This project, completed in collaboration with Loos & Co., focuses on the development of a dynamic strand tension monitoring and control system for use in tubular stranding machines. In current operations, wire tension is adjusted manually by operators, resulting in variability in product quality, increased training requirements, and frequent wire breakage that leads to costly downtime. With over one hundred machines and thousands of cradles in operation across multiple facilities, even small improvements in consistency and efficiency can produce significant operational and financial benefits. The objective of this project was to design and validate a proof-of-concept system capable of measuring wire tension in real time and transmitting that data wirelessly for monitoring and future control applications. The system integrates a load cell and roller-based sensing mechanism with a microcontroller and amplifier to capture and process tension data. Bluetooth Low Energy (BLE) is used to transmit data from the rotating cradle to an external receiver, enabling real-time visibility without requiring wired connections. A key challenge was designing within the strict geometric constraints of the B62 strander cradle while ensuring reliable performance in a high-vibration, electrically noisy industrial environment. The system also incorporates a mechanical brake strap and spring configuration to support tension control functionality and future closed-loop operation. The final prototype successfully demonstrated real-time tension measurement and wireless data transmission under controlled testing conditions. This project establishes a scalable foundation for reducing operator dependency, improving labor effectiveness, and supporting Loos & Co.’s broader modernization efforts across its manufacturing facilities.

Our team collaborated with Electrical and Computer Engineering 13 on this project.