ABSTRAK Stanley Kustamin (03320080017) SIMULASI PENGGUNAAN TEKNOLOGI KOMUNIKASI INDUSTRI MELALUI KOMUNIKASI ANTAR PLC PADA MESIN INDUSTRIAL COMMUNICATION (xv + 82 halaman: 20 gambar; 46 tabel; 5 lampiran) Komunikasi industri sudah semakin marak digunakan dalam beberapa dekade terakhir ini. Bentuk penggunaannya seperti pada sebuah alat pengontrol yang dikenal dengan PLC. PLC banyak digunakan untuk mengontrol sistem produksi seperti untuk sistem AS/RS, batch, distribution dan berbagai sistem lainnya. Penelitian ini membahas mengenai teknik komunikasi antara 2 PLC dalam mengontrol sebuah sistem kerja. Dua buah PLC dihubungkan dengan menggunakan sebuah kabel UTP (Unshielded Twisted Pair) dan diprogram dengan menggunakan software keluaran FESTO, FST4. Pemrograman dilakukan dengan memanfaatkan 2 buah driver, yaitu TCPIP untuk komunikasi dan ASI. ASI digunakan untuk mengakses peralatan Actuator Sensor Interface (AS-i) yang juga terpasang pada mesin Industrial Communication. Mesin ini adalah mesin yang merupakan objek pemrograman pada penelitian ini. Fasilitas lainnya seperti Call Module Program (CMP) dan flag pada software FST4 juga digunakan untuk melakukan komunikasi antara 2 PLC. Hasil dari pemrograman yang dilakukan yaitu berupa 2 buah siklus kerja aktuator, yaitu siklus A dan B, yang dimana siklus A dapat menyelesaikan 1 buah siklus kerja lebih cepat (3.78 sampai 4.66 detik) dibandingkan dengan siklus B yang lebih lambat (13.01 sampai 16.01 detik). Kedua siklus tersebut dapat berjalan karena adanya komunikasi antara kedua PLC yang terus menerus mengirimkan nilai dari keadaan sensor dan aktuator. Referensi: 13 (2003-2011)
vi
Stanley Kustamin (03320080017) SIMULATION OF COMMUNICATION TECHNOLOGY USAGE THROUGH THE COMMUNICATION BETWEEN PLC OF THE ‘INDUSTRIAL COMMUNICATION’ MACHINE (xv + 82 pages: 20 pictures; 46 tables; 5 attachments) Industrial communications are being used by more industries nowadays. One of the controller system known as PLC has also been integrated with communication technology to create more efficient system and control. PLC usually can be found at production systems such as, AS/RS, batching, distribution and so on. In this research, communications between two PLCs attached in one machine are simulated. Two PLCs are connected by one Unshielded Twisted Pair cable and programmed to operate one machine simultaneously. The software used to do the programming is known as FST4. Drivers such as TCPIP is used to activate the communication and others known as ASI is used to control Actuator Sensor Interface which is also attached to the machine system. In this software, there are also small programs called Call Module Program or simply CMP and flags. These small programs are also being used to assist the programming. As the result, two kinds of work cycle sequence are programmed and can be run by the machine. Those work cycles are called cycle A and B. Cycle A can finish one cycle faster than cycle B, that is, 3.78 until 4.66 seconds for one cycle A and 13.01 16.01 seconds for one cycle B. PLCs will keep on giving each other feedbacks about the condition of their own inputs and outputs, hence creating smooth work cycles. References: 13 (2003-2011)
vii
KATA PENGANTAR
Puji dan syukur kepada Tuhan Yang Maha Esa karena atas rahmat dan karunia-Nya lah, penulis dapat melaksanakan dan menyelesaikan Tugas Akhir ini. Tugas Akhir dengan judul “SIMULASI PENGGUNAAN TEKNOLOGI KOMUNIKASI INDUSTRI MELALUI KOMUNIKASI ANTARA PLC PADA MESIN INDUSTRIAL COMMUNICATION” ini ditujukan untuk memenuhi persyaratan akademik guna memperoleh gelar Sarjana Teknik Strata Satu Universitas Pelita Harapan Karawaci. Penulis menyadari bahwa tanpa adanya bantuan dari banyak pihak, Tugas Akhir ini tidak akan dapat diselesaikan pada waktunya. Oleh karena itu, penulis mengucapkan terima kasih sebesar-besarnya kepada pihak-pihak terkait tersebut yang diantaranya diantaranya adalah: 1. Bapak Laurence, MT selaku Kepala Jurusan Teknik Industri. 2. Bapak Eric Jobiliong, Ph.D selaku Sekretaris Jurusan dan penasehat akademik penulis. 3. Bapak Dr. Ing Anthony Riman dan Bapak Ishak, ST, MM, selaku dosen pembimbing Tugas Akhir penulis yang telah banyak memberikan masukan kepada penulis. 4. Staf Laboratorium Pak Arie yang sudah sering membantu penulis. 5. Keluarga penulis yang telah memberikan dukungan terus menerus.
viii
6. Rekan-rekan mahasiswa seperjuangan, Vicky, Rudy, Frenkie, Veronia, Vivi, dan Novita yang sudah saling memberikan dukungan serta semangat. 7. Semua pihak tidak dapat disebutkan satu per satu. Akhir kata, penulis mengetahui masih terdapat kekurangan dalam Tugas Akhir ini. Oleh karena itu, penulis sangat mengharapkan kritik dan saran dari berbagai pihak . Semoga laporan ini dapat bermanfaat bagi pihak-pihak yang membacanya.
