Design and Development of a DS-200C4 Proximity Sensor Control Panel for Automatic Gallon Brush

Abstrak

The gallon washing process in the Bottled Drinking Water industry plays a crucial role in maintaining cleanliness and product quality standards prior to filling. This final project research was motivated by operational problems in the gallon brush machine at PT. Rapid Tirta Sejahtera, which still utilizes a manual control system. The absence of object detection causes the brush drive motor to rotate continuously even when there are no gallons in the washing area, triggering electrical energy waste, accelerating component wear, and lowering production efficiency. As a solution, this experimental study implements an E3F-DS200C4 infrared photoelectric proximity sensor to automate the gallon brush control panel. The integrated system utilizes a switching power supply, 12 VDC relay, LM2596 step-down module, 10-second Omron H3Y timer, single-phase MCB, and a contactor to control the Shimizu water pump and single-phase induction brush motor. Based on electrical parameter testing, the system operates stably with pump operating voltages ranging from 223 to 225 VAC (current 1.30–1.35 A) and sensor voltages from 12.14 to 12.18 VDC (current 0.82–0.85 A). The sensor works effectively within a detection range of 2 cm to 20 cm. The implementation of this timer-based automatic control reduces average manual washing time from 18.6 seconds to a constant 10 seconds, achieving a working time efficiency increase of 46.24% while optimizing electricity and water usage.