During the cable manufacturing process, maintaining consistent tension in individual wire strands is critical to ensuring product quality and preventing material defects from dropped strands. Current tension control systems lack the precision and adaptability needed for real-time adjustments under varying production conditions. Building on last year’s work involving a strain sensor for tension measurement, this project aims to design an improved system capable of accurately monitoring and controlling strand tension throughout the manufacturing process. The system will utilize energy harvesting to power existing circuitry, reducing reliance on external power sources. In addition, it will collect and transmit manufacturing data for performance analysis and process optimization.

Our team collaborated with Management & Engineering for Manufacturing 9 on this project.