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All Journal JTT (Jurnal Teknologi Terpadu) EDUCATIONE: Journal of Education Research and Review
Moody Noldy Tumembow
Politeknik Negeri Manado
Civil Engineering, Building, Construction & Architecture Control & Systems Engineering Education Materials Science & Nanotechnology Mechanical Engineering Social Sciences

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PLC–HMI RETROFIT AS A WORK-BASED LEARNING PLATFORM IN MANUFACTURING VOCATIONAL EDUCATION Rick Resa Wahani; Michael Edward Gregerio Kimbal; Moody Noldy Tumembow; Priyono; Herotje Siwi
EDUCATIONE Vol. 4 No. 2 (2026)
Publisher : CV. TOTUS TUUS

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59397/edu.v4i2.278

Abstract

A 1995 Colgar sheet-metal cutting machine used in the Manufacturing Laboratory of Politeknik Negeri Manado experienced degraded cutting performance, a disabled automatic cycle, an unreliable safety function, and a non-functional blade-gap adjustment mechanism. This study aimed to retrofit the machine control system by integrating a programmable logic controller, a human-machine interface, limit sensors, a variable-frequency drive, and interlock-based emergency logic. The study used a research-and-development design combined with experimental validation. Data were collected through machine inspection, input-output mapping, ladder-diagram programming, HMI screen development, electrical installation, and functional testing with 2 mm and 6 mm steel plates. The retrofit restored manual and automatic blade movement, reactivated the worktable/blade-gap mechanism, enabled operator monitoring through HMI screens, and improved safety through upper and lower limit sensors, emergency stop logic, visual indicators, and audible alarms. Post-retrofit tests showed that the blade-gap setting operated normally, with a 0.35 mm gap for 2 mm steel plates and a 0.75 mm gap for 6 mm steel plates. The machine could perform a complete automatic down-and-up cycle through a single command while retaining full manual control. The findings indicate that PLC-HMI retrofitting is a practical modernization strategy for legacy sheet-metal machines because it improves functionality, operational accuracy, usability, and machine safety without replacing the main mechanical structure.
Retrofit Kontrol Kemiringan Pisau Mesin Pemotong Pelat Merek Colgar Berbasis HMI Dan PLC Omron Deko Trio Desembara; Moody Noldy Tumembow; Priyono Priyono
Jurnal Teknologi Terpadu Vol 14 No 2 (2026): JTT (Jurnal Teknologi Terpadu)
Publisher : Pusat Penelitian dan Pengabdian Kepada Masyarakat

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Abstract

A Colgar brand plate cutting machine (Guillotine Shear) manufactured in 1995 located at the Manufacturing Laboratory at Manado State Polytechnic is not functioning properly because the blade (cutter) angle adjustment mechanism is no longer working, thereby limiting the cutting capacity and quality of the results; currently, only the up-and-down movement of the cutting blade is controlled by a relay. This research employs the Research and Development (R&D) method with a design-and-build approach, which includes analyzing the machine’s initial condition, designing the mechanical and electrical systems, programming the PLC using CX-Programmer, and designing the HMI interface. Implementation was carried out by integrating hardware and software components, followed by functional testing to measure machine performance. The results of the study indicate that the retrofit system successfully improved machine performance, where the blade tilt angle can be adjusted using the HMI interface by controlling the movement of the solenoid connected to the hydraulic system. The system is also equipped with an audible alert (buzzer) when starting operation. It is recommended that the system be further developed by adding an automatic sensor capable of adjusting the angle according to the thickness of the material being used.
Co-Authors Deko Trio Desembara Herotje Siwi Michael Edward Gregerio Kimbal Priyono Priyono Priyono Rick Resa Wahani