Dust Management

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gkas
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Re: Dust Management

Post by gkas »

I'm wondering how well the gates perform after a period of use. The main problem would be jamming from excess sawdust. Would there be any way to sense 'no movement' after an open/close command? Or the alternative 'command completed'. Am I overthinking this?

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jimandi5000
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Re: Dust Management

Post by jimandi5000 »

gkas wrote:
Wed Feb 19, 2020 5:54 pm
I'm wondering how well the gates perform after a period of use. The main problem would be jamming from excess sawdust. Would there be any way to sense 'no movement' after an open/close command? Or the alternative 'command completed'. Am I overthinking this?
My son asked me the same question. I ran the gate cycles open then close every 2.5 seconds for about 3 hours no issues. I would have ran the test but the wife was going nuts from the cycling noise.
Thanks,
Jim

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FixitMike
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Re: Dust Management

Post by FixitMike »

A somewhat simpler system is to have a current sensor for the circuits that power the tools that use the dust collector. I installed separate power strips for those circuits. Anything plugged into the power strips will turn on the dust collector. Manual gates at each machine are easy enough to use.
Good judgement comes from experience.
Experience comes from bad judgement.

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gkas
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Re: Dust Management

Post by gkas »

I think then that we'd be missing the 'geek factor' :lol: Nowhere did we note 'easy' as a decision point. Then we wouldn't be able to go out and order a bunch of new toys.

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jimandi5000
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Re: Dust Management

Post by jimandi5000 »

Hi all,

I got it working!!! Now let me be clear, it is a mess! Here is a copy of my code.

Code: Select all

#include <Wire.h> 
#include <LiquidCrystal_I2C.h>
#include <Adafruit_PWMServoDriver.h>
#include <TimeLib.h>
LiquidCrystal_I2C lcd(0x27,20,4);  // set the LCD address to 0x27 for a 20 chars and 4 line display
Adafruit_PWMServoDriver pwm = Adafruit_PWMServoDriver();
//=============================================================
int gate[17][13] = {
/*   Array   J45   But  Servo  LED  Sen/Act Servo Servo Port   IR      Dust  Dust  Port 
     Number  Port  Pin  Pin    Pin  Pin     Close Open  Active Sensor  Light Relay Type
     0       1     2    3      4    5       6     7     8      9       10    11    12 */
    {0,      1,    0,   1,     31,  A11,    210,  338,  1,     0,      0,    0,    1},  // * 12 disk Sand - Sensor (110)      
    {1,      2,    0,   2,     32,  A12,    390,  520,  1,     0,      0,    0,    1},  // * Drum Sander  - Sensor (110)    
    {2,      3,    0,   3,     33,  A13,    200,  338,  1,     0,      0,    0,    1},  // * Belt Sander  - Sensor (110)   
    {3,      4,    0,   4,     34,  A14,    115,  260,  1,     0,      0,    0,    1},  // * Wire 18 Band saw   - Sensor (220)
    {4,      5,    0,   5,     35,  A15,    115,  238,  1,     0,      0,    0,    1},  // * Drill press   - Sensor (110)
    {5,      6,    0,   6,     36,  A10,    70,   250,  1,     0,      0,    0,    1},  // 4 inch Overhead Gate  - Sensor (110)
    {6,      7,    47,  6,     37,  0 ,     70,   250,  1,     0,      0,    0,    2},  // 4 inch Flex hose - button 
    {7,      8,    48,  8,     38,  0 ,     100,  250,  1,     0,      0,    0,    2},  // 4 inch Overhead Gate? - button 
    {8,      9,    49,  9,     39,  0,      90,   225,  1,     0,      0,    0,    4},  // CNC Mill - Run Relay 
    {9,      10,   0,   0,     0,   0,      0,    0,    0,     0,      0,    0,    5},  // Open
    {10,     11,   0,   0,     0,   0,      0,    0,    0,     0,      0,    0,    5},  // Open
    {11,     12,   0,   0,     0,   0,      0,    0,    1,     A13,    51,   52,   0},  // Dust Collector
    {12,     0,    20,  0,     0,   0,      0,    0,    0,     0,      0,    0,    2},  // CNC Mill - button 
    {13,     0,    5,   0,     0,   0,      0,    0,    1,     0,      0,    0,    3},  // A Control - Button (Green)
    {14,     0,    6,   0,     0,   0,      0,    0,    1,     0,      0,    0,    3},  // B Control - Button (Blue)
    {15,     0,    7,   0,     0,   0,      0,    0,    1,     0,      0,    0,    3},  // C Control - Button (Yellow)
    {16,     0,    24,  0,     0,   0,      0,    0,    0,     0,      0,    0,    5}   // Reset+Reset - Buttons (Red)
    };
  
