Smart Control Ice Tube Machine Using PLC and HMI with

Superheat Method Based on Compressor Low Pressure Parameters

Basuki Winarno1 a, Yuli Prasetyo1 b, Budi Triyono1 c, Agus Choirul Arifin1 d, Yoga Ahdiat
Fakhrudi1 e, Eva Mirza Syafitri1 f and Muhammad Hanif Nur Kholiq1 g
1
State Polytechnic of Madiun, Serayu Street No. 84, Madiun City, Indonesia
{basuki, yuliprasetyo2224, buditriyono, arifin07, yoga, evamirzas}@pnm.ac.id, [email protected]

Keywords: Smart Control, Ice Tube Machine, Superheat, PLC, HMI

Abstract: Ice tube is a variant of ice cubes in the form of a tube or cylinder that has a hole in the middle with certain
diameters and lengths. Ice tube machine is a cooling machine that has the main function of cooling
substances so that the temperature is lower than the ambient temperature. The main components of the ice
tube machine are the compressor, condenser, and evaporator as the working fluid that circulates on the parts
of the ice tube machine. However, the average ice tube machine in operation is carried out by human
operators, this can slow down the production process of the ice produced. Smart control system is needed so
that ice production can be maximized every day called Smart Control PLC (Programmable Logic
Controller) Based Ice Tube Machine. This control ice tube machine can work automatically and also no
longer requires an operator in the work process of making ice tubes and this control system can be designed
according to the needs of the machine. We can monitor the ice tube machine specifically when the machine
process is working on the HMI (Human Machine Interface). This can make it easier to operate the Ice tube
Machine.

1 INTRODUCTION shipping to various places (Triyono et

al., 2019). Because it will not be
Ice tube is a variant of ice cubes in possible if the freezer is also included
the form of a tube or cylinder with a during shipping. Thus, ice tube flakes
hole in the middle with certain are one of the shortcuts needed during
dimensions, diameters and lengths. Ice the delivery process of frozen food or
tube is in great demand by the public, beverage products, so that the product
in addition to its easy-to-use shape to will be maintained at low
mix various foods and drinks. This ice temperatures, and of course the
tube or ice crystal is more hygienic freshness of the product will not be
with a clearer and neater appearance. disturbed. In addition to shipping, it
With a very wide market share, this ice can also be used for storage of
making business can be said to be very products and raw materials that will be
potential, still wide open and very used to make these food products. At
promising. Indonesia has many this time, the demand for tube ice is
companies or home industries that use very much in demand by the public.
tube ice as a temporary cooler when Therefore, an ice tube maker was made
that has a large income capacity, in
a
https://orcid.org/0000-0000-0000-0000
b
https://orcid.org/0000-0000-0000-0000
c
https://orcid.org/0000-0000-0000-0000
d
https://orcid.org/0000-0000-0000-0000
e
https://orcid.org/0000-0000-0000-0000
f
https://orcid.org/0000-0000-0000-0000
g
https://orcid.org/0000-0000-0000-0000
 order to meet the needs of the compressor and condenser turning on.
community. The current tube ice When the filling is complete the
machine can produce approximately Freeze process starts, this process will
up to 1 ton for 24 hours. With an ice stop when the temperature in the
tube machine, the process of making evaporator reaches -90C. When the
tube ice does not require a long time sensor detects it, the freeze process
and the ice produced is more hygienic will stop and change to a defrost
(Eidan et al., 2021; Hervatte, 2021; process in which the evaporator will be
Salim et al., 2018). However, there sprayed with hot wind to melt the ice
will be not many people who cubes so that they are released from
understand the working principle of the evaporator and will go down to the
this tube ice machine, there must be an ice storage container. The falling ice
operator to run the ice tube machine. will be received by the cutting motor
Program Logic Controller (PLC) is and cut the ice into small shapes. After
a tool that is able to control the control the ice is cut out, the cutting motor will
system on a machine that can be stop then the working system will loop
adjusted automatically (Prasetyo, and start again at filling the water tank
Triyono, et al., 2021). Human Machine with the compressor running
Interface (HMI) is a communication continuously.
medium for the processes that occur in
the PLC (Mendoza et al., 2021;
Prasetyo, Hidayatullah, et al., 2021;
Triyono et al., 2021). One of the
functions of HMI is as monitoring data
that can be designed according to the
needs of the machine used. PLC and
HMI can be combined in the operation
of the tube ice machine. The ice tube Figure 1: Schematic diagram of ice tube
machine can work automatically and machine.
also no longer requires an operator in
the process of making tube ice. The
benefit of this PLC and HMI is that all
the programs we want can be set in the
PLC, and we can monitor specifically
when the machine process works on
the HMI. This can facilitate the
operation of the tube Ice Machine.

