Desain dan Implementasi Sistem Pelatihan Pengambilan dan Penempatan Berbasis PLC untuk Pembelajaran Otomasi Industri

Abstract

Trainer pick and place banyak digunakan dalam pembelajaran otomasi industri, tetapi sebagian media pembelajaran masih memiliki arsitektur tertutup, verifikasi berbasis sensor yang terbatas, dan keterhubungan yang kurang jelas antara ladder logic dan respons aktuator fisik. Penelitian ini mengembangkan trainer pick and place elektro-pneumatik berbasis programmable logic controller (PLC) yang modular dengan interlocking berbasis sensor sebagai platform praktik untuk mempelajari kontrol sekuensial, pemetaan input-output, commissioning, dan troubleshooting dasar. Penelitian menggunakan model rekayasa terapan yang mencakup analisis kebutuhan, perancangan sistem, konstruksi perangkat keras, pengembangan perangkat lunak, pengujian integrasi, validasi fungsional, dan revisi. Trainer mengintegrasikan PLC, perangkat input digital, sensor posisi, katup solenoid, silinder pneumatik, gripper, emergency stop, serta mode manual dan otomatis. Protokol validasi dirancang untuk mengukur respons input-output, operasi aktuator individual, kinerja siklus otomatis, perilaku interlocking, respons emergency stop, dan konsistensi return-to-home dalam pengujian berulang. Pengujian kuantitatif lanjutan perlu melaporkan jumlah siklus, tingkat keberhasilan, rata-rata waktu siklus, waktu respons aktuator, waktu respons emergency stop, dan error rate. Berdasarkan validasi fungsional awal, sistem dapat menjalankan urutan pick-transfer-place-return sesuai status sensor dan mencegah transisi tidak aman berdasarkan kondisi interlocking yang ditetapkan. Trainer ini berkontribusi sebagai platform pembelajaran PLC elektro-pneumatik yang replikatif serta menjadi dasar pengembangan modul human-machine interface, data logging, dan industrial Internet of Things.

Pick and place trainers are widely used in industrial automation learning, yet many learning systems remain limited by closed architectures, insufficient sensor-based verification, and weak correspondence between ladder logic and physical actuator responses. This study developed a modular programmable logic controller (PLC)-based electro-pneumatic pick and place trainer with sensor-based interlocking as a hands-on platform for learning sequential control, input-output mapping, commissioning, and basic troubleshooting. The study followed an applied engineering development model comprising need analysis, system design, hardware construction, software development, integration testing, functional validation, and revision. The trainer integrates a PLC, digital input devices, position sensors, solenoid valves, pneumatic cylinders, a gripper, an emergency stop, and manual/automatic operating modes. The validation protocol was designed to measure input-output response, individual actuator operation, complete automatic-cycle performance, interlocking behavior, emergency-stop response, and return-to-home consistency over repeated trials. Quantitative retesting should report at least the number of cycles, success rate, average cycle time, actuator response time, emergency-stop response time, and error rate. Based on the initial functional validation, the system can execute the pick-transfer-place-return sequence according to sensor-confirmed states and can prevent unsafe transition under predefined interlocking conditions. The trainer contributes a replicable learning platform for PLC-based electro-pneumatic automation and provides a foundation for future learning modules involving human-machine interface, data logging, and industrial Internet of Things integration.