Wires are drawn from steel wire rods with high carbon content. The typical manufacturing process of a motor tyre bead (MTB) wire is shown in Figure 1 and explained further.
We always strive to have uniform surface appearance without any surface abnormality such as die marks (refer Figure 2) or other mechanical damage (refer Figure 3) appearing on the wire surface. Wires that have surface abnormality are sold at lower rates.
To detect the surface abnormalities, a small portion of the wire is cut from one end of the finished wire spool (refer Figure 4) and sent to the lab for offline visual tests. Defects are located by rotating the cut sample & observing it from various angles. Most of the time, defects are present only on one side of the wire. This method of sampling and testing is not only manual but does not represent the entire length of the wire coiled on the spool.
Thus, a solution is sought which can accurately identify such surface abnormalities online, as and when they occur across the various process steps and generate alerts & reports. This will enable us to quickly take preventive/corrective actions.
The proposed solution should meet the following criteria: