Auto Sheet Metal Cutter
Overview
This project focused on developing an automated sheet-metal cutting system capable of handling large and heavy sheet-metal rolls (up to 500 kg). The goal was to reduce operator workload, improve cutting accuracy, and minimize human error by automating the measurement and feeding process.
The system pulls sheet metal from the roll using a motorized feeder, measures the material length, and triggers the cutting mechanism once the desired length is reached. The entire structure was designed using SolidWorks, and a miniature working prototype was built to validate the mechanical and electrical concepts.
The final prototype demonstrated reliable performance and proved that the design could replace multiple operators with a single user, while maintaining ±5 mm accuracy.
Key Features
- Heavy-roll handling: Designed for sheet-metal rolls up to 500 kg.
- Automated length measurement: User inputs the desired cut length; the system handles the rest.
- Motorized feeder: Automatically pulls the sheet metal to the correct distance.
- Integrated cutting trigger: Activates the blade mechanism once length is reached.
- Self-adjusting stand: Supports and stabilizes large and heavy rolls during feeding.
- Electronics and control system: Built using Arduino, relays, and sensors.
- Optimized for manufacturability: DFA principles applied to reduce assembly complexity and cost.
- Working miniature prototype: Validated the mechanical and control logic.
Challenge
Factories often cut heavy sheet-metal rolls manually, requiring multiple operators to feed, measure, and cut the material. This causes: -High labor cost -Inconsistent lengths -Significant operator fatigue -Increased chances of human error The challenge was to design a machine that would be low-cost, simple, and easy to manufacture, yet capable of improving precision and reducing required manpower from 3 operators to 1.
Solution
A fully engineered cutting system including: -A motorized feeder that automatically pulls sheet metal -A calibrated length-measurement system -An automated cutting trigger connected to a mechanical blade -A self-adjusting support stand for stabilizing large rolls -Full CAD design, 2D drawings, and electronic system architecture -A miniature working prototype demonstrating full workflow The electronics were arranged around an Arduino control unit that checks all sensors, initializes the feeder motor, stops at the required length, and activates the cutting stage.
Results
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