By
Robi Tubagus Yuni 22052006
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
June 2021
TO PREVENT ENGINE OVERHEAT USING IOT
By
Robi Tubagus Yuni 22052006
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
Revision after Thesis Defense on July 24, 2021
Robi Tubagus Yuni 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.
Robi Tubagus Yuni
_____________________________________________
Student Date
Approved by:
Dena Hendriana, B.Sc., S.M., Sc.D.
_____________________________________________
Thesis Advisor Date
Dr. Cuk Supriyadi Ali Nandar, ST., M.Eng.
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium S.Kom., M.Sc.
_____________________________________________
Dean Date
Robi Tubagus Yuni ABSTRACT
MONITORING HEAVY EQUIPMENT COOLANT TEMPERATURE TO PREVENT ENGINE OVERHEAT USING IOT
By
Robi Tubagus Yuni
Dena Hendriana, B.Sc., S.M., Sc.D., Advisor Dr. Cuk Supriyadi Ali Nandar, ST., M.Eng., Co-Advisor
SWISS GERMAN UNIVERSITY
All heavy equipment, including bulldozers, are expected to always be ready to operate and have maximum performance. However, there are still many bulldozers that have problems, one of which is engine overheating. This overheating can be caused by a reduced amount of coolant due to a leak or an inappropriate cooling fan rotation speed due to a loose fan belt. This study aims to monitor and provide early warning of rising coolant temperature along with the possibility of reducing the amount of coolant and decreasing the cooling fan rotational speed. This research was conducted by developing monitoring and warning devices, apart from being known by the operator, it can also be known by the maintenance department in a different place with the use of IoT. The result showed E18-D80NK proximity sensor can be used to read the cooling fan rotation speed. In addition, a contactless liquid water level sensor module XKC-Y25-V can be used to determine the coolant level in the sub tank/reservoir. On the other hand, NodeMCU V3 ESP8266 can be used with the Blynk application as an IoT platform, to be able to send information from sensors to Android.
Keywords: Engine Overheat, Blynk, NodeMCU, E18-D80NK, Contactless Liquid Level Sensor.
Robi Tubagus Yuni
© Copyright 2021 by Robi Tubagus Yuni
All rights reserved
Robi Tubagus Yuni DEDICATION
I dedicated this research for my family & PT United Tractors, Tbk.
Robi Tubagus Yuni ACKNOWLEDGEMENTS
I would like to thank to Mr. Dena Hendriana., B.Sc., S.M., Sc.D. and Mr. Dr. Cuk Supriyadi Ali Nandar, ST., M.Eng. and all Lecturers who have guided me while studying in Swiss German University. Thanks also to Mr. Eddhie Sarwono and the management of PT. United Tractors Tbk, who have given me the opportunity to pursue this master's program.
Robi Tubagus Yuni TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 3
ABSTRACT ... 4
DEDICATION ... 6
ACKNOWLEDGEMENTS ... 7
TABLE OF CONTENTS ... 8
LIST OF FIGURES ... 10
LIST OF TABLES... 13
CHAPTER 1 – INTRODUCTION ... 14
1.1 Background ... 14
1.2 Research Problems ... 20
1.3 Research Objectives ... 20
1.4 Significance of Study ... 20
1.5 Research Question ... 20
1.6 Hypothesis ... 20
CHAPTER 2 - LITERATURE REVIEW ... 21
2.1. Theoretical Perspectives ... 21
2.2. Previous Studies ... 37
CHAPTER 3 – RESEARCH METHODS ... 40
3.1. Research Framework ... 40
3.2. Scope of Study ... 41
3.3. Conceptual Design... 41
Robi Tubagus Yuni
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 64
4.1. Initial Evaluation ... 64
4.2. Experimental Result ... 75
CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 82
GLOSSARY ... 83
REFERENCES ... 86
CURRICULUM VITAE ... 89
Robi Tubagus Yuni LIST OF FIGURES
Figures Page
Figure 1. Heavy equipment models or types (form left to right is dump truck, loader,
grader, excavator, bulldozer) ... 14
Figure 2. The largest population of Komatsu bulldozers in Indonesia ... 14
Figure 3. Komatsu bulldozers engine, powertrain, and attachment. ... 15
Figure 4. UT Techcare application. ... 15
Figure 5. Summary problem D85ESS-2 at UT-Techcare. ... 16
Figure 6. D85ESS-2 engine and cooling system summary problem at UT-Techcare. 16 Figure 7. Examples of components damage due to overheating. ... 17
Figure 8. Komatsu bulldozer D85ESS-2 engine coolant temperature monitor. ... 18
Figure 9. KOMTRAX Technology. ... 19
Figure 10. KOMTRAX D85ESS-2 feature. ... 19
Figure 11. Diesel engine component. ... 21
Figure 12. Four stroke diesel engines. ... 22
Figure 13. S6D125-2 fuel system chart. ... 24
Figure 14. Cutaway view of a FIP. ... 25
Figure 15. Metering action of plunger and cutaway of governor. ... 26