char * toolName[] = {
  // 12345678901234567890  
    "12 inch Disk Sander ", //  0
    "Drum Sander         ", //  1
    "1.5 inch Belt Sander", //  2
    "18 inch Bandsaw     ", //  3
    "14 inch Drillpress  ", //  4
    "4 inch Flex Hose    ", //  5
    "4 inch Overhead Gate", //  6
    "CNC Mill Dust Gate  ", //  7
    "Dust Collector      ", //  8
    "Port 9 not used     ", //  9 Green button on box
    "Port 10 not used    ", // 10 tbd
    "Port 11 not used    ", // 11 tbd
    "Dust Collector      ", // 12
    "A - Button (Green)  ", // 13
    "B - Button (Blue)   ", // 14
    "C - Button (Yellow) ", // 15
    "All Gates Closed    ", // 16
    "Powered On          ", // 17
    "Powered Off         ", // 18
    "Pressed             ", // 19
    "====================", // 20
    "4 inch Gate Open    ", // 21
    "3 inch Gate Open    ", // 22
    "System              ", // 23
    "Loading...          ", // 24
    "Ready...            ", // 25
    "Gate Open           ", // 26
    "Gate Closed         ", // 27
    "Code:               ", // 28
    "All Gates Closed    ", // 29
    "Powered On          ", // 30
    "Powered Off         ", // 31
    "Pressed             ", // 32
    "====================", // 33
    "4 inch Gate         ", // 34
    "3 inch Gate         "  // 35
    };
//=============================================================
// Notes
//=============================================================
  float nVPP;                                //Voltage measured across resistor
  float PressLen = 0;                
  float DustLevelCount = 100000;
  float DustLevel = 1;
  float DustLevelLenth = 300;
  float vNumber[6] = {0.0, 0.0, 0.0, 0.0, 0.0, 0.0};
  int aValue = 99;
  String Button = "";
  int StayOn = 0;
  int Running = 0;
  int debug = 0;
// ============================================================
void setup() {           // Setup 
  pwm.begin();
  pwm.setPWMFreq(60);                                  //Default is 1000mS
  Serial.begin(9600);
  delay(1000);
  debuger("Loading",1);
  Display4("","System", "Start up"); 
  debuger("Code", 1);
  for(int i=0; i<18;i++){
    debuger("0", 2);
    if(gate[i][8] == 1 && gate[i][12] == 0){               //Dust Collector
      pinMode(gate[i][9],  INPUT);                         //IR Sencor
      pinMode(gate[i][10], OUTPUT);                        //Relays
      pinMode(gate[i][11], OUTPUT);                        //Relays
    }
   debuger("1", 2);
    if(gate[i][8] == 1 && gate[i][12] == 1){ 
      pinMode(gate[i][5], INPUT);                          //Sencor
    }
  debuger("2", 2);
    if(gate[i][8] == 1 && gate[i][12] == 2){ 
      pinMode(gate[i][2], INPUT_PULLUP);                   //Buttons
    }
  debuger("3", 2);
    if(gate[i][8] == 1 && gate[i][12] == 3){ 
      pinMode(gate[i][2], INPUT_PULLUP);                   //Control Buttons
    }
  debuger("4", 2);
    if(gate[i][8] == 1 && gate[i][12] == 4){ 
      pinMode(gate[i][2], INPUT_PULLUP);                   //CNC Relay
    }
  debuger("0", 2);
    if(gate[i][8] == 1 && gate[i][4] > 0){ 
      pinMode(gate[i][4], OUTPUT);                         //LEDs
    }
  }
  delay(2000);
  Cgate();
  delay(5000);
  debuger("Loaded Pin Settings", 1);
  ResetVolts();
  debuger("Loaded Code", 1);
}
//=============================================================
void debuger(String words, int Lev){   //Show data on the LED
  if(Lev == debug)
    {Serial.println(words)  ; 
  }
}
//=============================================================
void loop(){             //Looping 
  PressLen = 0;
  if (StayOn == 0){ // Sensor Sweep
    debuger("***** Sensor Sweep *******", 1)  ; 
    Button = "";
    aValue = 13;
       
