaller prototype and not directly to the current machine, because it impossible to try it directly with the current machine. The energy consumption of this prototype system that use LPG gas burner, electrical heater, and electrical heater with PID control will be compared to determine which system is more efficient.

Keywords: Heat Transfer, PID Control, gas burner, electric heater, LPG

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Giovanni Firdaus Putra DEDICATION

I dedicate this works to God My Family

My Friends My University

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Giovanni Firdaus Putra ACKNOWLEDGEMENTS

Thank you to God that let me do this thesis and finish this thesis on time. Thank you for my Dad and my Mom that fully support me while doing this project. Thank you for Drg. Claudia Regita for all her helpfulness during this thesis work. Lastly, thank you to my beloved brother Joe Nathanael.

Thank you for Mr. Edward Boris P. Manurung, M.Eng. as my advisor that has been spend so much time to give me a lot of advice while doing this thesis. Thank you to Mr. Leonard P. Rusli, M.Sc., Ph.D as Co-Advisor to give me a critical idea about this project. Also thank you for Dr. Yunita Umniyati, S.Si., M.Sc. for teach a lot of things about heat transfer.

To all of my friend, thank you for all of the support. Especially thank you for Einser Nahiman, Edrick Phoa, and Wilvan Gunawan to keep my stress level low.

Thank you for Pak Weten and Pak Erik to let me work on this topic in PT. Kreasi Solusi Mandiri. Also, while doing this thesis I learn a lot from the people that help me to do this research, in the office. Thank you for the help for Pak Endang, Pak Puji, Pak Sutri, and Pak Handoko.

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Giovanni Firdaus Putra TABLE OF CONTENTS

Page

STATEMENT BY THE AUTHOR ... 3

ABSTRACT ... 4

DEDICATION ... 6

ACKNOWLEDGEMENTS ... 7

LIST OF FIGURES ... 12

LIST OF TABLES ... 14

LIST OF EQUATION ... 15

CHAPTER 1 - INTRODUCTION ... 16

1.1. Background ... 16

1.2. Research Problems ... 17

1.3. Research Objectives ... 17

1.4. Significance of Study ... 17

1.5. Reseach Questions ... 18

1.6. Hypothesis ... 18

1.7. Scope ... 18

1.8. Limitation ... 18

1.9. Thesis Structure ... 18

CHAPTER 2 - LITERATURE REVIEW ... 20

2.1. Current Design of the Wafer stick Machine ... 20

2.1.1 Baking Wheel ... 20

2.1.2 Combustion Pipe and Mixing Tube ... 21

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2.2.1 Conduction ... 24

2.2.2 Convection ... 24

2.2.3 Radiation ... 25

2.3. Thermodynamics ... 26

2.3.1. Zeroth Law of Thermodynamics ... 26

2.3.2. First Law of Thermodynamics ... 26

2.3.3. Second Law of Thermodynamics ... 26

2.3.4. Third Law of Thermodynamics ... 27

2.4. Thermal Expansion of Solids ... 27

2.5. Converting Electrical Energy to Heat Energy ... 28

2.5.1. Induction Heating ... 28

2.5.2. Joule Heating ... 29

2.6. Temperature Sensor ... 31

2.6.1. Thermocouple ... 31

2.6.2. Resistance Temperature Detector ... 32

2.6.3. Infrared Temperature Sensor ... 33

2.7. Pulse Width Modulation ... 33

2.8. Relay ... 34

2.8.1 Contactor ... 34

2.8.2 Electromagnetic Relay ... 35

2.8.3 Solid State Relay ... 35

2.9. Controller ... 36

2.9.1. Microcontroller ... 36

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2.9.3. Programmable Logic Controller ... 38

2.10. PID Control ... 38

2.10.1. Proportional Term ... 39

2.10.2. Integral Term... 39

2.10.3. Derivative Term ... 40

2.10.4. Parameter Tuning ... 40

CHAPTER 3 – RESEARCH METHODS ... 42

3.1. Mathematical Calculation ... 42

3.1.1. Current System ... 42

3.1.2. System Identification ... 47

3.2. Mechanical Components for Oven Prototype ... 48

3.2.1. Sample Plate Design ... 48

3.2.2. Oven Design ... 50

3.2.3. Burner Design ... 51

3.2.4. Heating Block ... 52

3.2.5. Mechanical Assembly ... 53

3.3. Electrical Components for Oven Prototype ... 54

3.3.1 Cartridge Heater ... 54

3.3.2 Solid State Relay ... 54

3.3.3. Infrared Temperature Sensor ... 55

3.3.4. Wiring Diagram ... 56

3.4. Controller ... 57

3.4.1. PLC ... 57

3.4.2. Temperature Controller ... 59

CHAPTER 4 – RESULTS AND DISCUSSIONS... 60

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4.1.3. Data of Electric Heater with PID Control ... 73

4.2. Data Analysis and Energy Calculation ... 92

4.3. Efficiency Comparison ... 93

CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 94

5.1. Conclusions ... 94

5.2. Recommendations ... 94

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Giovanni Firdaus Putra LIST OF FIGURES

