IOT-BASED POWER USAGE CONTROL SYSTEM FOR SMAW WELDING MACHINES AT UPT PKPTK, WEST KALIMANTAN PROVINCE

Abstrak

This study analyzes electrical power consumption in welding processes and identifies factors contributing to energy inefficiency, including plate thickness, welding job type, arc height, welder skill level, and machine idle time. The results indicate that welding operations require relatively high electrical power and can lead to significant energy waste if not properly managed. For 8 mm plates, the routing welding job operates at an average current of 8–9 A, resulting in the lowest average power consumption of approximately 900 W. The filling job requires an average current of 15–16 A with a power consumption of about 1,900 W, while the capping job consumes approximately 1,800 W. For 10 mm plates, the routing job operates at 9–10 A with an average power consumption of 900 W, the filling job uses 17–18 A with a power consumption of approximately 2,500 W, and the capping job consumes around 2,300 W. These results confirm that increased plate thickness leads to higher electrical power consumption. In addition, welding arc height significantly influences power usage, where a higher arc increases power consumption. The welder’s skill level also has a substantial impact on energy efficiency. Tests involving beginner students, skilled welders, and instructors show that beginners generate the highest energy waste due to longer preparation times and frequent rework, resulting in extended machine idle time. Recorded idle times were 89.20 minutes for beginner students, 61.47 minutes for skilled welders, and 29.33 minutes for instructors.