EventsThe 12th International Electronic Conference on Sensors and Applications
Event submissions
Published
with-doi10.3390/ECSA-12-26550
This submission belongs to the session S6. Electronic Sensors, Devices, and Systems of the event The 12th International Electronic Conference on Sensors and Applications
Published date
07 Nov, 2025
Academic Editor
author-avatarStefano Mariani
Citation
Nisala Damith, Aruna Kulasinghe, Teshan Gunasekara, Narmada Ranaweera, Nipun Shantha Kahatapitiya, Hansa Hettiarachchi, Udaya Wijenayake, Bhagya Nathali Silva, Mansik Jeon, Jeehyun Kim, Ruchire Eranga Wijesinghe, Nishan Dharmaweera, Real-Time Sheath Damage Detection in Multicore Wire Production Using Laser-Diffused Reflection, in Proceedings of The 12th International Electronic Conference on Sensors and Applications, 12 November–14 November 2025, MDPI: Basel, Switzerland, doi: 10.3390/ECSA-12-26550
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Real-Time Sheath Damage Detection in Multicore Wire Production Using Laser-Diffused Reflection

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Nisala Damith 1
Aruna Kulasinghe 1
Teshan Gunasekara 1
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Narmada Ranaweera 1
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Nipun Shantha Kahatapitiya 2
Hansa Hettiarachchi 2
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Udaya Wijenayake 3
Bhagya Nathali Silva 4,5
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Mansik Jeon 2
Jeehyun Kim 2
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Ruchire Eranga Wijesinghe 5,6
Nishan Dharmaweera 1
1. Department of Electrical and Electronic Engineering, Faculty of Engineering, University of Sri Jayewardenepura, Nugegoda, Sri Lanka., Sri Lanka
2. School of Electronic and Electrical Engineering, College of IT Engineering, Kyungpook National University, Daegu, Republic of Korea., South Korea
3. Department of Computer Engineering, Faculty of Engineering, University of Sri Jayewardenepura, Nugegoda, Sri Lanka, Sri Lanka
4. Department of Information Technology, Faculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka., Sri Lanka
5. Center for Excellence in Informatics, Electronics and Transmission (CIET), Sri Lanka Institute of Information Technology, Malabe, Sri Lanka.
6. Department of Electrical and Electronic Engineering, Faculty of Engineering, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka., Sri Lanka
Abstract

This study presents a real-time system for detecting sheath damage in multicore wire production, addressing the limitations of conventional high-voltage testing. After evaluating multiple sensing techniques, laser-diffused reflection emerged as the most reliable, non-intrusive, and effective for continuous monitoring. A calibrated system combining a laser source and photodetector was implemented and tested on a live production line, achieving 83.75% detection accuracy. The system maintained consistent performance across wire colors and insulation conditions. This advancement offers a safer, more efficient alternative for in-process quality control. Future work aims to enhance robustness and incorporate intelligent algorithms to further optimize detection accuracy.

Keywords
sheath damage detection
real-time monitoring
laser-diffused reflection
multicore wire and cable production
insulation defects
embedded detection systems
industrial automation
Manuscript
engproc-sciforum_125744_S6_original_sciforum_125744-done.pdf
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