Wire Prepping Machine

Overview

The Wire Prepping Machine automates the processing of 5.5mm diameter, 4-core wire by performing cutting, sheathing removal, core stripping, and tinning. The system is controlled via a local web portal and integrates sensors and actuators for seamless operation. The project focuses on automation, control system design, and sensor-actuator integration.

Features

• Automated Wire Processing: Cutting, sheathing removal, core stripping, and tinning.
• Local Web Portal Control: Start/stop operations and monitor system status.
• Error Handling: Real-time error detection and display on an OLED/7-segment screen and the web portal.
• Sensor Integration: IR sensor for wire length detection and a limit switch for runout detection.

System Components

Hardware

• Controller: NodeMCU V3 ESP8266
• Actuators:
  • DC Motors (for wire feeding)
  • Servo Motors (for cutting, sheathing removal, and stripping/tinning)
• Sensors:
  • IR Sensor (for wire length measurement)
  • Limit Switch (for wire runout detection)
• Display: OLED or 7-segment display
• Error Indication: LED indicators and dry contact points

Software

• Developed using Arduino IDE.
• Features include:
  • Motor and Servo Control: Sequential operations for wire processing.
  • Web Interface: Allows users to start/stop operations and configure wire lengths.
  • Error Monitoring: Detects and reports operational failures.

Installation and Setup

Hardware Setup

1. Connect the NodeMCU ESP8266 to the actuators and sensors.
2. Wire the DC motors for wire feeding and servo motors for cutting and stripping.
3. Attach the IR sensor and limit switch for wire detection.
4. Connect the OLED/7-segment display for status updates.
5. Ensure error indication LEDs and dry contact points are functional.

Software Installation

1. Install the Arduino IDE.
2. Add the required libraries:

   #include <Servo.h>
   #include <ezButton.h>
   // #include <ESP8266WiFi.h>
   // #include <ESP8266WebServer.h>

3. Upload the provided code to NodeMCU ESP8266.
4. Configure WiFi credentials in the code:

   const char* ssid = "Your_SSID";
   const char* password = "Your_PASSWORD";

5. Deploy and test the machine.

Operational Flow

1. Wire Detection: Limit switch detects wire presence.
2. Wire Feeding: DC motor feeds wire; IR sensor measures length.
3. Wire Cutting: Servo motor activates the cutting mechanism.
4. Sheathing Removal: External sheathing is removed at both ends.
5. Core Stripping & Tinning: Wire cores are stripped and tinned with solder.
6. Error Handling: Alerts are displayed in case of failures.

Limitations

• WiFi and display functions were not fully tested in Proteus.
• Wire length precision depends on motor calibration.

Future Improvements

• Implement an advanced error logging system.
• Optimize motor control algorithms for better precision.
• Expand to handle multiple wire diameters and configurations.

Contributing

Contributions are welcome! Feel free to submit issues and pull requests to improve the project.

License

This project is licensed under the MIT License.

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Author: Abdullah Zunorain

For inquiries, contact: [email protected]