WIRE LENGTH MEASURE AND CUTTER

You need to explain your design, how;

• does the wire come is it on drums-Wires are in form of spool, we will make approx. 100 mtrs roll for demonstration, also if require I will make spool holding device.
It has to a manual feeding in to tubes for the first time, once the wire spool over, we have to feed once again.
• were you thinking of measuring the lengths- I want to build machine should cut for variable length. As mentioned earlier I want to make a project for maximum 20 mtrs length
• will the wire be fed into the cutter
• fast does the system have to operate : I want to make feeder with variable speed, slow and fast and respect to the same cutter motor timing, once feeder motor stop cutter motor start for cutting operation.
• will the wire be clamped in position during cutting, not necessary, because wire is so thin in dia (0.5mm to maximum 3mm thick). And also according to my design I will put cutter edge near edge of feeder tube approx. 5mm away.
• will you know the wire has been cut- yes, and after that feeder motor start functioning to feed another length. So we need to set delay for feeder motor, or I can use relay, once cutting done sensor stop the cutting motor at pre-defined position. I think so programming delay time is a best solution for each interval. I will interface sensor to stop machine once wire over for feeding.
• is the cut wire removed -just bellow I will keep a plastic container or a long tray for the collection of cut wire.

Will you use a PC to provide the interface to the Arduino e.g. to tell it what length you want cut, how many pieces and the wire dia?
Yes sir. And I would also like to make standalone type with display and commanding button like nos feeding, length size, and (Feeder Motor) m1 slow fast- controller.

Is it possible to give some guidance for what Arduino type, and Touch Screen type Coomanding boards are available to interface?

The mechanical aspects of this project are probably the difficult bit.-
Mechanical aspects I will handle. I have already made cutting device and now feeder mechanism roughly made. Final piece I will get by next Wednesday. Mean time I must ready with Arduino code and Circuit diagram. So once the Mechanical thing ready I will interface two motor connection, sensors, with Arduino.

You probably will not need much IO and the control logic should be relatively simple, but you should firm up the physical design first.

Also you should say what skills you and your son have. Have you done anything like this before are you good at building machines and working with electricity, do you have programming and electronics experience.- Mechanical thing I will handle. Programming is little difficult. I require your 100% help.
Please do suggest Arduino Board type with specific model number if any.
And also type of Motor for feeder Servo or Stepper.

For presentation I am going to utilize 12V 7 Ah, Lead Acid Battery.

There are sites on the internet that let you load pictures then you can post a link to them. The other thread posted a picture and it makes it a lot clearer to people what you are trying to do. Could you please send link so I will post Cutter and let you know to see.

Programming is little difficult. I require your 100% help.

Do you want me to move this to "gigs and collaborations" ?

Do you want me to move this to "gigs and collaborations" ?
Are you asking me for Gigs and Collaborations?

Jignesh

No, I'm asking if you want to move me to this topic into "Gigs and collaborations".

Is it going to help me further?
Or as per your advice is final. I want mind.
thanks.

I have no idea if it will help you further, but if you want someone else to write the software, I'd suggest that is a better place.

Your call.

Ok please do d needful.

JIGNESHDHARIA:
Accuracy as you said 1% is ok.

How do you plan to measure the wire to that degree of accuracy?

Thanks,
Accuracy 1% is OK.

Accuracy 1% is OK.

That wasn't the question. The question was how you intend to achieve that accuracy? Over what range of lengths? At what speed?

Ok!

  1. Length range will be:
    50mm to 20000mm
  2. Smaller the length more accuracy require and large length accuracy maximum should be 1%
  3. Speed I will consider Slow speed for small length, and little fast at large length.
  4. I require your assistance to select the speed respect to type of motor i.e. stepper or Servo.
  5. First manual feeder of wire till the tube end where we will keep sensor. Which control the length after every cut. Feeder motor work reverse to till the sensor (or tube end) and stop. The length of reverse will be manual feeding data respect to the distance of cutter edge from the (sensor) tube edge.
  6. On start feeder motor start feeding till the predefined length achieved and stop feeder motor.
  7. As soon as feeder motor stop cutter motor start to cut and returned to its open position once again for second cut.
  8. We put sensor to stop cutter motor.
  9. And again the new function will start (repeat the same cycle) till the pre-decided number of cut pieces of wire require.
  10. One more sensor we will keep on starting of feeder tube to sense the wire is feed or not. If there is no wire or wire can over the entire process will stop. And start once wire will insert inside the tube.
  11. It will continue with the previous cycle if any cut is pending, once wire over from spool. Or we can reset for new cycle.
  12. **Cutter will start once feeder motor stop after feeding predefined length.

JIGNESHDHARIA:
Ok!
On start feeder motor start feeding till the predefined length achieved

How will you know when the predefined length has been achieved?
How do you propose to measure how much has been fed out?

Good Morning

  1. How will you know when the predefined length has been achieved?
    I will keep sensor near rear end of feeder tube. And co-ordinate with the programme.

The diameter of feeder roller is 50mm, In one revolution it will feed the wire is 50mm x 22/7=157.143mm.
Now we need to count revolution of the feeder roller require with respect to the length.

For example :- if I require to cut 100mm length then revolution will be 100mm/157.143=0.63636.
One revolution=360 deg.
One step = 1.8 deg
So one revolution has 200 steps of 1.8 deg each
Now I want 0.63636 revolution = 0.63636 x 200 = 127.27 steps.
In brief:-
To cut size L=100mm==Steps is 127.27 nearest steps will be 127
(if statement require or Rounded Off or Absolute value)

Total Number of Steps after which Feeder Motor Stops with respect to Length is equal to

(( ( L / ((Diameter of feeder roller x 22)/7) ) * 200)

In this diameter of feeder roller is fixed i.e. 50mm.

2.How do you propose to measure how much has been fed out?
In this case We keep constant value i.e Distance between Cutter and Feeder Tube rear end.
I have made rough diagram, can I have your email ID so I can send you.

The diameter of feeder roller is 50mm, In one revolution it will feed the wire is 50mm x 22/7=157.143mm.

Assuming no slippage. Which is a lousy assumption.

PaulS:
Which is a lousy assumption.

Which might be a lousy assumption. If it's a valid assumption in this environment then there's no problem using rotation of the rollers to determine the dispensed length, as long as it's calibrated correctly.

Which might be a lousy assumption. If it's a valid assumption in this environment then there's no problem using rotation of the rollers to determine the dispensed length, as long as it's calibrated correctly.

Fair enough.

PaulS:

The diameter of feeder roller is 50mm, In one revolution it will feed the wire is 50mm x 22/7=157.143mm.

Assuming no slippage. Which is a lousy assumption.

That was what I was getting at, but he could be using a pinch roller which would reduce (but not eliminate) the possibility of slippage. The other problem is with thinner, softer, wires tending to bend and 'bunch' in the feeder tube.

Please give me code for measuring the length of wire. I will rectify with respect to my requirement. i HAVE ARDUINO uno AND A5020E SENSOR.

I would use a set of passive rollers to measure how much has been pulled out, with a separate set of drive rollers pulling the cable through the passive measuring rollers.

Do you really mean that you need better than 1% accuracy at 50mm? So 50.5mm or 49.5mm would not be close enough?

I would use a set of passive rollers to measure how much has been pulled out, with a separate set of drive rollers pulling the cable through the passive measuring rollers.

Do you really mean that you need better than 1% accuracy at 50mm? So 50.5mm or 49.5mm would not be close enough? If possible for small size we require more accurate but for the size 10 mtr to 20 mtr 1% accuracy is perfect. If possible ......otherwise we work for 1%accuracy for all.