Cable length cutter

A custom built system that winds and cuts cable to a specified length.

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)

image 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

image 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
  • Safety relay - Siemens 3SK1111-1AB30
  • Wiper motor
  • Various push buttons and LED lights


image Cabinet with power supply, safety relay and VFD

Course of action

Planning

All electrical aspects were planned in the following document: connection-plan Complete Document

CAD

Most mechanical parts were 3d-printed. Those were designed in FreeCAD, sliced in Cura and 3d-printed using a CR-10 3d-printer.

image 3d model of a cable guide

image Sliced model for 3d-printing

Wiring

The wiring was straightforward using the beforehand created connection plan.

image Wiring the control box

image Wiring the cabinet

Programming

The firmware for this custom pcb was programmed 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