JOURNAL OF MECHANICAL ENGINEERING, MANUFACTURES, MATERIALS AND ENERGY
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172 research outputs found
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Damage Analysis and Repair of a Small-Scale ORC (Organic Rankine Cycle) Prototype Turbine During Testing
Full text linkThis research discusses the damage analysis and repair of an Organic Rankine Cycle (ORC) prototype turbine that experienced failure during testing. The damage occurred due to a collision between the rotor blades and stator blades, causing the rotor blade to break. The primary cause was identified as a manufacturing error in the turbine stator, where the flange holes were misaligned with the shaft. Additionally, the use of improper locking flange bolts and loose fitting on the coupling and stator shaft contributed to this issue. The research methodology included failure analysis using Process Failure Modes and Effects Analysis (PFMEA) to identify potential failures and prioritize corrective actions. The results indicate that adjustments in the manufacturing process, the use of high-precision measurement technology, improved material quality control, and better technician training can significantly reduce the risk of future failures. Furthermore, evaluating operational conditions and conducting regular inspections are recommended to ensure optimal turbine performance. With the implementation of these corrective actions, the ORC turbine prototype is expected to operate more reliably and efficiently during testing and use. This research is expected to make a significant contribution to enhancing the reliability and efficiency of ORC system turbines, and provide guidance for the future development and testing of turbines
Modification of Nyamplung Seed Peeling Machine Transmission
Full text linkDesign of a nyamplung seed peeling machine with a 0.5 HP electric motor drive source with 1400 rpm rotation using a Ø76 mm pulley transmission system with a 1:1 ratio with a v-belt type A-24. After testing, it was found that from 100% of the nyamplung seeds there were seeds that were crushed and their contents were not processed, as many as 55% of the nyamplung seeds were found, apart from that when the machine was run there were seeds that were thrown out of the hopper so that the results of the machine design were deemed not to be as expected. To overcome this problem, it is necessary to modify the previous research machine so that the peeling process between the seeds and the nyamplung shell can improve the quality. The results of the modification of the nyamplung seed peeler tool were obtained with a duration of 13 seconds, the number of nyamplung seeds was 25 pcs, of which 17 were peeled. There were 5 pcs of whatever were not peeled, and 3 pcs were crushed. The second trial had a duration of 14 seconds, the number of seeds sampled was 25, 18 were peeled, the remaining 4 were not peeled and 3 were crushed. The third trial lasted 15 seconds out of a total of 25 pieces peeled, the result was 19 pieces peeled and the remaining 2 pieces failed, 4 pieces were destroye
Evaluation of Occupational Safety and Health Requirements in Confined Space at Turbine Maintenance PT. Sinergi Nusantara Gula PG Tjoekir
No full textConfined space is a high-risk workplace because it contains various sources of danger such as toxic gases, lack of oxygen, and fire risk. PT. Sinergi Gula Nusantara PG Tjoekir has implemented work procedures based on BINWASNAKER No. 113/DJPPK/XI/2006, but evaluation is needed to ensure compliance with the latest regulations, namely Permenaker No. 11 of 2023. The study aimed to evaluate the OSH Requirements in confined space turbine maintenance at PT. SGN PG Tjoekir is by Permenaker no. 11 of 2023, including confined space classification, access restrictions to enter confined spaces, entry permits, safe work procedures, equipment and equipment, and OSH confined space personnel. The type of research method used is qualitative descriptive, namely providing an overview of OSH requirements in a limited space for turbine maintenance. Then the data obtained is compared to its conformity with Permenaker No. 11 of 2023. The results of this study out of 17 conditions that must be met only 60% that have been met. The conditions that have not been met are the classification of confined space, testing and monitoring of hazardous atmospheric gases, labeling and energy isolation forms, supply respirators, testing, and monitoring equipment for hazardous atmospheric gases, penetrating voltage measuring instruments, and OSH confined space personnel. This study concludes that the OSH requirements in confined space turbine maintenance are in the category of lacking. The advice provided by the company can update the entry permit procedure and increase compliance with the latest regulation, namely Permenaker No. 11 of 2023 to improve work safety
