Design of integrated SCADA systems in piston production manufacturing case study on the conveyor, the coolant, the hydraulic, and the alarm systems using PLC CJ1M and CJ1W-ETN21

Abstract

This research was conducted at the company in Indonesia which is engaged in the production of piston. Piston is an important part of a vehicle. This research is based on the condition of the manufacturing plant, where there is an abnormality on all production lines, the invisibility of the motor coolant conditions, the conveyors, the hydraulic, and the alarm line. In addition, there are no scheduling program that led to the inefficient use of power from the motor coolant, the conveyor and the hydraulic. This is because when the hours of rest, the condition of the electric motor are still active. Undetected condition of the motor coolant, the conveyors, the hydraulic, and the alarm line, can cause unknowledgeable the condition of the production line that is currently in producing or being stopped. The duration of treatment by the maintenance operator can cause more lost time in the production process. While the duration of treatment by maintenance operators, one of them is caused by the distance between the control panel and monitoring for all conveyor motors, the coolant, the hydraulic, and the alarm line with maintenance space. This makes the maintenance so difficult to check the condition of the panel. We made a scheduling program and wiring the integrated monitoring with SCADA (Supervisory Control and Data Acquisition) systems that can automatically control and monitor the power usage of conveyor motors, the coolant, the hydraulic and also can monitor the alarms in the line. This integrated SCADA system using PLC (Programmable Logic Controller) CJ1M and CJW-ETN21 is based on Visual Basic. Based on the experiments conducted, the system can be more efficient energy output, amounting to 20,430 Watt per day. In addition, the overall state of the production line can be monitored in real-time.