Method and apparatus for making cored wire

A method for making continuously a cored wire filled with at least one fill material to a desired core ratio comprising:

• feeding a flat metal strip at a first speed during a run;
• measuring automatically dimensions of the strip continuously during the run;
• forming the strip into a channel open upwardly and sized to hold a quantity of the at least one fill material as the strip is fed during the run;
• transporting the at least one fill material continuously during the run, wherein the at least one fill material is delivered through a metering device at a delivery speed;
• determining automatically volume of a quantity of the at least one fill material in transport by the metering device;
• depositing the at least one fill material from the metering device into the channel continuously during the run at the delivery speed;
• and
• adjusting automatically the delivery speed during the run to ensure that the quantity of the at least one fill material deposited into the channel is in a desired core ratio range about the desired core ratio, the delivery speed adjustment being based on the first speed, the measured dimensions of the strip, and the volume of the at least one fill material determined to be in transport by the metering device.