Experimental Study on the Effect of a Cooling System on an Unmanned Surface Vehicle Prototype Using a Zenoah G32FC Engine
No full textThis study presents a performance test of the cooling system on an unmanned vessel prototype using a Zenoah G32FC engine. The purpose of this research is to evaluate the impact of the cooling system on engine temperature, radiator effectiveness, and vessel speed. The experiment was conducted using a platform supply vessel (PSV) prototype with a monohull design, measuring 120 cm in length and 35.15 cm in width. The Zenoah G32FC engine is a 2-stroke engine with a displacement of 31.8 cc, serving as the main propulsion unit for the prototype. Two types of coolant fluids were tested: water and radiator coolant. The results showed that the use of a radiator helped maintain engine temperature more effectively compared to operating without one, with an average test temperature of 64.3°C and a peak temperature of 71.6°C. The radiator coolant achieved the highest effectiveness, reaching 57.6%, with a heat transfer rate of 341 watts. Vessel speed remained relatively constant throughout all tests, indicating that the use of a radiator had minimal impact on speed, while still maintaining engine temperature within a safe range. Therefore, the use of a radiator is strongly recommended to optimize engine performance
Design of a 2 HP Power Waste Shutter Machine Using on-Grid PLTS With 6 x 290 WP
Full text linkIn the campus environment, the management of organic waste such as leaves is of particular concern, so a 2 HP organic waste shredder was designed with a rotation speed of 1450 rpm, a 150 mm diameter pulley, and a 6200 mm long shaft with 21 blades 15 mm thick, 25 mm wide, 100 mm long, and 24 mm diameter motor shaft made of S45C steel, supported by a 1.47 kW motor; Testing of this machine at various waste loads shows optimal results with different electrical power and engine rotation, such as at loads of 0.2 kg (237.8 V, 6.27 A, 1.49 kW), 3.5 kg (184 .1 V, 5.97 A, 1.15 kW , 1493 rpm), 5 kg (221.2 V, 6.37 A, 1,409 kW, 1990 rpm), and 8 kg (234.6 V, 6.38 A, 1,496 kW), so that this machine is supported by an on-grid PLTS with a power of 1740 WP which is able to increase the efficiency of electricity costs for the needs of operating the chopping machine.
Keywords: 2HP AC motor; organic chopping machine
Characteristics of SKD 61 and Aluminium 7075 Tools in High Density Polyethylene (HDPE) and Polypropylene (PP) Welding in Terms of Tensile Strength and Bending strength
No full textEffective welding procedures are necessary to preserve structural integrity due to the growing usage of lightweight polymers in industry, such as polypropylene (PP) and high density polyethylene (HDPE). This study sought to determine how the tool materials, SKD 61 and Aluminum 7075, affected the tensile and bending strength of HDPE and PP friction stir welded (FSW) joints. A quantitative comparative design was used in the experiment, and the FSW tool was modified milling equipment with screw cylindrical pin tools. Temperature control was observed using a thermogun and no preheating was used to guarantee process stability. Based on the results, SKD 61 generated higher weld quality, which was characterized by fewer flaws, regulated heat input, and more consistent material flow. SKD 61 outperformed than aluminium 7075, which had an average tensile strength of 11.09 MPa and bending strength of 19.11 MPa, while aluminium 7075 had an average tensile strength of 7.8 MPa and bending strengths of 16.28 MPa. This discrepancy is explained by SKD 61's higher heat conductivity and stability, whereas tool geometry had little effect because the screw cylindrical pin profile was the same. SKD 61 is more suited for FSW of HDPE-PP dissimilar joints, according to the study's findings, offering higher joint quality and stronger mechanical performance
Design and Construction of Electric Car Chassis for KMLI Competition Needs Using Solidwork
No full textThe purpose of this study is to obtain a lightweight electric car frame design, providing a sense of security and comfort with the intention of being the basis for the placement of the steering, engine, battery, vehicle body, and other components for the needs of the Indonesian Electric Car Competition. This study was conducted using the Research Development method with the help of software that is capable of making a model in the form of a 3-dimensional image, in this case the software used is Solidwork software. Based on the results of the study, it can be concluded that: (1) Chassis design using Solidwork software with the design of KMLI competition needs before implementation (2) Car frame design with a 2000 watt BLDC motor specification with a 1/2 inch Black Iron Pipe frame material. (3) Analysis of the frame height when receiving a load of 100 kg is 16.5 cm with a chain ratio of 1500 rp
