CONTROLLING PALM SUGAR MACHINE BY PNEUMATIC SYSTEM

P.Dhadung1, P.Frandika1, K.Mahendra1, W.Miko Hadi1, R.Wahid1

1

Faculty of Mechanical, UteM, Malaysia

ABSTRACT
Palm sugar was originally made from the sap of the Palmyra palm, the date palm or
the sugar date palm. Now it is also made from the sap of the Arenga pinnata (sugar palm) and
the nipa palm, and may therefore also be sold as "arenga sugar". Palm sugar is produced by
tapping the sap from the inflorescence of the tree and boiling it down to produce a syrup,
which is then sold as is, or allowed to crystallize into various shapes and sizes. But there is a
problem in the old machine have an inaccuracy when fill gula melaka into container causing
the size of the gula Melaka to be small. So we design new machine system using a sensor and
pneumatic to increase the accuracy.
KEYWORD: pneumatic, accuracy, palm sugar, design and block diagram

INTRODUCTION
Control engineering or control systems engineering is the engineering discipline that
applies control theory to design systems with desired behaviors. The practice uses sensors to
measure the output performance of the device being controlled and those measurements can
be used to give feedback to the input actuators that can make corrections toward desired
performance. When a device is designed to perform without the need of human inputs for
correction it is called automatic control (such as cruise control for regulating a car's speed).
Multi-disciplinary in nature, control systems engineering activities focus on implementation
of control systems mainly derived by mathematical modeling of systems of a diverse range.
Likewise, if something happens to disturb the systems output without any change to
the input value, the output must respond by returning back to its previous set value. In the
past, electrical control systems were basically manual or what is called an Open-loop System
with very few automatic control or feedback features built in to regulate the process variable
so as to maintain the desired output level or value.
For example, an electric clothes dryer. Depending upon the amount of clothes or how
wet they are, a user or operator would set a timer (controller) to say 30 minutes and at the end
of the 30 minutes the drier will automatically stop and turn-off even if the clothes are still wet
or damp.

In this case, the control action is the manual operator assessing the wetness of the
clothes and setting the process (the drier) accordingly.

PROBLEM DEFINITION
SME Corporation Malaysia has hired your company to design a control system for
gula Melaka filling system. The filling system consists of filler that fills the gula Melaka into
container those are being transported on a conveyor. However, the systems that have been
designed have an inaccuracy causing the size of the gula Melaka to be small.
As a control system engineer, we are required to propose a solution for the system.
The design must include the assumption and justification of the selected approach in
analyzing the problem.

3. Concept and Solution

Fact

Idea

1. the system that 1.

have

been

Learning Issue
We

design

Action Plan

a 1. how to control the 1. observe the failure

machine

that

pressure

designed have an

considering

time

pneumatic system

inaccuracy

variable,

causing the size

accuracy when we

time to operate

make

of

gula

fill gula Melaka

pneumatic

diagram

be

into the container

system

the

Melaka

to

small

so

the 2. how to set the right

will increasing.
2. we using pneumatic
system to operate
this

of

machine,

3. how to make an
argonomic design

of the system
2.calculate
and

3.we

formula

scheme

to

ladder

create

the

diagram ladder for

system
4.we make the design
of the machine

because its more

simple and cheap,
with minimal risk

Pneumatic System
A pneumatic system is a system that uses compressed air to transmit and control
energy. Pneumatic systems are used in controlling train doors, automatic production lines,
mechanica clamps, etc

The advantages of pneumatic systems

Pneumatic control systems are widely used in our society, especially in the industrial
sectors for the driving of automatic machines. Pneumatic systems have a lot of advantages

a. High effectiveness
Many factories have equipped their production lines with compressed air
supplies and movable compressors. There is an unlimited supply of air in our
atmosphere to produce compressed air. Moreover, the use of compressed air is not
restricted by distance, as it can easily be transported through pipes. After use,
compressed air can be released directly into the atmosphere without the need of
processing.

b. High durability and reliability

Pneumatic components are extremely durable and can not be damaged easily.
Compared to electromotive components, pneumatic components are more durable and
reliable.

c. Safety
Pneumatic systems are safer than electromotive systems because they can
work in inflammable environment without causing fire or explosion. Apart from that,
overloading in pneumatic system will only lead to sliding or cessation of operation.
Unlike electromotive components, pneumatic components do not burn or get
overheated when overloaded

d. Easy selection of speed and pressure

The speeds of rectilinear and oscillating movement of pneumatic systems are
easy to adjust and subject to few limitations. The pressure and the volume of air can
easily be adjusted by a pressure regulator.

