Design Control Systems of Marking Machine and Total Length Check
Damper Assembly Based on Programmable Logic Controller
To cite this article: Syahril Ardi and Juliantito Ardianto 2020 J. Phys.: Conf. Ser. 1500 012033
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Design Control Systems of Marking Machine and Total Length
Check Damper Assembly Based on Programmable Logic
Controller
Syahril Ardi1 and Juliantito Ardianto2
1Mechatronics Department, Politeknik Manufaktur Astra, Jakarta, Indonesia 2Engineering Production & Manufacturing, Politeknik Manufaktur Astra
Email: [email protected]
Abstract. This research was conducted at an automotive manufacturing company in
Indonesia that produces shock absorber (damper). Case study was conducted on the front shock absorber of the motorcycle (front fork). This new product will be given special marking at the designated place. Previous Front Fork products did not have a marking process at the Front Fork Assembly Line. We designed the marking machine control system. This machine control system uses the main MC2000N machine actuator and MC2000T Controller². The machine design is then added to the total length check function. The results obtained are the traceability of the damper made easier and faster in handling claims from the customer. The damper becomes in accordance with the standard.
1. Introduction
This research was conducted at a company that manufactures Front Fork and Oil Cushion Unit Shock Absorber types. Shock Absorber itself functions to reduce vibrations that occur when a vehicle is passing through an uneven or bumpy surface. In making Shock Absorber parts themselves, they will go through the FFASSY (Front Fork Assembly) process. This process is the process of uniting parts from the previous process, in this line all parts are put together to become a complete damper assembly.
The new product to be made is a type of Front Fork which functions to reduce vibration or shock absorbers on the front of a motorbike. For this Front Fork product, special marking is given on the part that has been determined. None of the products in the FF assembly line have gone through the marking process on the FF assembly Line, and the FF assembly Line does not have the marking machines needed for this new product. This machine is a machine that uses the main actuator MC2000N machine and MC2000T controller so that it can be used on damper (Front Fork) products. The machine added the total length check function. In this study we designed a PLC-based control system from the marking machine and total length check damper assembly.
2. Methodology and Design
This company is a manufacturing industry company engaged in the automotive components field, specifically producing shock absorber. Shock Absorber is a part that functions as a shock absorber. One of the Shock Absorber products manufactured is the Front Fork type. Front Fork is the front shock absorber on a motorcycle. Figure 1 shows the front fork moped.
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Figure 1. Front Fork Moped
On a motorcycle, the shock absorber functions as a shock absorber when crossing bad road conditions or when crossing the speed bump, so that the rider still feels comfortable when riding his motorcycle. The front fork assembly process plan for this new model has several stages. Figure 2 shows the assembly process of a new front pork model.
Figure 2. The assembly process of a new front pork model.
Figure 2 shows the Front Fork assembly process starting with Innertube Cleaning. The next process is to enter Cyl Complete into the Innertube, then innertube through the caulking process. Next is the process of Oil Seal, which is given grease in the form of grease, caulking that has been put into the outertube and put oil seal into the innertube. Next is the union between Innertube and Cyl Compelete with Outertube with a bolt that is rotated with a predetermined torque. After that, Oil Seal is pressed to close the gap between the innertube and the outertube. Then put the dust seal into the innertube and press it. Next, check for leaks using a leakage tester. After passing the leak test, fill the damper with oil and put the spring in the damper. After that close the innertube with a stamp and the cap is locked with c-pin. The next process is the Function test, which is to check the function of the damper, whether it functions according to standards or not. The final process is marking and total length check, which is the marking process for pre-existing models not done in the assembly line.
In this marking machine design, we determine the minimum specifications of the tools needed are as follows:
• Using a marking machine (dot peen marking) from Couth MC 2000 series.
• It can detect the Total Length Damper automatically.
• The existence of the HMI display to display the damper measurement results, and parameter settings.
• The program is in the form of a ladder diagram.
• During the marking process the damper's position must not be shifted.
