A custom built system that winds and cuts cable to a specified length.
Details
- Power supply: 230 V 800 W
- Measuring accuracy: 0.0005 m
- Min Length: 0.5 m
- Max Length: 50 m
- Max Cable Diameter: 14 mm
- Speed: 2 m/s
- Features:
- Custom electric cable cutter
- 2-hand operation
- Emergency switch
- Changeable cable reel
- Silent guide rolls with ball bearings
- Dynamic speed (slow start, slow end)
Finished machine
Components
Mechanical
- Frame: 40x80 mm “Item” Aluminium profile
- Metal components:
- 18x 6x13x5 mm ball bearings for rolls
- Various nuts and bolts
- Custom angle-iron parts and adapter plate
- 3d-printed Parts:
- Cable reel
- Guides, Rolls
- Control box
- Encoder mount
- Cutter main body
- Cable mounts
Disassembled machine
Electrical
- Custom pcb with ESP-32 microcontroller
- Rotary encoder - LPD3806-600BM
- Three-phase motor - 0.3kW with 18:1 Gearbox
- Variable frequency drive (VFD) - T13-750W-12-h
- Switching power supply - 12 V, 8 A
- Wiper motor
- Safety relay - Siemens 3SK1111-1AB30
- 2x 7-Segment display MAX7219
- Various push buttons and LED lights
Cabinet with power supply, safety relay and VFD
Course of action
Planning
All electrical aspects were planned in the following document:
Complete Document
CAD
Most mechanical parts were 3d-printed. Those were designed in FreeCAD, sliced in Cura and printed using a CR-10 3d-printer.
3d model of a cable guide
Sliced model for 3d-printing
Wiring
The wiring was straightforward using the beforehand created connection plan.
Wiring the control box
Wiring the cabinet
Programming
The firmware for this custom pcb was created using the following components:
- C++ (Programming language)
- ESP-IDF (Development framework)
- diagrams.net (Flowcharts)
- git (Version control)
The repository with the source code and all other documentes will be made public in near future.
Videos
Tests
First setup
2022.08.18
Cutter
2022.09.02
Without bearings
2022.09.17
Demonstration
Complete start
2022.09.30
Closeup
2022.09.30
Gallery