Karawaci, 6 Desember 2011
Penulis
ix
DAFTAR ISI
PERNYATAAN KEASLIAN TUGAS AKHIR ............................................... iii PERSETUJUAN DOSEN PEMBIMBING ...................................................... iv PERSETUJUAN TIM PENGUJI TUGAS AKHIR.......................................... v ABSTRAK......................................................................................................... vi KATA PENGANTAR ..................................................................................... viii DAFTAR ISI ...................................................................................................... x DAFTAR GAMBAR ........................................................................................ xii DAFTAR TABEL ........................................................................................... xiii DAFTAR LAMPIRAN .................................................................................... xv BAB I PENDAHULUAN ................................................................................... 1 1.1
Latar Belakang .................................................................................. 1
1.2
Pokok Permasalahan .......................................................................... 2
1.3
Pembatasan Masalah .......................................................................... 2
1.4
Tujuan Penelitian ............................................................................... 2
1.5
Sistematika Penulisan ........................................................................ 3
BAB II LANDASAN TEORI ............................................................................. 5 2.1
Programmable Logic Controllers (PLC) ............................................ 5
2.1.1
Input .................................................................................................. 7
2.1.2
Output ............................................................................................... 9
2.1.3
Bahasa Pemrograman PLC ................................................................ 9
2.1.4
Logika Pemrograman....................................................................... 10
2.1.5
Aplikasi PLC di Dunia Industri ........................................................ 12
2.2
Industrial Communication ............................................................... 13
2.3
Fieldbus ........................................................................................... 14
2.4
TCPIP vs. Field PC Net ................................................................... 17
2.5
Generator Vakum ............................................................................ 18
BAB III METODE PENELITIAN .................................................................. 20 3.1
Penelitian Awal ............................................................................... 20
x
3.2
Identifikasi Masalah......................................................................... 20
3.3
Studi Pustaka ................................................................................... 20
3.4
Tujuan Penelitian ............................................................................. 21
3.5
Pemrograman dan Simulasi.............................................................. 21
3.6
Analisis Program (Analisis Data dan Pembahasan) .......................... 22
3.7
Kesimpulan dan Saran ..................................................................... 22
3.8
Diagram Alir Metode Penelitian ...................................................... 22
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA ............................ 25 4.1
Jenis Peralatan ................................................................................. 25
4.2.
Deskripsi Peralatan .......................................................................... 27
4.3.
Peletakan Peralatan .......................................................................... 47
4.3.1
Tata Letak Meja Atas ....................................................................... 48
4.3.2
Tata Letak Meja Bawah ................................................................... 48
4.4.
Wiring Diagram............................................................................... 49
BAB V SISTEM KERJA MESIN.................................................................... 51 5.1
Sistem Kerja Mesin Industrial Communication ................................ 51
5.2
Sistem Kerja Tombol ....................................................................... 52
5.3
Siklus Kerja Aktuator ...................................................................... 58
BAB VI ANALISIS PROGRAM ..................................................................... 62 6.1
Instruksi Program ............................................................................ 62
6.2
Komunikasi Antar IPC..................................................................... 64
6.3
Program IPC Kiri ............................................................................. 66
6.4
Program IPC Kanan ......................................................................... 69
6.5
Pengukuran Waktu Siklus Kerja Aktuator ........................................ 72
6.6
Keuntungan dan Kerugian Komunikasi antar IPC/PLC .................... 75
BAB VII KESIMPULAN DAN SARAN ......................................................... 77 7.1
Kesimpulan ..................................................................................... 77
7.2
Saran ............................................................................................... 78
DAFTAR PUSTAKA ....................................................................................... 80 LAMPIRAN ..................................................................................................... 82
xi