Based on the minimum specifications required, a marking & total length check machine is designed to meet the specified standards. Figure 3 shows the marking machine design & total length check.
Figure 3. the marking machine design & total length check
This marking machine is designed using a type of dot peen marking, so the results of marking on the workpiece in the form of dots that form a special pattern in accordance with a predetermined shape. This marking machine will be equipped with a damper length measurement system (total length check) to ensure that the damper reaching the customer is a standardized product in accordance with the tolerances allowed. Measurement of the total length of the damper will use a smart sensor that will be integrated with the PLC as the control center of this machine.
The smart sensor measurement results will be displayed on the HMI. This machine is also designed to have wheels which will be very useful when placing this marking machine in the Assembly Line. Although this machine is designed to have wheels, but the wheels in this machine are only designed to facilitate the positioning of the engine in the Assembly Line, not designed for moving machines with a distance of more than 10 meters from the original position. Because of this machine is designed with all four wheels using a swivel type.
This type of dot peen marking machine is prone to cause vibrations when the marking process is running, so this can result in poor marking and unreadability. This is due to the vibration so that the workpiece shift occurs when the marking is running. To reduce the effects of vibration on the marking results, the machine is equipped with a clamp mechanism that is useful to ensure that the workpiece does not experience a shift when the marking process is running. This clamp mechanism also serves to ensure the exact measurement position at the same position at each damper, so that measurements become precise at the specified position.
2.2.1 Control Systems Design. Based on the minimum specifications required, a control system is
designed for the Marking & Total Length Check machine that meets the specified standards [2,3,4, and 5]. Figure 4 shows the diagram of control systems design.
Figure 4. The diagram of Control systems design
2.2.2 Programmable Logic Controller. In this design, the PLC is chosen as the control center to control the output based on the input received by the PLC. Inputs come from sensors, switch
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HMI (Human Machine Interface) is used as an intermediary between the user (operator) and the
machine. So the operator can interact well with the machine. In this case, interacting is making it easy for the operator to operate the machine or find out the output data or monitor the ongoing system. HMI communicates in two directions using serial communication which can transmit data in the form of binary, decimal, hex decimal or text.
This controller is the control center of the MC2000N marking machine, which is used to adjust the direction of movement of the MC2000N marking machine toolpen to form a pattern or shape of the marking needed.
Smart Sensor functions as a sensor to detect the distance between the workpiece and the sensor tip. This sensor utilizes the amplifier unit to get analog data from the measurement of the distance between the workpiece and the end of the proximity sensor.
Emergency Switch is used as a button to stop the process when a problem occurs in the machine. Nagara Switch is used as a trigger to start the marking process
Push Button is used as input with special functions.
Pilot Lamp, Tower Lamp, and Buzzer are used as indicators related to the engine. Pilot Lamp is used as an indicator of Power On. Tower Lamp is used as an indicator of process information including when the engine is active, in operation (auto mode) and when the engine is in error. While the buzzer serves to warn that there are products that are NG (Not Good).
This Pneumatic Dot Marking is used to give a mark (marking) in the form of a production code at a predetermined place.
The Pneumatic actuator used in this design uses a Linear or Swivel clamp and air gripper rack & Pinion Type, both of which are used as the grip of the workpiece.
In the design for the HMI interface will be divided into three displays, namely Auto Mode, Manual Mode, and Select Model.
In this section, the interface will be created with some content, including: information about OK or NG (Not Good) products running on the machine, the length of the damper measured, the model that is running, the number of workpieces that have been processed, the number of OK workpieces that have been processed, the number of NG working objects that have been processed, and the virtual button to go to the Manual Mode and Select Mode menus. On this interface there is also information about today's date, the date when the operator uses the machine.
