International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 09 | Sep 2025 www.irjet.net p-ISSN: 2395-0072
Modification in Copper Wire Trimming Machine to Improve Product Quality
Mr. Sachin Morti1 , Vaishnavi Biranje2 , Vedika Thorat3 , Sanyojita Badakar4 , Srushti Sanadi5 , Pranali Aundhkar6
1Head, Department of Mechatronics Engineering, Sant Gajanan Maharaj Rural Polytechnic, Mahagaon, Kolhapur, Maharashtra, India 2, 3, 4, 5, 6Students, Department of Mechatronics Engineering, Sant Gajanan Maharaj Rural Polytechnic, Mahagaon, Kolhapur, Maharashtra, India. ***
Abstract – The project titled ‘Modification in Copper Wire Trimming Machine to Improve Product Quality’ , is carriedout in company named as Midea Pvt. Ltd., Chh. Sambhajinagar. There is problem in existing trimming machinetocutthesetof copper wire in uneven format. After trimming operation the length of each copper wire in not uniform, whereas it’s need to be trimmed in precise length. The set of copper wire after trimming operation by previous method affects inaccurate cutting of various wire types, excessive material wastage, frequent maintenance issues and limited compatibility with advanced monitoring and control technologies. To resolve these issues, there is a critical need for a high-precision, automated copper wire trimming machine that integrates advanced cutting mechanisms, smart control systems and sustainability-oriented features to enhance productivity, quality and cost-effectiveness across multiple industrial applications. The existing copper wire trimming machine is modified by inserting plate at the base of machine and precise trimming operation is achieved with good product quality as well as improved efficiency.
Key Words: Copper wire, Trimming Machine, Cutting, operation
1. INTRODUCTION
Trimmingisafinishingoperationinmanufacturingwhere surplus material such as flashes, runners or unwanted edges is removed from a part to give it the precise dimensions and shape required. This step is essential in processeslikediecastingandsheetmetalwork,asitensures the component meets both functional and design specifications.
Acopperwiretrimmingmachineisspecializedequipment designed to cut and process copper wires according to requiredlengthsorconditions.Thesemachinesarewidely used in industries that deal with electrical and electronic wiring, cable manufacturing and recycling of copper materials.Theirmainroleistoeliminateextra sectionsof wiresothatthefinalproducthasaccuratemeasurements.In addition,somemodelsarecapableofstrippinginsulationor dividing wire bundles into smaller, uniform pieces for downstreamprocessing.
Inrecyclingoperations,copperwiretrimmingmachinesplay an important role by cutting old or discarded cables and separating the conductive metal from insulation or other coveringmaterials.Thisnotonlyimprovesmaterialrecovery butalsostreamlineshandlingandenhancestheefficiencyof reuse. By supporting both manufacturing precision and sustainablerecycling,thesemachinesserveasvaluabletools inthecopperprocessingindustry.
Thecopperwiretrimmingmachineusedintheorganization for removing excess material. This machine has several drawbackssuchaswastageofexcessivematerial,repetitive maintenance issues, lack of productivity. Therefore it is necessarytoresolvethesedrawbackswehavemadesome design modifications in this equipment and results are calculated.
2. Literature Survey
The literature surveyiscarried out by analyzingfollowing journalsrelatedtotrimmingmachine.
Prof.VijayL.Kadlaget.Al.[1]haspublishedresearchstudy onwirestrippingmachinewithadjustablelengthwithkeep in mind on automation. In this study researcher has concentrated on insulation removal in shortest time. This projectistotallybasedonpedaloperatedpneumaticcircuit. This project focuses on manufacturing the machine with minimalamountofcostwithimprovedspeedofproduction.
SushilSahebraoPatil[2]hasstudiedonvibrationabsorption of grass trimmer handle. The vibrations of electric grass trimming machineeffects on the work efficiency therefore vibrations are attenuated by installing absorber The experimentalresultsarecalculatedafterinstallingabsorber andconcludedthatvibrationsarereducedatgreatlevelafter installingTVA.
C. M. Vivek et. Al. [3] has researched on reducing the musculoskeletal disorders of operators of motorized grass trimmingmachine.Shrubtrimmingmachineprovidesbest uniformity in trimming operation after attaching reciprocatingbladestotheframes.Themachineworkswith minimum operation time which results in reduced engine
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 09 | Sep 2025 www.irjet.net p-ISSN: 2395-0072
temperature. The accidents relates with trimming process alsominimizedtogreatlevel.