2 MANUSCRIPT PREPARATION
2.1 Schematic Diagram
The design model of the PLC program Figure 2: PLC program reads the data from
sensors.
is connected to a 220V AC source as
shown in Figure 1. To start the circuit
work, when the ON button is pressed it Testing using a PLC Schneider
will send a signal to the PLC and start Modicon with a working step that is in
the work process. The stages of the ice the PLC program with temperature
tube machine work process are starting mode. The temperature mode working
with filling the water tank, then the system is when the ON button is
tank enters the freezing tank, namely pressed, the compressor, condenser,
the evaporator, along with the pump, freeze will work. Then when
the pressure sensor reads the pressure
 as shown in Figure 2. Temperature – 1. Compressor : serves to supply air to the engine.
90C is configured as pressure, the 2. Evaporator : air tank from freeze and defrost.
process will move to the second stage, 3. Condenser : a fan that serves to help the freeze
namely the defrost process and ice process
cutting. 4. Receiver tank : ice tube formation.
5. Water pump : a water pump that delivers water
2.2 HMI Design to the receiver tank
6. Water tank : a water reservoir.
Making the HMI program using 7. Motor cutting : serves to cut the ice that falls
the Schneider type, namely HMI from Receiver tank.
Magelis as shown in figure 3. The ice 8. Valve freeze : serves as a regulator of the cold
tube machine works in 2 stages, wind pressure opening valve for
namely stage 1 of the ice making the freezing process.
process and stage 2 of the ice cutting 9. Valve defrost : serves as a regulator of the hot air
process starting with the compressor pressure opening valve for the
on, followed by the condenser, pump, defrosting process.
and valve defrosting, then after the
sensor or timer works then stage 1 is The second display consists of set
complete and turns off. Then stage 2 of points for the timer and temperature as
the cutting process starts with Valve well as monitoring for the sensors used
defrost flashing (on – off repeatedly) and then there are manual and
after a while followed by cutting lit at automatic buttons for switching
the specified time and after the process panels/pages as shown in Figure 4.
is complete the machine will loop back
to the stage 1 process.
3. RESULTS
3.1 Specification data on pressure
sensor
The bit value is the configuration value
to be entered on the PLC. Here, the
test is carried out when the sensor is
given wind pressure, the maximum bit
value that is read in the PLC is 106bit.
Figure 3: First view of HMI design of ice Because the bit value is unstable up
tube machine. and down, the bit value is rounded up
to 100. This value will later be used as
the basis for calculating the PLC
configuration.
The sensor voltage value is the
value that becomes the basis for
calculating other values. Here the test
is carried out when the sensor is given
a maximum wind pressure, the voltage
value that can be read on the sensor is
3 Volt with a maximum wind pressure
of 110 Psi as shown in table 1.
Figure 4: Second view of HMI design of 1 psi = 0.06 bar
ice tube machine. 110 psi x 0,06 bar = 6,6 bar
3 V: 100 bit = 0,03 V
Output voltage in PLC is 110 psi:
Parts of tube ice machine 100bit = 1.1bit
 Table 1: Test Specification Data 7
-
Cond 2
Test
ition 30 0 0,99
Data
value -
Pressure 110 1
sensor Psi/6, 40 4 1,32
capacity 6 Bar -
Maximu 50 9 1,65
m output 10-13 -
voltage Volt 60 5 1,98
on sensor -
Maximu 70 1 2,31
m output 110
pressure Psi 80 3 2,64
on sensor 90 6 2,97
Range bit 100 9
read by 100 1
sensor 110 1 3,3
Measurab
3 Volt
le voltage
1 bit in 0,03 Table 3: Calibration sensor on compressor
PLC Volt V. V.
1.1 bit in Step Compressor Condenser Cutting
1 Psi Freeze Defrost
PLC

