Design of Integrated Control and Protection System for Pipe Transfer Conveyor Using Zelio Smart Relay

Abstract

Material handling efficiency and operator safety are essential in the pipe manufacturing sector. This research was motivated by the pipe transfer process at PT DSAW, which was previously operated manually, leading to the risk of human error and unsynchronized machine operation. This study developed and validated an integrated control and protection system for the Pipe Transfer Conveyor using the Schneider Zelio Smart Relay. The research methodology consisted of a literature review, hardware and software design, followed by simulation-based validation using Zelio Soft 2 and SimuRelay. The implementation successfully achieved synchronized lifter operation, prevented conflicting commands through interlock logic, integrated motor protection functions, and enabled real-time fault monitoring during system validation. The results demonstrate that the proposed Zelio Smart Relay-based control system provides a practical and cost-effective automation solution that improves the operational safety, reliability, and efficiency of the pipe transfer process.