Components
a. Compressor
A compressor can compress air to the required pressures. It can convert the
mechanical energy from motors and engines into the potential energy in compressed
air (Fig. 2). A single central compressor can supply various pneumatic components

with compressed air, which is transported through pipes from the cylinder to the
pneumatic components. Compressors can be divided into two classes: reciprocatory
and rotary

b. Double acting cylinder

In a double acting cylinder, air pressure is applied alternately to the relative
surface of the piston, producing a propelling force and a retracting force (Fig. 6). As
the effective area of the piston is small, the thrust produced during retraction is
relatively weak. The impeccable tubes of double acting cylinders are usually made of
steel. The working surfaces are also polished and coated with chromium to reduce
friction.

Figure 1 :double acting cylinder

c. Directional control valve

Directional control valves ensure the flow of air between air ports by opening,
closing andswitching their internal connections. Their classification is determined by
the number of ports, the number of switching positions, the normal position of the
valve and its method of operation.
Common types of directional control valves include 2/2, 3/2, 5/2, etc. The first
number represents the number of ports; the second number represents the number of
positions. A directional control valve that has two ports and five positions can be
represented by the drawing in Fig. 8, as well as its own unique pneumatic symbol.

Principles of pneumatic control

1. Pneumatic circuit
Pneumatic control systems can be designed in the form of pneumatic circuits. A
pneumatic circuit is formed by various pneumatic components, such as cylinders, directional
control valves, flow control valves, etc. Pneumatic circuits have the following functions:
1. To control the injection and release of compressed air in the cylinders.
2. To use one valve to control another valve.

2. Basic principles
The basic principles of drawing pneumatic circuit diagrams, the numbers in the
diagram correspond to the following points:

Figure 2: Basic principles of drawing pneumatic circuit diagrams

1. When the manual switch is not operated, the spring will restore the valve to its original
position.
2. From the position of the spring, one can deduce that the block is operating. The other block
will not operate until the switch is pushed.
3. Air pressure exists along this line because it is connected to the source of compressed air.
4. As this cylinder cavity and piston rod are under the influence of pressure, the piston rod is
in its restored position.
5. The rear cylinder cavity and this line are connected to the exhaust, where air is released

ENGINEERING ANALYSIS
Block Diagram
Pressure
calculation, G1(s)

Valve time,G2(s)

Sensor
Figure 3: Block diagram

Conveyor
velocity G3(s)

scale

Block Diagram

G2(s)

G1(s)

G3(s)

H1(s)

H2(s)

Figure 4: Block diagram

Block Diagram
G1(s) G2(s) G3(s)
H1(s) H2(s)

Generate Transfer function and Laplace equation.

( )
( )

( ) ( ) ( )
( ) ( ) ( ) ( )
( )(

)(

( )( ) ( ) (
( )(

( )(

)(

)(

)
)(

( )(
( )(

(
(

)(

( )(

( )

)(

)(

)
)(

=
1 = a(

)(

) + b( )(
If s = 0 ; a = 0.33

) + c( )(

If s = 1 ; c = (-b(5.3027)-1.696)/1.6972
c = -0.99 b 3.12
If s = -1 ; c = 1.33+b 3.3027

Y(s) =
y(t) =

Time Respond
From the y(t) equation, we are managed to plot the graph of system output against
time, t. The polar of the graph shows that, the graph of step response has been achieved.
Time (second)

Output , y(t)

0.1456

0.1420

0.2344

0.2883

0.3059

0.3179

output
0,35
0,3
0,25
0,2
output

0,15
0,1
0,05
0
0

Figure 5: The Graph Of Time Response

4.6 Pneumatic Diagram

Figure 6: pneumatic diagram

Machine Design
1. Overall design

2. Machine Part
a. Piston and valve

b. Tank

c. Compression Piston

CONCLUSION
From our report we can conclude from the equation of block diagram that changed
into time response.From the y(t) equation, we are managed to plot the graph of system output
against time, t. The polar of the graph shows that, the graph of step response has been
achieved.Therefore The time respone is increasing following the time.

ACKNOWLEDGEMENT
We would like to express our special thanks of gratitude to our lecturer Dr.Mohd
Khairy B Mohamed as well as our principal who gave me the opportunity to do this project,
which also helped me in doing a lot of Research and i came to know about so many new
things we are really thankful to them.Secondly we would also like to thank my parents and
friends who helped me a lot in finalizing this project within the limited time frame.