Design of an IoT-Based Control System for Energy Storage Efficiency and Monitoring
Full text linkThe increasing demand for efficient, transparent, and adaptive energy storage systems presents a significant challenge in supporting the global transition to renewable energy. This study presents the development of an Internet of Things (IoT)-based control system designed to optimize intelligent energy storage management. The system is built around an ESP32 microcontroller and integrates voltage, current, and temperature sensors, alongside wireless communication modules, all connected to a web-based dashboard for real-time monitoring. A dynamic control algorithm is employed to enhance the efficiency of the charging and discharging processes. Experimental results show a charging efficiency of 95% and a discharging efficiency of 94.74%, accompanied by a low data latency of 120 ms. The monitoring sensors demonstrate exceptional accuracy, with deviations within ±1% for voltage and current, and ±2°C for temperature, surpassing conventional systems. Compared to traditional approaches, the IoT-based system offers significant improvements in operational efficiency, data accuracy, and transparency in energy management. These findings highlight the potential of IoT integration in electronic control systems as an innovative solution for smart, efficient, and reliable energy storage. Future research should focus on scaling the system for industrial applications and incorporating artificial intelligence to predict performance and adapt system conditions in real-tim
A Energy Efficiency Strategy in Manufacturing Industry Through Implementation of Automation Technology
No full textThe implementation of automation technology in the manufacturing industry has become a critical solution in facing global energy efficiency challenges. Amid increasing demands for reduced energy consumption and carbon emissions, the manufacturing sector is required to adopt innovative solutions in their operations. This study aims to analyze and evaluate energy efficiency strategies through the application of automation technology in the manufacturing sector, with a focus on optimizing energy consumption and increasing productivity. The research methodology uses both quantitative and qualitative approaches, including analysis of historical energy consumption data from 50 manufacturing facilities that have implemented automation systems, in-depth interviews with industry experts, and comparative evaluation of various automation technologies available in the market. The results show that the implementation of automation technology can reduce energy consumption by an average of 27.5% in the first 12 months, with an increase in production efficiency by 35%. Further analysis reveals that automation systems based on the Internet of Things (IoT) and artificial intelligence provide optimal results in energy management, with an average return on investment of 2.3 years. The integration of smart sensors and automated control systems has proven to be effective in optimizing energy use in production processes, predictive maintenance, and peak load management. The study also identified key challenges in implementation, including high initial investment costs, personnel training needs, and the complexity of system integration. The study found that key factors for successful implementation include strategic planning, top management support, and a comprehensive training program. In conclusion, the application of automation technology in the manufacturing industry is an effective strategy to achieve long-term energy efficiency, with the potential for significant savings and increased industrial competitiveness
Development of a Soybean Crushing Machine Based on the VDI 2221 Method at UKM Tempe Tiga Putra
Full text linkUKM Tempe Tiga Putra, located in Jepara, faces challenges in the manual soybean crushing process. This process takes approximately 2 hours and 30 minutes per day to handle a daily capacity of 65 kg and imposes significant physical strain on workers, especially on the wrists. This study aims to design a more efficient and ergonomic soybean crusher using the VDI 2221 method. The resulting machine features specifications such as a ¼ hp AC motor, a hollow galvanized frame, an A-type V-belt, and dimensions tailored to the operator's anthropometry. The machine reduces processing time to 24 minutes per day, improving efficiency by 83.97%. The VDI 2221 method facilitated a design that meets the technical and economic requirements of the UKM while enhancing operator comfort. This innovation not only boosts production efficiency but also minimizes the risk of injury from manual labor. Consequently, the tool significantly enhances productivity and fosters a better working environment at UKM Tempe Tiga Putra