HANDLING FACILITIES WITH AUTOMATED SURGE BIN
By Ari Apriandi 2-2015-1108
MASTER’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY EduTown BSD City
Tangerang 15339 Indonesia
Revision after Thesis Defense on July 29, 2016
Ari Apriandi 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.
Ari Apriandi Student
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Date
Approved by:
Dr. Ir. Hanny Berchmans, M.T., M.Sc.
Thesis Advisor
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Dena Hendriana, B.Sc., S.M., Sc.D.
Thesis Co-Advisor
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Dr. Ir. Gembong Baskoro, M.Sc.
Dean
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Ari Apriandi ABSTRACT
ENGINEERING DESIGN AND SIMULATION OF INTEGRATED CONTROL SYSTEM FOR OPTIMIZATION OF TRANSPORT SYSTEM IN COAL
HANDLING FACILITIES WITH AUTOMATED SURGE BIN
By Ari Apriandi
Dr. Ir. Hanny Berchmans, M.T., M.Sc., Advisor Dena Hendriana, B.Sc., S.M., Sc.D, Co-Advisor
SWISS GERMAN UNIVERSITY
At this time, technological developments continue to rise and get into all aspects such as telecommunications, banking, construction, oil and gas, trade, marine, mining, etc.
Technology creates the change to become more effective and efficient. It is also happening in the world of mining with infrastructure facilities. In this study focuses on automation in the coal handling facility. The control system has been developed from two stations into one integrated station that can increase production time and the system becomes more efficient. Integration of the system is created with designing surge bin system as a liaison both stations into automatic system. Next, simulations have been done by developing ladder logic using a PLC. This study focuses designing the surge bin into the automatic system so that the integrated system can be developed.
Keywords: PLC, Ladder Logic, Surge Bin, Sensor, Automation.
Ari Apriandi
© Copyright 2016 by Ari Apriandi All rights reserved
Ari Apriandi DEDICATION
I dedicate this works for the future of the country to support infrastructure and technology development
I loved Indonesia
Ari Apriandi ACKNOWLEDGEMENTS
Praise and great gratitude to Almighty God submitted by the author to the Allah SWT for blessings and help to complete this thesis on time.
This thesis is arranged to fulfill the requirements for obtaining master's degree, in Mechanical Engineering (Mechatronics) Study Program, Faculty of Engineering and Information Technology, Swiss German University.
On this occasion with great humility, I would like to thank you to all of those who have given me help and guidance so that this thesis can be finished. Completion of writing of this thesis, the author would like to thank to:
1. Dr. Ir. Gembong Baskoro, M.Sc. as the Dean of Engineering and Information Technology Faculty.
2. Dena Hendriana, B.Sc., S.M., Sc.D. as the Deputy Head of Master Mechanical Engineering Department.
3. My best gratitude to Dr. Ir. Hanny Berchmans, M.T., M.Sc. as my advisor in completing this thesis through the guidance and direction as well as the encouragement that are very useful and helpful for the preparation and writing of this thesis.
4. All lecturers in Master of Mechanical Engineering Department, especially in Mechatronics Study Program, thanks for the teaching during this time.
5. All the administration staffs of Engineering and Information Technology Faculty that gave helping during arrangement of thesis.
6. I also honor highly to Prof. Ir. Houtman P. Siregar, M.Si., Ph.D. I remember during his life, he supported me since I registered firstly to study in SGU until he teached me with his extensive knowledge. Thank you very much.
Ari Apriandi 7. The biggest thanks especially to my lovely wife Suci Ladya Fartana as the best
wife ever in this world who always pray, encouraging, giving love and compassion, giving material I need, always trying to do the best, to accompany me the day by day, support me all the time and happiness in my life. I also love my children to give a smile and happiness in my life. I can survive and spirit to face everything until today just because of them.
8. I say thanks to all of my collegues in my company for giving material I need and supporting me so I can finished this well. I can not mention them one by one here but I always remember and pray for them for all those who support and pray for me. I do not forget also to say great thanks to my supervisors in my company for always support and pray in other I can finished my thesis. Thanks for all.
9. Wonderful thank for all my greatest friends in class MME that I can mention their names one by one as well as the junior and senior in Engineering and Information Technology Faculty thanks for your support. Love you all.
Final words, the author say thank you so much indeed for all for those who I can not mentions the names. Hopefully this thesis can be useful for us and become the input for the parties in need.
Ari Apriandi TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 8
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER 1 - INTRODUCTION ... 13
1.1 Background ... 13
1.2 Objectives ... 16
1.3 Significance of Study………17
1.4 Research Question……….18
1.5 Hypothesis... 18
CHAPTER 2 - LITERATURE REVIEW...19
2.1 Solid Bulk Material Handling...19
2.2 Principle of Surge Bin ... 23
2.3 Strain-Gauges Load Sensor...30
2.4 Radar Level Measurement Sensor...32
2.5 Programmable Logic Controller (PLC) ... 35
2.6 Previous Studies...37
CHAPTER 3 – RESEARCH METHODS ... 39
3.1 Materials and Equipment ... 39
3.2 Analytical Method ... 48
CHAPTER 4 – RESULTS AND DISCUSSIONS... 58
4.1 Loading Time Evaluation ... 58
4.2 Operational Cost Evaluation ... 61
4.3 Other Savings...63
Ari Apriandi
CHAPTER 5 – CONCLUSION AND RECCOMENDATIONS ... 64
5.1 Conclusions ... 64
5.2 Recommendations ... 64
GLOSSARY ... 65
REFERENCES ... 66
CURRICULUM VITAE ... 68