Maximum low pressure on the

compressor 110 psi = 110C. Sensor
read data on refrigerant R404A Ice 3.2 PLC Program Testing in
tube freezing temperature -90Celsius = Temperature Mode
50 Psi as shown in table 2.
The working process of the tool is System testing using PLC Modicon
sequential with stages starting with and HMI Magelis. The test runs
stage 1 of the freezing process then according to the working stages of the
after stage 1 is complete proceed to tool. When the temperature mode must
stage 2 of the defrost process and the wait until the adjusted temperature is
program will loop back to the reached. The results of parameter
beginning as in table 3. testing on the PLC in temperature
mode are as in table 4.
Table 2: Calibration sensor on compressor
T Temperature Mode Stages:
e a. Display the monitoring data page on the HMI
m by pressing the DATA button.
p
e b. Select in the selector to temperature mode.
r c. Select the thickness of the ice tube on the
Press a Voltag selection buttons provided on the HMI monitor,
ure t namely 2cm, 3cm, 4cm, before running the
(Psi) u (volt)
r program.
e d. When the selection is correct and the ON button
(
0
is pressed then the program can run. The effect
of temperature on the ice machine is that it can
C
) adjust the thickness of the ice using the bit value
- setting point on the PLC control in the HMI as
5 shown in table 5.
0 0,03 Set points are entered on the HMI
-
3 monitor when you want to make
10 5 0,33 changes to the thickness of the ice
20 - 0,66 tube. The following is a display of the
2 thickness of the ice tube on the HMI
 monitor. When the ice thickness is set -
to a thickness of 2 cm with a 3 5 66
temperature of -10C, the sensor will -
read the bit value at 55bit and display 4 9 77
it on the HMI monitor as shown in
Figure 5.
When the ice thickness is set at
a thickness of 3 cm with a temperature
of -50C, the sensor will read the bit
value at 66bit and display it on the
HMI monitor as shown in Figure 6.
When the ice thickness is set at a
thickness of 4 cm with a temperature
of -90C, the sensor will read bit value
in the 77bit number and displayed on Figure 5. HMI display when the ice tube
the HMI monitor figure 7. thickness is 2 cm.

Table 4: Test parameters on PLC in

temperature mode
Pressure
No. (Psi) High Low Temperature Step 1 Step 2
1 > 350 1 0 0 0 0
2 < 20 0 0 0 0 0
Temp.
High Low Temperature Step 1 Step 2
(0C)
1 < -9 0 0 0 1 0
2 > -9 0 0 1 0 1
Figure 6. HMI display when the ice tube
thickness is 3 cm.
Table 5: Result in mode temperature
T
h
i
c
k
n
e
s
s Figure 7. HMI display when the ice tube
thickness is 4 cm.
o
f
Temperature
i 3 CONCLUSIONS
c
e The ladder diagram program in the
PLC and the tool design display in the
t
u HMI work smoothly according to the
b working stages of the ice tube
e machine. The effect of temperature on
the ice tube machine is as a regulator
( Bit of the thickness parameter on the ice
c valu tube in temperature mode. The effect
m e in of wind pressure on the ice tube
) PLC machine is that it functions as a helper
-
for the freezing process and the
2 1 55
melting process of tube ice formation
 and is also one of the main APPENDIX
components of the tube ice machine.
If any, the appendix should appear
directly after the references without
ACKNOWLEDGEMENTS numbering, and not on a new page.

Financial support for this paper from

LPDP of the Indonesia research fund
of Ministry of Finance Republik
Indonesia (LPDP Kementerian
Keuangan RI) for this gratefully
acknowledged.

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