Akash B. Patil et. Al. [4] has presented their study on automatic bush trimming machineoperated on renewable sourceofenergyi.e.solarenergy.Thisstudyfocusonreduce the environmental pollution by using solar powered D.C. motortorunthetrimmingmachineinsteadofengine.Burnt fuelsofenginecauseenvironmentpollution.Toreducethis badeffectonenvironmentelectricmotorisusedwithfacility ofchargeablebatteryarrangements.
N. A. Azmir et. Al. [5] has researched on petrol hand held grass cutting machine. The effect of vibrations generated from this machine is mentioned as health problems of workerswhooperatethis.Researchersuggestedthatinthe sector of agriculture chronic health surveillance for hand vibrationsisneedtoberecognized.
3. Problem Definition
During the process of copper wire trimming, there are several drawbacksraisedsuchaswastageofcopper wire, uneven wire length, reduced efficiency and losses in production. Therefore it is necessary to make the certain modificationincopperwiretrimmingmachinetoimprove productqualitywithpreciselengthofwires.
4. Solution
In above mentioned Fig -1, there is scope to make the foundational changes in overall design of copper wire trimmingmachinetoenhancethequalityofproducts.After studyingandanalyzingonvariouscasestudiestheproblem of uneven copper wire trimming is reduced to great level withimprovingtheefficiencyandproductqualityofmachine whichresultsincreasedproductionrate.
Theplateisattachedatthebaseofthemachineasshownin Fig -2. After installation of this plate, the drawbacks of copperwiretrimmingmachineareminimized.
5. CONCLUSIONS
After modificationsincopper wiretrimmingmachineitis concludedthat,
1. Thematerialwastageisreducedwithpreciselengthof copper wires after inserting the plate at the base of trimmingmachine.
2. The product quality is improved which results in minimizingthelossesofproduction.
3. Themaintenanceisreducedascomparedtopreviously usedset-upwhichconcentratesonimprovedefficiency.
Fig -1:Trimmingmachinewithoutplate (Curtesy:-MideaPvt.Ltd.)
Fig -2: TrimmingMachinewithattachedplate
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 09 | Sep 2025 www.irjet.net p-ISSN: 2395-0072
6. REFERENCES
[1] Prof.VijayL.KadlagetAl.,“DESIGN&DEVELOPMENT OF WIRE STRIPPING MACHINE WITH ADJUSTABLE LENGTH”, International Research Journal of ModernizationinEngineeringTechnologyandScience, 2021,3(7),1165-1171.
[2] SushilSahebraoPatil,“VibrationSuppressionofGrass TrimmerHandleusingTunableVibrationAbsorber”,Int J Advanced Design and Manufacturing Technology, 2019,12(2),39-44.
[3] C.M.Vivek, J.Kesavan, S.P.Manikandan, “Design And Fabrication Of Ergonomic Hedge Trimming Machine WithAngleAdjustment”,INTERNATIONALJOURNALOF SCIENTIFIC & TECHNOLOGY RESEARCH, 2020, 9(2), 983-986.
[4] Akash B. Patil et. Al., “AUTOMATIC BUSH TRIMMING MACHINE”, International Research Journal of EngineeringandTechnology,2020,7(5),2992-2996.
[5] N.A.Azmira,M.I.Ghazalia,M.N.Yahyaa,M.H.Alib&J.I. Songc, “Effect of Hand Arm Vibration on the DevelopmentofVibrationInduceDisorderamongGrass CutterWorkers”,2ndInternationalMaterials,Industrial, and Manufacturing Engineering Conference, MIMEC2015,2015,87-91.
7. BIOGRAPHIES
Mr. Sachin S. Morti Bachelor of Mechanical Engineering, Master of Design EngineeringfromSanjayGhodawat Institutions,Atigre,Kolhapur. CompletedtheIndustrialResearch project on ‘Design Modification and Acoustic Analysis of Silencer used for Single Cylinder Water CooledDieselEngine’. Worked as a Lecturer at MechanicalEngineeringDept.and currently working as a Head, Department of Mechatronics Engineering,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.
Ms. Vaishbavi Kapil Biranje Student,Third YearMechatronics Department,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.
Ms. Vedika Subhash Thorat Student,Third YearMechatronics Department,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.
Ms. Sanyojita Mahantesh Badkar Student,Third YearMechatronics Department,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.
Ms. Srushti Sateri Sanadi Student,Third YearMechatronics Department,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.
Ms. Pranali Rajendra Aundhkar Student,Third YearMechatronics Department,SantGajananMaharaj Rural Polytechnic, Mahagaon, Maharashtra,India.