    Display4("--------------------","Sweeping", "Sensors");     
    for(int i=0; i<18; i++){  // Sweeping Sensors
      if(gate[i][8] == 1 && gate[i][12] == 1){             //Must be a Sensors
        debuger("**", 2)  ; 
        Running = 1;
        debuger("------", 2);
        nVPP = getVPP(gate[i][5]);
        aValue = i;
        debuger(aValue,2);
        debuger(String(nVPP), 2);
        while(nVPP > vNumber[aValue]){
          Dust_On();                                       //Dust Collector On
          Ogate();                                         //Gate Open
          LED_On(aValue);                                  //LED On
          Running = 0;
          DisplaySencor(aValue);
          debuger(String(nVPP), 2);
          Button = String(toolName[aValue]);               //Tool Name Running
          nVPP = getVPP(gate[aValue][5]);
        }  
        if (Running == 0){          
          Dust_Off();                                      //Dust Collector Off
          LED_Off();                                       //LED Off          
          Cgate();                                         //Gate Close 
        }
      }
    }
  }
  //"***** CNC Relay Sweep *******"
  debuger("***** CNC Relay Sweep *******", 1)  ; 
  for(int i=0; i<18; i++){  // CNC Relay
    if(gate[i][8] == 1 && gate[i][12] == 4){               //Must be a CNC Relay
      aValue = i;  
      debuger("***** CNC Relay *******", 2)  ;
      Running = 0;       
      while (digitalRead(gate[aValue][2]) == LOW){
        Button = String(toolName[aValue]);                 //Tool Name Running
        debuger("***** CNC Running *******", 2)  ;
        Display4(Button, Button, Button);
        if (Running == 0){
          Ogate();                                           //Gate Open
          LED_On(aValue);                                    //LED On  
          Dust_On();                                         //Dust Collector On
          Running = 2;
        }
      }      
      if(Running == 2){
        LED_Off();                                           //LED Off
        Dust_Off();                                          //Dust Collector Off      
        Cgate();                                             //Gate Close      
        Running = 0;
     }
    }
  }
  //***** Button Sweep *******  
  debuger("***** Button Sweep *******", 1); 
  Display4("--------------------","Sweeping", "Buttons");
  for(int i=0; i<18; i++){   // Sweeping Buttons
    if(gate[i][8] == 1 && gate[i][12] == 2) { 
      aValue = i;
      debuger("*+*", 2); 
      while (digitalRead(gate[aValue][2]) == LOW){
         PressLen = PressLen + 101;
         debuger("While " + String(PressLen), 2);
         delay(500);   
         if (PressLen >= 500){
           LEDs_On();                                  // All LED's On
         }else{
           LED_Off();
         }
      }  
      debuger("*-*", 2); 
      debuger(String(aValue), 2);
      debuger(String(PressLen), 2);
      if (PressLen >= 500){
        if (StayOn == 0){
            StayOn = 1;            
            debuger("Stay On", 2);
            Ogate();                                   //Gate Open
            Dust_On();                                 //Dust Collector On
            PressLen = 0;
        }
        }
        if(PressLen > 1 && PressLen < 500){
          LED_Off();                                   //LED Off
          StayOn = 0;
          Dust_Off();                                  //Dust Collector Off  
          debuger("Stay Off", 2);          
          Cgate();                                     //Gate Close          
        }        
     }
  } 

