SMART WIRE CUTTER MECHANISM
DOI:
https://doi.org/10.54554/jmet.2025.17.01.002Keywords:
Automated Wire Cutting, Precision Cutting Mechanism, Stepper Motor Control, Industrial Safety Enhancement, Wire Processing EfficiencyAbstract
The Smart Wire Cutter Mechanism deals with the same old problems of manually operated wire cutting, such as inefficiency and even danger to operators. The inconsistent lengths of wires from manual operations have often caused high material waste that requires expensive and time-consuming reworks. The study intends to counter these problems by developing an automated wire-cutting system designed to enhance precision, smoothen efficiency, and hence reduce injury risks greatly. The main aims of the project are minimization of safety risks, improvement in accuracy with accurate control mechanisms, and an 80 percent cut in wire-cutting time. Precisely fabricated to handle wires of 1.25 mm gauge, the machine fabricates the said gauge of wire with high precision. The automated system was able to achieve an astonishing testing accuracy of ±0.5 mm, reducing the inconsistencies associated with manual cutting by a great amount. The key components include a stepper motor and a metal extruder mechanism that plays an important role in the automatic feeding of the wire to the cutting blade with consistency and accuracy at every cut. Besides the core functionality of cutting, the Smart Wire Cutter Mechanism has safety enhancements that make it much safer compared to manual methods. The system features a safety option during the operating process to minimize the possibility of injury. In addition, the machine is designed with an inbuilt conveyor mechanism where the cut wires are automatically transported to further smooth the entire process without much need for human interaction. It saves not only time but also assures a much safer and efficient work environment. The result of this project depicted the following productivities: the system greatly reduced the time cut and increased efficiency in the overall operation process. The project was a milestone in wire-cutting technology for industries relying heavily on precision and efficiency in wire processing. It fulfills some very important industrial requirements by providing a solution that improves safety and boosts productivity, marking a major leap in automation related to wire processing.
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