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All Journal EDUCATIONE: Journal of Education Research and Review
Priyono
Politeknik Negeri Manado
Education Social Sciences

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PROGRAMMABLE CONTROLLER AND HUMAN-MACHINE INTERFACE RETROFIT FOR SHEET-METAL CUTTING CONTROL Rick Resa Wahani; Michael Edward Gregerio Kimbal; Moody Noldy Tumembow; Priyono; Herotje Siwi
EDUCATIONE Volume 4, Issue 2, July 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.
SIMULATION-BASED DESIGN AND EVALUATION OF A DUAL-AXIS SOLAR-TRACKING MECHATRONIC SYSTEM FOR A 50-WATT-PEAK PANEL Excellsdeo Jonathan Polii Ndahawali; I Komang Ardika; Priyono; Tammy Tinny Veisy Pangow; Adriyan Warroka
EDUCATIONE Volume 4, Issue 2, July 2026
Publisher : CV. TOTUS TUUS

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59397/edu.v4i2.288

Abstract

Dual-axis photovoltaic tracking requires coordinated mechanical, electronic, control, and safety subsystems. This simulation-based design study develops an integrated mechatronic architecture for a 50 Wp panel using an Arduino Mega 2560, four light-dependent resistors, two 3 N·m closed-loop NEMA 23 motors, 20:1 worm reducers, 20T:60T timing pulleys, normally closed limit switches, an anemometer, an RTC DS3231, driver alarms, and a hardware emergency stop. The outer loop uses normalized azimuth and elevation light errors, an eight-sample moving-average filter, a deadband equivalent to 0.5°, and dominant-axis pulse scheduling; the inner motor loop uses encoder feedback, and a supervisory state machine manages INIT, HOMING, TRACKING, HOLD, PARK, STOW, and FAULT modes. A deterministic seven-day scenario was evaluated from 08:00 to 17:00, comprising ten hourly reporting points and nine one-hour integration intervals per day (70 reported observations). The environmental and orientation profiles were prescribed for design evaluation rather than sampled from a documented field site. Under these assumptions, the tracked-panel model produced 283.93 Wh/day versus 237.48 Wh/day for the fixed comparator, a descriptive gain of 19.56%. The model-residual combined RMSE was 0.158°, maximum residual error was 0.44°, estimated actuator consumption was 0.495 Wh/day, and estimated net gain was 45.95 Wh/day. These values describe internal model behavior, not validated hardware performance. No physical prototype, independent output-shaft measurement, stochastic uncertainty analysis, or location-specific economic assessment was conducted. The contribution is therefore a system-level integration and verification framework, together with explicit requirements for subsequent prototype and field validation.
Co-Authors Adriyan Warroka Excellsdeo Jonathan Polii Ndahawali Herotje Siwi I Komang Ardika Michael Edward Gregerio Kimbal Moody Noldy Tumembow Rick Resa Wahani Tammy Tinny Veisy Pangow