REFERENCE
Hazem I. Ali, Samsul Bahari B Mohd Noor, S.M Bashi, M.H Marhaban, A review of
Pneumatic Actuators (Modeling and Control), Australian Journal of Basic and
Applied Sciences,3(2): 440-454,
Igor L Krivts, German V Krejnin, Pneumatic Actuating Systems for Automatic
Equipment Structure and Design, Taylor & Francis Group, 2006
Ferdinand P.Beer, John T.Mazurek, (2012). Engineering: Mechanics of Materials (6th
ed.). The McGraw-Hill Companies, Inc.,1221 Avenue of the Americas, New York, NY.

APPENDIX

MINIT MESYUARAT /2014

TEMPAT

TARIKH/HARI

MASA

KEHADIRAN

: Dhadung Prihananto

B041410286

Frandika Primayoga

B041410288

Mahendra Kurniawan

B041410284

Miko Hadi Wijaya

B041410285

Wahid Ramadhan

B041410287

TIDAK HADIR DENGAN MAAF :

NO
1.0
1.1
2.0

PERKARA
Aluan pengurus
Ucapan

PERBINCANGAN

1.
2.

PERLAKUAN/
KEPUTUSAN

TINDAKAN

MINIT MESYUARAT 2/2014

TEMPAT

: BK.7 FKM

TARIKH/HARI

: 13 November 2014

MASA

: 10:00-11:00 a.m

KEHADIRAN

: Dhadung Prihananto

B041410286

Frandika Primayoga

B041410288

Mahendra Kurniawan

B041410284

Miko Hadi Wijaya

B041410285

Wahid Ramadhan

B041410287

TIDAK HADIR DENGAN MAAF :

NO
1.0
1.1

2.0

PERKARA
Aluan pengurus
Ucapan

PERBINCANGAN

1. Greetings, to all member.

First of all wed like to say
basmallah to our success
2. To make a flow chart to do
this project
3. We discuss about the new
design of machine that will
solve the problem

4. We decide the way to fill up

the gula malaka by
controlling the valves by
pneumatic system that
powered by compressor

PERLAKUAN/
KEPUTUSAN

TINDAKAN

MINIT MESYUARAT 3/2014

TEMPAT

: BK.7 FKM

TARIKH/HARI

: 24 November 2014

MASA

: 10:00-11:00 a.m

KEHADIRAN

: Dhadung Prihananto

B041410286

Frandika Primayoga

B041410288

Mahendra Kurniawan

B041410284

Miko Hadi Wijaya

B041410285

Wahid Ramadhan

B041410287

TIDAK HADIR DENGAN MAAF :

NO
1.0
1.1

2.0

PERKARA
Aluan pengurus
Ucapan

PERBINCANGAN

1. Greetings, to all member.

First of all wed like to say
basmallah to our success
1. We decide the block
diagram to control the
accuration of valve that
related by scale.

Explanation:
From our block diagram we
can control flow rate by
controlling valve after the
scale read some Melaka
sugar and make a feedback
to main control. So, main
control will control about
valve with controlling
pressure.
2. We discuss about valve
design by pneumatic
concept

PERLAKUAN/
KEPUTUSAN

TINDAKAN

We use 3 pneumatic valves

moved by piston that
powered by compressor.
Look at the figure above

3.0

1. Gathering information and

the data about gula Melaka
such as density, viscosity,
etc. So we can do
calculation that necessary to
pneumatic system, that will
influence when the machine
fill up gula Melaka into
conveyor and it will help to
increase efficiency.

LOG BOOK
No
1

Date
First meeting

Care taker
Miko hadi wijaya and Wahid
ramadhan
Frandika primayoga
Mahendra kurniawan
Dhadung prihananto

No
1

Date
Second meeting

Care taker
Miko hadi wijaya
Frandika primayoga
Wahid ramadhan
Mahendra kurniawan
Dhadung prihananto

No
1

Date
Thirth meeting

Result
Make a concept of machine
design
Search all about pneumatic
concept
search all about gula melaka
properties
Search about principle of
pneumatic
Result
machine design
Make a block diagram
Find The mechanisme of machine
Find the formula of pneumatic
diagram
Search about principle of
pneumatic

Care taker
Miko hadi wijaya
Frandika primayoga
Wahid ramadhan
Mahendra kurniawan

Result
Machine design
Calculation block diagram
Find The mechanisme of machine
Silmulation of pneumatic diagram

Dhadung prihananto

Silmulation of pneumatic diagram