In this section, the interface will be made virtual button to activate and deactivate the upper clamp, lower clamp, and run marking. On this interface there are also indicators when the upper clamp, lower clamp, and run marking are active or not. There is also a virtual button to return to the auto menu. In this section, the interface will be made a virtual button up and down to choose the damper model to be run. Models that can run on this machine are limited to 15 models, so that this interface is designed to only choose 15 models. In this section, it is designed to display a damper model that can be selected between 1 and 15, the length of the damper that will be run, the range of tolerance that will be run, as
well as the maximum and minimum measurement values that are still included in the OK product category.
Based on the machine system marking & total length check that has been made, and then a flow chart program is made. Figure 5 shows the flow chart program of marking & total length check machine for "Auto Mode".
Figure 5. Flow Chart Program Mesin Marking & Total Lenth Check "Auto Mode"
When the power is turned on, the system is on and detects the Auto or Manual switch in the Auto or Manual position. If the switch is in the Manual position, the HMI will display the Manual Mode interface and the machine is ready to operate manually. Meanwhile, if the Auto or Manual switch is in the Auto position, the HMI will display the Auto Mode interface and the machine is ready for marking damper.
When the nagara switch (Start) is pushed, the photoelectric sensor and Smart Sensor will detect whether there is a damper or not. When the photoelectric sensor and Smart Sensor detect a workpiece (damper), then the clamp1 & clamp2 are active. After Clamp1 & Clamp2 are active, the smart sensor detects the total length of the damper. If the total length of the damper meets the standard, then the marking runs. After marking is complete, Clamp1 & Clamp2 will unclamp. Next, the operator will unload the damper from the engine.
In manual mode, the design is focused on the individual movements of each actuator used. This section is used to check the function of the actuator is it still optimal or needs improvement. This manual mode also aims to facilitate when the need for repositioning on the actuator and checking some Inputs and Outputs related to the actuator.
3. Testing and Analysis
From the parts that have been discussed, the parts are assembled according to the design as in Figure 3. Next, Figure 6 shows the realization of design the marking machine and total length check.
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Figure 6. The realization of design the marking machine and total length check
Comparison of Figure 3 and Figure 6 can be seen clearly, that the realization of the Marking & Total Length Check machine design has been made as identical as possible from the designs that have been designed before. Before assembling, all parts made of S45 material are coated with Black Plating to prevent oxidation processes that can cause rust on S45 material.
In the main jig assembly, one of which uses the Cavity feature, this is intended so that the workpiece can stick perfectly to the jig. With so expected workpiece position is not easy to shift when the marking process is running. In parts that are in direct contact with work objects, this jig section uses POM material, thus minimizing the potential for blisters to occur on the workpiece.
After making and testing functions on the system, HMI, and work processes on the marking machine & total length check, whether the results are in accordance with the required engine specifications, the explanation is as follows [6, 7]:
• Marking machines use the Dot peen marking system from Couth MC 2000 series. In making this marking machine & total length check, we have used the Dot peen marking system from Couth which is MC 2000 N using the MC 2000 T² controller.
• Can detect Total Length Damper automatically. The machine is designed and built using smart sensors that function as a detector of the total length of the damper.
• There is a HMI display to display the damper measurement results. From the designs that have been made and implemented, we use the OMRON NS5-series HMI.
• Programs in the form of ladder diagrams. This PLC program uses CX-Programmer which can program the CJ2M-CPU11 PLC using ladder diagrams.
• During the marking process, the position of the damper should not be shifted. To overcome the shift in the workpiece when the marking is running, we designed a jig equipped with a swivel camp to ensure the workpiece does not experience a shift during the marking process.
4. Conclusions
In this paper, we have discussed the design of system control systems of marking machines and the total length of check damper assembly based on Programmable Logic Controllers. Marking & total length check damper assembly machines have been made with electrical parts that meet the required specifications. Furthermore, it is controlled through a PLC programmed with CX-Programmer software with ladder diagrams. There is a special marking in the form of a production code on each damper, so when there is a product claim from Customer trace ability it becomes easy and fast. By looking at the existing marking code you can quickly find out when and where the product was produced. In addition, with the total length check conducted, products that are not in accordance with the standards can be eliminated so that the product received by the customer is a standardized product.
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