Improvement of conveyor using motor inverter as automatic overload shutdown

Abstract

Conveyor systems in industrial manufacturing often face overloading, causing motor damage and high downtime. This study improves conveyor reliability at PT Sumitomo Wiring System Batam Indonesia by implementing a motor inverter for automatic overload shutdown. The system integrates the inverter with an overload protection relay and an emergency stop. Comparative results between the Delica Floor Lane (without inverter) and Delica Inpanel Lane (with inverter) show that the inverter reduced overload incidents from 18 to 6 and cut total downtime duration from 420 to 75 minutes. Additionally, average recovery time decreased from 30 to 15 minutes, while protection effectiveness reached 94%. This optimization boosted production output by 700 sets. Furthermore, Failure Mode and Effects Analysis (FMEA) showed that a daily inspection check sheet lowered the highest Risk Priority Number (RPN) from 378 to 108, proving highly effective in preventing unplanned maintenance.