Innovative Wire Cutting Automation: Reducing Material Waste and Human Error

Wires of different lengths are often utilized for a range of applications in industries and daily life, from manufacturing to electrical installations. However, several issues affect traditional wire-cutting techniques, such as high labor costs, time-consuming, inaccuracy, inefficiency, and safety hazards. Incorrect cutting, wire wastage, and higher expenses for production are the results of traditional manual cutting procedures. These conventional approaches are unfit for the high precision requirements of the current world since they are not only labour intensive but also prone to errors and inconsistencies. These limitations call for an Automated Wire Cutting Machine that incorporates an embedded system with a microcontroller-based control unit, stepper motor-driven wire feeding, and a linear actuator for precise cutting. This machine design allows users to input wire lengths and quantities via a touchscreen interface, ensuring fully automated cutting. Key components, including the stepper motor, cutting mechanism, and touch display for input, work in harmony to ensure accuracy across a wide range of wire lengths. Testing showed that the machine achieved over 97% accuracy in cutting operations, saving labor hours and reducing cutting time while greatly enhancing safety. This automated system offers a scalable, cost-effective solution, enabling industries such as manufacturing, automotive assembly, and electrical installations to operate more efficiently, precisely, and sustainably.