DAFTAR GAMBAR Gambar 2.1 Sistem Hubungan 6 Komponen PLC (Sumber: Bolton 2009, 4) ........ 7 Gambar 2.2 NO contact (a) dan NC contact (b).................................................... 8 Gambar 2.3 Fungsi AND ................................................................................... 11 Gambar 2.4 Fungsi OR ...................................................................................... 11 Gambar 2.5 Fungsi NOT .................................................................................... 12 Gambar 2.6 Perkembangan dan Bidang Penerapan Fieldbus (Sumber: Zurawski 2005, 7-8)......................................................................... 15 Gambar 2.7 Efek Venturi ................................................................................... 18 Gambar 3.1 Diagram Alir Metode Penelitian ..................................................... 23 Gambar 3.2 Diagram Alir Metode Penelitian (untuk Pemrograman dan Simulasi) ......................................................................................... 24 Gambar 4.1 Skema Tata Letak Peralatan Meja Atas ........................................... 48 Gambar 4.2 Skema Tata Letak Peralatan Meja Bawah ....................................... 49 Gambar 4.3 Wiring Diagram.............................................................................. 50 Gambar 5.1 Mesin Industrial Communication .................................................... 51 Gambar 5.2 IPC kiri dan IPC kanan ................................................................... 52 Gambar 5.3 Panel Tombol ................................................................................. 53 Gambar 5.4 Posisi awal aktuator ........................................................................ 54 Gambar 5.5 Flow Chart Alur Kerja Panel Tombol ketika Mesin Menyala .......... 56 Gambar 5.6 Siklus A .......................................................................................... 59 Gambar 5.7 Siklus B .......................................................................................... 61 Gambar 6.1 Waktu Satu Siklus Kerja ................................................................. 74
xii
DAFTAR TABEL
Tabel 4.1 Daftar Peralatan .................................................................................. 26 Tabel 4.1 Daftar Peralatan (Lanjutan) ................................................................ 27 Tabel 4.2 Filter Catridge ................................................................................... 28 Tabel 4.3 Filter Regulator.................................................................................. 28 Tabel 4.4 On-off Valve ....................................................................................... 29 Tabel 4.5 Branching Module .............................................................................. 29 Tabel 4.6 Solenoid Valve.................................................................................... 29 Tabel 4.7 Vacuum Generator ............................................................................. 30 Tabel 4.8 Swivel Module .................................................................................... 30 Tabel 4.9 Linear Drive ....................................................................................... 31 Tabel 4.10 One Way Control Valve .................................................................... 31 Tabel 4.11 Power Supply PSU 245..................................................................... 32 Tabel 4.12 Combi Power Supply Unit ................................................................ 32 Tabel 4.13 Emergency Relay .............................................................................. 33 Tabel 4.14 Circuit Breaker ................................................................................. 33 Tabel 4.15 EMI Filter ........................................................................................ 34 Tabel 4.16 Double Socket................................................................................... 34 Tabel 4.17 Single Socket .................................................................................... 34 Tabel 4.18 Mainswitch ....................................................................................... 35 Tabel 4.19 Mushroom Head ............................................................................... 35 Tabel 4.20 Flush Head ....................................................................................... 36 Tabel 4.21 Standard Lever ................................................................................. 36 Tabel 4.22 Pilot Light Head ............................................................................... 37 Tabel 4.23 Contact Block NO ............................................................................ 37 Tabel 4.24 Contact Block NC............................................................................. 37 Tabel 4.25 Direct Supply.................................................................................... 38 Tabel 4.26 Busboard .......................................................................................... 38 Tabel 4.27 Digital I/O Module ........................................................................... 39
xiii
Tabel 4.28 CPU Module..................................................................................... 39 Tabel 4.29 Ethernet Control ............................................................................... 40 Tabel 4.30 AS-i Master Module ......................................................................... 40 Tabel 4.31 AS-i Slave Module............................................................................ 40 Tabel 4.32 Valve Terminal ................................................................................. 41 Tabel 4.33 Solenoid Coil .................................................................................... 41 Tabel 4.34 Plug Socket....................................................................................... 42 Tabel 4.35 Proximity Sensor .............................................................................. 42 Tabel 4.36 Connecting Cable ............................................................................. 43 Tabel 4.37 Flate Cable....................................................................................... 43 Tabel 4.38 UTP Cable ....................................................................................... 44 Tabel 4.39 Suction Cup ...................................................................................... 44 Tabel 4.40 Mounting Kit .................................................................................... 45 Tabel 4.41 Raceway ........................................................................................... 45 Tabel 4.42 Electric Cable................................................................................... 45 Tabel 4.43 Air Distribution Unit ........................................................................ 46 Tabel 4.44 Mechanical Parts ............................................................................. 47 Tabel 6.1 Tabel Pengkuruan Waktu Siklus Kerja Aktuator................................. 72
xiv
DAFTAR LAMPIRAN
Lampiran 1. Prosedur Pemrograman ................................................................ L-2 Lampiran 2. Allocation List IPC Kiri.............................................................. L-17 Lampiran 3. Allocation List IPC Kanan .......................................................... L-20 Lampiran 4. Program IPC Kiri (statement list) ............................................... L-23 Lampiran 5. Program IPC Kanan (statement list) ........................................... L-31
xv