  //***** Control Button Sweep *******
    debuger("***** Control Button Sweep *******", 1)  ; 
    for(int i=0; i<18; i++){ // Control Button
      if(gate[i][8] == 1 && gate[i][12] == 3){
        aValue = i;
        if(digitalRead(gate[aValue][2]) == LOW){   
          debuger("Control Button", 1);
          debuger(String(aValue), 1);  
          ResetVolts();        
          Button = toolName[aValue];
          if (aValue == 13){
              debuger("-13-", 1);
              LEDs_On();                                  //All LED's On
              for(int x=0; x<18; x++){
                if(gate[x][12] == 1) {  
                   debuger(String(x), 1);
                   nVPP = getVPP(gate[x][5]);
                   debuger(String(nVPP), 1);
                   aValue = 20;
                   Display4("-Sensor Value-","Sensor Value: " + String(x), String(nVPP));
                   delay(2000);
                }
              }
              LED_Off();                                   // LED Off
            }
            if (aValue == 14){
              debuger("-14-", 1); 
              LEDs_On();                                  // All LED's On                   
              for(int x=0; x<18; x++){
                if(gate[x][6] > 1) {  
                   debuger(String(x), 1);
                   aValue = 20;
                   Display4("-Gate Value-", String(toolName[x]), "Gate Cycling");
                   debuger("Gate Cycling the " + String(toolName[x]) ,1);
                   pwm.setPWM(gate[x][3], 0, gate[x][7]);  //Gate Open
                   delay(3000);
                   pwm.setPWM(gate[x][3], 0, gate[x][6]);  //Gate Open
                   delay(2000);
                }
              }
              LED_Off();                                           // LED Off
            }
          if (aValue == 15){       
            debuger("-15-", 1);  
            LEDs_On();                                             // All LED's On          
            Ogates();                                              // Gates Open 
            Display4("-Gate Value-", "Dust Collector", "Run 15 Seconds");
            Dust_On();                                            //Dust Collector On    
            delay(15000);   
            aValue = 20;
            Display4("-Gate Value-", "Dust Collector", "Off");
            Dust_Off();                                           //Dust Collector Off   
            delay(5000); 
            Cgate();                                              // Gate Close    
            LED_Off();                                            // LED Off      
          }
        }
      }
    }
}
//=============================================================
void LED_Off(){          // All LED Off
  //Display("All LEDs", "Off");
  for(int i=0; i<18; i++){
    if(gate[i][4] > 1){ 
       digitalWrite(gate[i][4], LOW); 
    } 
  }
}
//=============================================================
void LEDs_On(){          // All LED's On
  //Display("All LEDs", "On");
  for(int i=0; i<18; i++){
     if(gate[i][4] > 1){ 
       digitalWrite(gate[i][4], HIGH);
     }
  }
}
//=============================================================
void ResetVolts(){       // Sets the Sensor Array
  for(int a=0; a<18; a++){
    if(gate[a][8] == 1 && gate[a][12] == 1){ 
      vNumber[a] = getVPP(gate[a][5]) + 0.2;
      debuger("Amp Value: ", 2);
      debuger(String(vNumber[a]), 2);
    }
  }
}
//=============================================================
void Ogates(){            // Open All Gates 
  debuger("--- Open All Gates ---", 1);
  delay(2000);
  for(int a=0; a<18; a++){
    if(gate[a][6] > 1){ 
      pwm.setPWM(gate[a][3], 0, gate[a][7]);      
    }
  }
}
//=============================================================
void Ogate(){            // Close Gates 
  pwm.setPWM(gate[aValue][3], 0, gate[aValue][7]);  //Gate Open
}
//=============================================================
void Cgate(){            // Close All Gates 
  debuger("--- Closing Gates ---", 1);
  delay(2000);
  for(int a=0; a<18; a++){
    if(gate[a][6] > 1){ 
      pwm.setPWM(gate[a][3], 0, gate[a][6]);      
    }
  }
}
//=============================================================
void LED_On(int x){      // LED On
  debuger(Button + String(x) + " ", 1); 
  debuger("LED On", 2)  ;
  digitalWrite(gate[x][4], HIGH);
  delay(250);
}
//=============================================================
void Dust_On(){          // Dust Collector On
  debuger("Dust Collector On", 1);
  Display4("--------------------","Dust Collector", "On ");
  digitalWrite(gate[11][11], HIGH);    // sets the Dust Collector On
}
//=============================================================
