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.

This paper presents the design and implementation of a speed-controlled Interior-Permanent Magnet Synchronous Motor (IPMSM) drive using an incremental position encoder. The control scheme is based on Field-Oriented Control (FOC), with the speed regulator modeled using the Maximum Torque Per Ampere (MTPA) technique utilizing the machine’s reluctance torque. A Vector-Tracking Observer (VTO) is designed for precise speed estimation based on rotor position. The dynamic performance of the drive is analyzed through experimental testing.