For my Capstone Project with Encore Wire Corp, I designed and prototyped this semi-automated machine in cooperation with a team of five other engineering students.
The wire insulation measurement apparatus involves a mechanical thickness measuring solution using four needle penetrometers (linear actuators with linear variable differential transformer attachments) and a load cell for mass measurements. A 12-inch sample is inserted into the apparatus and thickness measurements are taken at 2” intervals along the length of the wire before it is scored and massed. The apparatus GUI then provides the operator with the thickness, alignment, and mass measurements to be included in quality control forms.
The wire insulation measurement apparatus consists of a penetrometer plate consisting of four needle penetrometer units, two roller system units, a cutting mechanism, and a load cell basket encased in an 8020-Aluminum frame and polycarbonate external structure. The apparatus streamlines a 12-inch wire sample through a traversal and measurement sampling process in which the wire insulation is cut and remeasured in each iteration of the process.
Upon entry, the wire is traversed through the first motorized roller system and then controlled to
stop using an ultrasonic proximity sensor. The wire insulation thickness is measured using four
needle penetrometer units, equidistant about the sample, consisting of linear actuators with
attached needle probes and LVDT feedback. The penetrometers are extended such that the needle
penetrates through the insulation and stops once it has reached the core material. The
penetrometers then retract and the wire sample is traversed 2 inches further by the first roller
system. The penetrometers then extend to take subsequent thickness measurements.
Following the penetrometer plate, the wire sample is traversed through a secondary roller system featuring a perpendicular boxcutter blade that slices along the length of the wire so that the operator has a simpler time making a straight cut along the insulation. The wire sample is then dropped into the load cell basket where the mass is taken. An LED indicator lights up green to demonstrate that the process is over and the operator may safely remove the wire sample from the apparatus.
The wire insulation measurement apparatus involves a mechanical thickness measuring solution using four needle penetrometers (linear actuators with linear variable differential transformer attachments) and a load cell for mass measurements. A 12-inch sample is inserted into the apparatus and thickness measurements are taken at 2” intervals along the length of the wire before it is scored and massed. The apparatus GUI then provides the operator with the thickness, alignment, and mass measurements to be included in quality control forms.
The wire insulation measurement apparatus consists of a penetrometer plate consisting of four needle penetrometer units, two roller system units, a cutting mechanism, and a load cell basket encased in an 8020-Aluminum frame and polycarbonate external structure. The apparatus streamlines a 12-inch wire sample through a traversal and measurement sampling process in which the wire insulation is cut and remeasured in each iteration of the process.
Following the penetrometer plate, the wire sample is traversed through a secondary roller system featuring a perpendicular boxcutter blade that slices along the length of the wire so that the operator has a simpler time making a straight cut along the insulation. The wire sample is then dropped into the load cell basket where the mass is taken. An LED indicator lights up green to demonstrate that the process is over and the operator may safely remove the wire sample from the apparatus.
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