void Dust_Off(){         // Dust Collector Off  
  debuger("Dust Collector Off = 10 seconds", 1)  ;
  Display4("--------------------","Dust Collector", "Off in 10 seconds");
  delay(5000);                         // Time to clear the line 
  debuger("Dust Collector Off = 5 seconds", 1)  ;
  Display4("--------------------","Dust Collector", "Off in 5 seconds");
  delay(5000);                         // Time to clear the line 
  debuger("Dust Collector Off", 1);
  Display4("--------------------","Dust Collector", "Off ");
  digitalWrite(gate[11][11], LOW);     // sets the Dust Collector Off
}
//=============================================================
void DustLevel_On(){     // Dust Collector Light On  
  debuger("Dust Collector Level Light On", 1) ; 
  Display4("--------------------","Dust Collector", "Level Light On");
  digitalWrite(gate[11][10], HIGH);    // sets the Dust Collector On
}
//=============================================================
void DustLevel_Off(){    // Dust Collector Light Off  
  debuger("Dust Collector Light Off", 1); 
  Display4("--------------------","Dust Collector", "Level Light Off");
  digitalWrite(gate[11][10], LOW);     // sets the Dust Collector Off
}
//=============================================================
void DisplaySencor(int X){ // Displays the sensor information 
  uint32_t now_time = millis();
  lcd.init();
  debuger("1a",2);
  // Print a message to the LCD.
  lcd.backlight();
  debuger("2", 2);
  lcd.clear();
  lcd.setCursor(0,0);
  debuger("2a", 2);
  lcd.print("-- Voltage Sensor --");
  lcd.setCursor(0,1);
  String hr = String(hour());
  String mn = String(minute());
  String sc = String(second());
  if (hr.length()==1){    hr = "0" + hr;  }  
  if (mn.length()==1){    mn = "0" + mn;  }  
  if (sc.length()==1){    sc = "0" + sc;  }
  lcd.print("Run Time: " + hr + ":" + mn + ":" + sc);
  lcd.setCursor(0,2);
  lcd.print(toolName[X]);
  lcd.setCursor(0,3);
  lcd.print(toolName[26]);  
}
//=============================================================
void Display4(String Word1, String Word2, String Word3) {  // Post info to LCD Display
  uint32_t now_time = millis();
  lcd.init();
  // Print a message to the LCD.
  debuger("1", 2);
  lcd.backlight();
  //lcd.clear();
  lcd.setCursor(0,0);
  debuger("1", 2);
  if (DustLevelCount > 100){
    DustLevel = getDist();
    DustLevelCount = 0;
  }
  DustLevelCount = DustLevelCount + 1;
  lcd.print("Dust Level = " + String(DustLevel));
  lcd.setCursor(0,1);
  String hr = String(hour());
  String mn = String(minute());
  String sc = String(second());
  if (hr.length()==1){    hr = "0" + hr;  }  
  if (mn.length()==1){    mn = "0" + mn;  }  
  if (sc.length()==1){    sc = "0" + sc;  }
  lcd.print("Run Time: " + hr + ":" + mn + ":" + sc);
  lcd.setCursor(0,2);
  lcd.print(Word2);
  lcd.setCursor(0,3);
  lcd.print(Word3);  
}
//=============================================================
float getDist(){         // Get Dust Level Distance from the dust bin
  float result;
  float readValue;                        //value read from the sensor
  float maxValue = 0;                     //Store max value here
  float minValue = 50000;                 //Store min value here
  uint32_t start_time = millis();
  while((millis() - start_time) < 1000){    //Sample for 1 Sec
    debuger("a",2);
    readValue = analogRead(gate[11][9]);     //See if you have a new maxValue
    debuger(String(readValue),2);
    if (readValue > maxValue){           
      maxValue = readValue;          //Record the maximum sensor value
    }
    if (readValue < minValue){           
      minValue = readValue;          //Record the maximum sensor value
    }
  }     
  result = ((maxValue + minValue) * 0.5);                //Convert the digital data to a voltage
  debuger("Dust Level", 2)  ;
  debuger(String(result), 2)  ;
  debuger(String(DustLevelLenth), 2)  ;
  /*if (result > DustLevelLenth){
    DustLevel_On();
  }else{
    DustLevel_Off();
  }*/
  return result;
}
//=============================================================
float getVPP(int Pin){   // Get Amp Level Reader
  float result;
  int readValue;                          //value read from the sensor
  int maxValue = 0;                       //Store max value here
   uint32_t start_time = millis();
   while((millis()-start_time) < 50)      //Sample for 1 Sec
   {
       readValue = analogRead(Pin);       //See if you have a new maxValue
       if (readValue > maxValue){           
           maxValue = readValue;          //Record the maximum sensor value
       }
   }     
   result = (maxValue * 5.0)/1024.0;      //Convert the digital data to a voltage
   return result;
}
//=============================================================

