Abstract:
Cargo handling operations aboard MV. Bulk Batavia face the risk of operational
disruption caused by hatch cover wheel dislocation from the track, yet no system capable
of early detection of such displacement has been available. This study aims to design and
develop an ultrasonic sensor-based early detection system for hatch cover wheel
dislocation that operates in real-time to enhance the efficiency and safety of cargo
handling operations. The research employs the Research and Development (R&D)
method using the prototype. The problem was obtained through direct observation
conducted during the sea practicum aboard MV. Bulk Batavia, prototype system testing,
and validation by three expert validators and twenty experienced cadets. The developed
product integrates an HC-SR04 ultrasonic sensor, ESP32 microcontroller, LED
indicators, buzzer, 16×2 LCD, and the Blynk IoT platform for real-time remote
monitoring. Results demonstrate that the system detects hatch cover wheel position
changes with a response time of 0.016–0.020 seconds, operating consistently under both
normal and dislocation conditions. Expert validation yielded a feasibility percentage of
97.33%, while user validation produced 94.4%, both categorized as highly feasible. The
developed system proved effective as a proactive early detection solution, capable of
issuing warnings before full dislocation occurs, thereby minimizing downtime and
supporting improved cargo handling efficiency on bulk carrier vessels.
