Syahril Ardi, Mohamad Bintang Febriansyah, Muhammad Hidayat, Sirin Fairus, Heru Suprapto

Modification of control system using PLC and HMI on drill oil hole machine to speed up piston model replacement process time in automotive manufacturing industry

Introduction

Modification of control system using plc and hmi on drill oil hole machine to speed up piston model replacement process time in automotive manufacturing industry. Enhance automotive piston manufacturing. Upgrade drill oil hole machine's NC control to PLC & HMI for faster model replacement, reduced downtime, and improved efficiency.

Abstract

This research was conducted at an automotive manufacturing company that produces pistons. In the piston production process, there are two stages, the first stage is the casting process which can be called the Foundry process, and the second stage is the manufacture of parts which can be called the Machining process. In the Machining process, there is a piston drilling process to make oil holes using a Drill Oil Hole (DOH) machine. The Drill Oil Machine process has a clamping process using a pneumatic cylinder, then determining the points using a servo motor, and the drilling process using a selfeeder motor. This Drill Oil Hole machine has a weakness, namely it still uses the old control system, NC. This NC Control System program cannot be changed, and to change the program, you must contact the vendor directly. In addition, Troubleshooting takes a long time. Therefore, this study aims to change the control system from NC to PLC. This is done by adding a piston template system to reduce downtime and change the piston type model"”furthermore, changes to the HMI display on the DOH machine layer using the Omron NB10W HMI. Meanwhile, the servo motor and its driver use Servo Delta Asda-A2. After replacing the control system from NC-based to PLC CJ2M CPU-11, the DOH machine testing was carried out by the provisions. The use of HMI as the basis for monitoring and the machine operating system by the operator makes it much easier to operate and has several additional features such as piston templates and sensor indicators that are not available in numerical-based control systems. In addition, for the next piston model replacement process, there is no more machine downtime.

Review

This research addresses a critical operational challenge in automotive piston manufacturing, specifically concerning the Drill Oil Hole (DOH) machine. The authors identify a significant bottleneck caused by an outdated Numerical Control (NC) system, which exhibits inflexibility in programming, reliance on external vendors for modifications, and prolonged troubleshooting times. This issue is particularly problematic in an environment requiring frequent adjustments for different piston models, leading to considerable machine downtime during the replacement process. The paper effectively frames the problem within the context of piston production's machining stage, highlighting the need for a more adaptable and efficient control solution. The proposed solution involves a comprehensive upgrade of the DOH machine's control system from NC to a modern Programmable Logic Controller (PLC) architecture. Specifically, the study details the implementation of an Omron CJ2M CPU-11 PLC, complemented by an Omron NB10W HMI for enhanced operator interface and monitoring. Critical to the improved flexibility is the integration of a Delta Asda-A2 servo motor and driver, and the introduction of a novel "piston template system" designed to streamline model changes. This systematic replacement of key control components is intended to directly address the limitations of the legacy system, integrating existing mechanical elements like pneumatic cylinders and selfeeder motors into the new, more agile control framework. The results presented indicate a successful transformation, with the new PLC-HMI based system demonstrably improving machine operation and efficiency. Operators benefit from an intuitive HMI display, offering critical features such as real-time sensor indicators and the new piston template system, which were absent in the numerical-based predecessor. Crucially, the research claims to have eliminated machine downtime associated with piston model replacement, a direct and significant achievement for an automotive manufacturing environment where production continuity is paramount. This modification not only enhances operational ease and monitoring capabilities but also provides a more flexible, maintainable, and self-sufficient control system, offering substantial practical benefits for industrial application.

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