Automatic Wire Length Measurement Using Webcam in Wiring Harness Production

Abstract

Measuring excess cable length in wire harness production is typically done manually using measuring tools, which can lead to measurement errors, longer inspection times, and inconsistent results. This study aims to develop an automated cable length measurement system using a webcam and computer vision technology. The system is designed to detect the cable’s position, calculate the distance in pixels, and convert it to millimeters through a calibration process. The research methods include image acquisition, image processing, and performance evaluation using accuracy and error analysis. Experimental results on 20 cable samples showed an average error of 1,28% and an accuracy of 98,72% compared to manual measurements. These findings indicate that the proposed system can provide fast, accurate, and consistent measurements, making it a practical solution for improving the efficiency of quality control in the cable harness production process.