RANCANG BANGUN WHEEL TIRE ASSEMBLY UNTUK MAINTENANCE PADA PESAWAT KING AIR MODEL 200 & 350i DI BALAI BESAR KALIBRASI FASILITAS PENERBANGAN

Proses pemasangan roda (wheel and tire assembly) pada pesawat King Air model 200 dan 350i di Balai Besar Kalibrasi Fasilitas Penerbangan (BBKFP) selama ini masih dilakukan manual sehingga membutuhkan rata-rata 18,33 menit dengan melibatkan 4 teknisi. Kondisi tersebut kurang efisien,menimbulkan kelelahan, dan berpotensi menyebabkan kesalahan pemasangan. Penelitian ini bertujuan merancang alat bantu pemasangan roda yang lebih efisien, ergonomis, dan aman. Metode perancangan menggunakan pendekatan sistematis VDI 2221, meliputi klarifikasi tugas, pengembangan konsep, perancangan bentuk, dan detail desain. Alternatif rancangan disusun berdasarkan kriteria fungsional, keamanan, dan kemudahan manufaktur. Konsep terbaik kemudian divisualisasikan dalam desain tiga dimensi dengan perangkat lunak CAD serta dianalisis kekuatannya.Hasil perhitungan menunjukkan faktor keamanan alat sebesar 18,75, menandakan struktur mampu menahan beban dengan baik. Material utama menggunakan galvanis karena tahan korosi dan mudah difabrikasi. Hasil uji fungsional menunjukkan alat mampu menurunkan waktu pemasangan menjadi 7,28 menit dan dapat dioperasikan hanya oleh satu teknisi. Desain berbasis data antropometri meningkatkan kenyamanan kerja serta menjaga posisi tubuh tetap netral. Struktur alat terbukti stabil tanpa deformasi maupun getaran berarti. Meski demikian, terdapat perbedaan antara rancangan awal dan produk akhir, seperti penggantian pegangan pin lock menjadi nylon ergonomis, penambahan titik pengaturan batang penahan roda dari 7 menjadi 19, serta adopsi engsel pin lock yang lebih fleksibel. Kekurangan yang masih ditemukan adalah kemiringan penahan roda atas dan dimensi mangkok penampang yang kurang presisi untuk velg King Air 200. Secara keseluruhan, penelitian ini berhasil menghasilkan alat bantu yang efektif dalam mengurangi waktu kerja, jumlah teknisi, serta meningkatkan kenyamanan, keselamatan, dan presisi operasional. Metode VDI 2221 terbukti mampu memberikan solusi teknik yang sistematis dan aplikatif, serta dapat dijadikan dasar pengembangan desain lebih optimal di masa depan.

Kata kunci : Wheel and tire assembly, perancangan teknik, VDI 2221, efisiensi, kerja, struktur alat, ergonomi, pesawat King Air, hidrolik

The wheel and tire assembly process on King Air model 200 and 350i aircraft at the Balai Besar Kalibrasi Fasilitas Penerbangan (BBKFP) is still carried out manually, requiring an average of 18.33 minutes with the involvement of 3–4 technicians. This method is inefficient, causes fatigue, and increases the risk of installation errors. This study aims to design an auxiliary tool for wheel installation that is more efficient, ergonomic, and safe. The design process employed a systematic approach based on VDI 2221, which includes task clarification, concept development, embodiment design, and detail design. Several alternatives were generated according to functional, safety, and manufacturability criteria. The best concept was then visualized in a three-dimensional CAD design and analyzed for structural strength. The calculation results show a safety factor of 18.75, indicating that the tool structure can reliably withstand the load. The main material used is galvanized steel due to its corrosion resistance and ease of fabrication. Functional testing demonstrated that the tool reduced installation time to 7.28 minutes and allowed operation by only one technician. The design, based on anthropometric data, improved working comfort by maintaining a neutral body posture. The tool structure was proven stable without deformation or significant vibration. However, several differences were found between the initial concept and the final product, such as replacing the pin lock handle with ergonomic nylon, increasing the adjustment points of the wheel holder from 7 to 19, and adopting a more flexible detachable pin lock hinge system. Remaining shortcomings include a slight tilt of the upper wheel holder during pressing and dimensional mismatches of the wheel cup for the King Air 200 rim. Overall, this study successfully produced a tool that effectively reduces working time and manpower requirements while improving ergonomics, safety, and operational precision. The VDI 2221 method proved effective in providing a systematic and applicable engineering solution, which can serve as a foundation for further design development.

Keywords : wheel and tire assembly, engineering design, VDI 2221, work efficiency, structural system, ergonomics, King Air aircraft, hydraulic system