RANCANG BANGUN PROTOTYPE SISTEM KONTROL MESIN POTONG BERBASIS PLC MITSUBISHI DAN HMI DENGAN METODE PID KONTROL POSISI DI CV PERJUANGAN STEEL SURABAYA

RANCANG BANGUN PROTOTYPE SISTEM KONTROL MESIN POTONG BERBASIS PLC MITSUBISHI DAN HMI DENGAN METODE PID KONTROL POSISI
DI CV PERJUANGAN STEEL SURABAYA

Nama Mahasiswa : Syaiful Anwar
NIM : 20221330010
Jurusan : Teknik Elektro FT- UM Surabaya
Dosen Pembimbing : Ridho Akbar, S., ST., M.T.
Rudi Irmawanto, S.T., M.T.

ABSTRAK

CV Perjuangan Steel Surabaya merupakan perusahaan yang bergerak di bidang pengolahan logam yang membutuhkan proses pemotongan material dengan tingkat ketelitian yang tinggi. Berdasarkan hasil observasi, proses pengukuran panjang material sebelum pemotongan masih dilakukan secara manual sehingga sering terjadi ketidaksesuaian panjang hasil potong, kesalahan pengukuran akibat human error, pemborosan material, serta menurunnya efisiensi proses produksi. Selain itu, sistem yang digunakan belum mampu memberikan pengendalian posisi secara otomatis dan umpan balik (feedback) secara real-time sehingga akurasi posisi material belum optimal. Oleh karena itu, diperlukan suatu sistem kontrol otomatis yang mampu meningkatkan akurasi posisi, kestabilan sistem, dan konsistensi hasil pemotongan.
Penelitian ini bertujuan merancang dan membangun prototype sistem kontrol mesin potong berbasis Programmable Logic Controller (PLC) Mitsubishi FX3U dan Human Machine Interface (HMI) Weintek dengan menerapkan metode Proportional Integral Derivative (PID) sebagai pengendali posisi. Sistem menggunakan motor stepper NEMA 23 sebagai aktuator, rotary encoder 1000 PPR sebagai sensor umpan balik, driver TB6600 sebagai penggerak motor, serta sensor proximity sebagai pendeteksi posisi mekanik. Parameter PID diperoleh melalui pemodelan sistem orde dua dan penalaan menggunakan metode Ziegler-Nichols, kemudian diimplementasikan pada PLC untuk mengurangi error antara posisi aktual dan nilai set point.
Hasil penelitian menunjukkan bahwa prototype berhasil diimplementasikan dan mampu mengintegrasikan PLC Mitsubishi FX3U, HMI Weintek, motor stepper NEMA 23, driver TB6600, rotary encoder, dan sensor proximity dalam satu sistem kontrol otomatis. Berdasarkan hasil pengujian, sistem dengan metode PID menghasilkan nilai parameter Kp = 10,8, Ki = 8,64, dan Kd = 3,37 Sistem mampu mencapai akurasi pemotongan sebesar 99 %, dengan rata-rata error sebesar 0-05 mm, nilai overshoot sebesar 0-5%, serta settling time selama 0,5-2detik. Dibandingkan sistem tanpa PID, penerapan PID memberikan respon yang lebih cepat, lebih stabil, mengurangi error posisi, serta meningkatkan akurasi dan konsistensi hasil pemotongan material. Dengan demikian, sistem kontrol yang dikembangkan mampu meningkatkan efisiensi proses pemotongan dan layak diterapkan sebagai solusi otomatisasi pada mesin potong material.

Kata kunci: PLC Mitsubishi FX3U, HMI Weintek, Motor Stepper NEMA 23, PID, Rotary Encoder, Mesin Potong.

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Design and Development of a Cutting Machine Control System Prototype Based on Mitsubishi PLC and HMI with Pid Position Control Method at CV Perjuangan Steel Surabaya

Student Name : Syaiful Anwar
Student ID : 20221330010
Department : Electrical Engineering FT- UM Surabaya
Advisors : Ridho Akbar, S., ST., M.T.
Rudi Irmawanto, S.T., M.T.

ABSTRACT

CV Perjuangan Steel Surabaya is a company engaged in the metal processing industry that requires high-precision material cutting. Based on the observation results, the process of measuring the material length before cutting is still performed manually, leading to frequent discrepancies in cut length, measurement errors, material waste, and decreased production efficiency. In addition, the system used is not yet capable of providing automatic position control and real-time feedback, resulting in suboptimal material position accuracy. Therefore, an automatic control system is needed that can improve position accuracy, system stability, and cutting result consistency.
This research aims to design and build a prototype cutting machine control system based on the Mitsubishi FX3U Programmable Logic Controller (PLC) and Weintek Human Machine Interface (HMI), using the Proportional Integral Derivative (PID) method as the position controller. The system uses a NEMA 23 stepper motor as the actuator, a 1000 PPR rotary encoder as the feedback sensor, a TB6600 driver as the motor driver, and a proximity sensor as the mechanical position detector. PID parameters were obtained through second-order system modeling and Ziegler-Nichols tuning, and then implemented on the PLC to reduce the error between the actual position and the set point.
The research results show that the prototype was successfully implemented and capable of integrating the Mitsubishi FX3U PLC, Weintek HMI, NEMA 23 stepper motor, TB6600 driver, rotary encoder, and proximity sensor into a single automatic control system. Based on the test results, the PID method produced parameter values of Kp = 10.8, Ki = 8.64, and Kd = 3.37. The system achieved a cutting accuracy of 99%, with an average error of 0-05 mm, an overshoot of 0-5%, and a settling time of 0.5-2 seconds. Compared to the system without PID, PID provides faster response time, greater stability, reduced position error, and improved accuracy and consistency in material cutting. Thus, the developed control system can improve cutting process efficiency and is suitable for implementation as an automation solution for material-cutting machines.

Keywords: Mitsubishi FX3U PLC, Weintek HMI, NEMA 23 Stepper Motor, PID, Rotary Encoder, Cutting Machine.