Figure 16. Simplified governor operation. ... 26
Figure 17. Komatsu D85ESS-2 engine speed control. ... 27
Figure 18. S6D125-2 cooling system chart. ... 28
Figure 19. Radiator structure. ... 29
Figure 20. Radiator Komatsu bulldozer D85ESS-2. ... 30
Figure 21. S6D125-2 fan drive. ... 30
Figure 22. Komatsu D85ESS-2 Coolant temperature sensor and panel gauge. ... 31
Figure 23. Komatsu D85ESS-2 troubleshooting chart. ... 32
Figure 24. Some operating procedures of Komatsu bulldozer D85ESS-2. ... 33
Figure 25. Coolant level check Komatsu bulldozer D85ESS-2. ... 34
Robi Tubagus Yuni
Figure 28. ESP8266 microcontroller (a) V1 (b) V2 (c) V3. ... 37
Figure 29. Research workflow. ... 40
Figure 30. Input, process, and output diagram. ... 42
Figure 31. Monitoring and warning flow diagram. ... 43
Figure 32. Device block diagram. ... 44
Figure 33. NodeMCU V3 Lolin. ... 45
Figure 34. NodeMCU V3 pin’s location and identification... 46
Figure 35. NodeMCU V3 Lolin base board. ... 48
Figure 36. Step-down module LM2596. ... 49
Figure 37. Coolant temperature sensor. ... 50
Figure 38. Coolant temperature sensor structure of circuit. ... 50
Figure 39. Voltage divider circuit. ... 51
Figure 40. Contactless liquid level sensor. ... 52
Figure 41. Contactless liquid level sensor pin description and installation. ... 53
Figure 42. Proximity sensor E18-D80NK. ... 53
Figure 43. Proximity sensor E18-D80NK pin description and installation. ... 54
Figure 44. Proximity sensor E18-D80NK logic output. ... 54
Figure 45. OLED display 0.96 inch. ... 54
Figure 46. Relay 1 channel 3.3 volt. ... 55
Figure 47. Engine stop solenoid. ... 56
Figure 48. Active buzzer. ... 56
Figure 49. RTC DS3231. ... 57
Figure 50. SparkFun openlog. ... 57
Figure 51. Arduino IDE preference. ... 59
Figure 52. Installing ESP8266. ... 59
Figure 53. Successfully installed the board. ... 60
Figure 54. Blynk login page. ... 61
Figure 55. Selecting the microcontroller model and connection type. ... 61
Figure 56. Create new project and send the auth token. ... 62
Figure 57. Widget/command block selection page. ... 62
Robi Tubagus Yuni
Figure 59. Temperature sensor working test. ... 64
Figure 60. Temperature sensor reading compared to thermometer reading. ... 65
Figure 61. Level sensor working test and position setting. ... 67
Figure 62. Setting fan belt tension to maximum deflection. ... 68
Figure 63. Measuring fan speed at maximum deflection of fan belt tension. ... 69
Figure 64. Fan speed sensor reading... 69
Figure 65. Box dimension, upper and side view. ... 70
Figure 66. Front and back box view. ... 71
Figure 67. Inside box view. ... 71
Figure 68. Box location... 72
Figure 69. Coolant temperature sensor location. ... 72
Figure 70. Coolant level sensor location... 73
Figure 71. Fan speed sensor location. ... 73
Figure 72. Blynk application interface for monitoring coolant temperature. ... 74
Figure 73. Superchart data download menu display. ... 75
Figure 74. First state simulation display result. ... 76
Figure 75. Second condition simulation display result. ... 77
Figure 76. Third condition simulation display. ... 78
Figure 77. Fourth state simulation display result. ... 79
Figure 78. Cooling system abnormality notification. ... 80
Figure 79. Buzzer alarms, relays, and fuel solenoids experimental results. ... 81
Figure 80. Fuel solenoid placement requires consultation with the principal... 81
Robi Tubagus Yuni LIST OF TABLES
Table Page
Table 1. Komatsu D85ESS-2 engine specification. ... 23
Table 2. Radiator type of Komatsu D85ESS-2. ... 29
Table 3. Abnormal conditions in the cooling system. ... 42
Table 4. List of materials and equipment... 44
Table 5. Node MCU V3 Lolin specification. ... 45
Table 6. Node MCU V3 Lolin GPIO pin description. ... 47
Table 7. Node MCU V3 base board specification. ... 49
Table 8. Step-down module LM2596 specification. ... 49
Table 9. Contactless liquid level sensor specification. ... 52
Table 10. Proximity sensor E18-D80NK specification. ... 53
Table 11. OLED display 0.96 inch specification. ... 55
Table 12. RTC DS3231 specification. ... 57
Table 13. SparkFun openlog specification. ... 58
Table 14. Temperature reading. ... 65
Table 15. t-test result ... 66
Table 16. Result of coolant level sensor test ... 68
Table 17. Cooling fan speed reading ... 70
Table 18 . LED function on Blynk application. ... 74
Table 19. Simulation conditions. ... 76
Table 20. First state simulation result. ... 77
Table 21. Second state simulation result... 78
Table 22. Third state simulation result. ... 79
Table 23. Fourth state simulation result. ... 80