Figures Page

Figure 1 – Technical Drawing of the Machine 20

Figure 2 – The Piping Circuit of the Wafer Stick Machine 22

Figure 3 – Nozzle Design 23

Figure 4 – Burner Nozzle Arrangement 23

Figure 5 – Illustration of Convection 25

Figure 6 – Example of Induction Heating 29

Figure 7 – Tubular and Cartridge Heater 31

Figure 8 - Thermocouple 31

Figure 9 – Resistance Temperature Sensor 32

Figure 10 – Infrared Temperature Sensor 33

Figure 11 – PWM illustration 34

Figure 12 – Example of Contactor 34

Figure 13 – Example of Electromagnetic Relay 35

Figure 14 – Example of Solid-State Relay 36

Figure 15 – Arduino Uno 37

Figure 16 – Example of Custom Controller 37

Figure 17 – Example of Programmable Logic Controller 38

Figure 18 – PID Block Diagram 39

Figure 20 – HMI on the Wafer Stick Machine 42

Figure 21 – Wafer Stick Machine Temperature Over Time 45

Figure 22 – LPG Flowrate Meter 46

Figure 23 – Sample Plate 300mm x 300mm x 60mm 49

Figure 24 – Oven Design – 320mm x 320mm x 320mm 50

Figure 25 – Burner Design with 6 Nozzle Output 52

Figure 26 – Heating Block Design 295mm x 110mm x 15mm 52

Figure 27 - Mechanical Assembly 53

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Figure 31 – Wiring Diagram 56

Figure 32- PLC on the Current Machine 57

Figure 33 – Flowchart of the Program 58

Figure 34 – Temperature Controller OMRON E5cc-RX2asm 59

Figure 35 – Fluke Max 62+ for Calibrating Sensor 60

Figure 36 – Burner Prototype Data Taking Process 61

Figure 37 – Burner Prototype Temperature Over Time Graph 64

Figure 38 – LPG Consumption Data Taking 64

Figure 39 – Electrical Heater Data Taking Process 66

Figure 40 - Unequal Heat Distribution of Heating Block 67

Figure 41 – Temperature at the Hottest Point of Heating Block 67 Figure 42 - Electrical Heater Temperature Graph (On-Off control) 72

Figure 43 – Measuring Power Consumption by the Heater 73

Figure 44 - PID Block Diagram for Simulation 74

Figure 45 – P Control Xcos Simulation 75

Figure 46 – PI Control Xcos Simulation 75

Figure 48 - Electrical Heater Temperature Graph (P Control, Kp = 15,1) 80 Figure 49 - Electrical Heater Temperature Graph (P Control, Kp = 150) 86 Figure 50 - Electrical Heater Temperature Graph (PI Control, Kp = 150, Ki = 0.1) 92

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Giovanni Firdaus Putra LIST OF TABLES

Table Page

Table 1 - Ziegler Nichols Method 41

Table 2 – Wafer Stick Machine Temperature 43

Table 3 – LPG Consumption Over Time 46

Table 4 – Burner Prototype Temperature Table 61

Table 5 – Energy Consumption Table 65

Table 6 – Electrical Heater Temperature Table (On-Off Control) 68

Table 7 – Ziegler Nichols Table to approximate Kp, Ti, Td 74

Table 8 – Electrical Heater Temperature Table (P Control, Kp = 15,1) 76 Table 9 - Electrical Heater Temperature Table (P Control, Kp = 150) 81 Table 10 - Electrical Heater Temperature Table (PI Control, Kp = 150, Ki = 0.1) 86

Table 11 – Energy Consumption Comparison 93

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Equation Page

Equation 1 - Air Fuel Ratio 21

Equation 2 - Fourier law ODE 24

Equation 3 - Fourier Law Scalar Form 24

Equation 4 - Newton Law of Cooling 25

Equation 5 - Newton Law of Cooling 25

Equation 6 - Stefan Boltzmann’s Law 25

Equation 7 - First Law of Thermodynamics 26

Equation 8 - Linear Thermal Expansion 27

Equation 9 - Volumetric Thermal Expansion 27

Equation 10 – Volumetric Thermal Expansion Coefficient 28

Equation 11 - Area Thermal Expansion Coefficient 28

Equation 12 – Electrical Power 29

Equation 13 - Electrical Energy 30

Equation 14 - Heat Energy 30

Equation 15 - Energy Conversion 30

Equation 16 - Joule Heating Current Density 30

Equation 17 - Proportional Term 39

Equation 18 - Integral Term 39

Equation 19 - Derivative Term 40

Equation 20 - Heat Total 47

Equation 21 - Fourier's Law 47

Equation 22 - Heat Loss 48

Equation 23 - Thermal Capacitance 48

Equation 24 - Heat Total System ODE 48

Equation 25 – General Form of First Order Transfer Function 73

Equation 26 – Transfer Function of the System 74