It is late so I will be posting some pictures this weekend.
Last edited by jimandi5000 on Sat Feb 29, 2020 4:00 am, edited 1 time in total.
Thanks,
Jim

User avatar
highpockets
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Model of CNC Machine: PDJ Pilot Pro

Re: Dust Management

Post by highpockets »

Can't wait to see it!!!
John
Maker of Chips

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gkas
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Re: Dust Management

Post by gkas »

Lookin good..... :D

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jimandi5000
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Model of CNC Machine: Home Made 60 x 120
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Re: Dust Management

Post by jimandi5000 »

Thanks...
Thanks,
Jim

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jimandi5000
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Re: Dust Management

Post by jimandi5000 »

Pictures
Attachments
Sanders
Sanders
Ban Saw and Table Saw
Ban Saw and Table Saw
mount over head
mount over head
Control panel
Control panel
Slide5.JPG
Slide6.JPG
Slide7.JPG
Slide8.JPG
Slide9.JPG
Slide10.JPG
Slide11.JPG
Thanks,
Jim

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highpockets
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Re: Dust Management

Post by highpockets »

Wow!!!! Fantastic Jim. Well designed and your code looks great....
Thanks for the pics....
John
Maker of Chips

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jimandi5000
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Model of CNC Machine: Home Made 60 x 120
Location: North Houston Tx.

Re: Dust Management

Post by jimandi5000 »

Thanks High Pockets,
One of my next item is to re-pipe the shop... Okay, it is a mess... I need to move everything out, cleanup and re-setup the shop. :wink:
Thanks,
Jim

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highpockets
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Re: Dust Management

Post by highpockets »

Looks pretty good to me...
Can't wait to get back into my shop....
John
Maker of Chips

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gkas
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Re: Dust Management

Post by gkas »

That is one lotta work in a short time... :shock: It really looks great. How did you implement the dust level sensor. It's gotta be touchy to keep down the false positives.

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highpockets
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Joined: Tue Jan 06, 2015 4:04 pm
Model of CNC Machine: PDJ Pilot Pro

Re: Dust Management

Post by highpockets »

gkas wrote:
Sun Mar 01, 2020 7:23 am
How did you implement the dust level sensor. It's gotta be touchy to keep down the false positives.
Mine works off of vacuum pressure....
John
Maker of Chips

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jimandi5000
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Model of CNC Machine: Home Made 60 x 120
Location: North Houston Tx.

Re: Dust Management

Post by jimandi5000 »

gkas wrote:
Sun Mar 01, 2020 7:23 am
That is one lotta work in a short time... :shock: It really looks great. How did you implement the dust level sensor. It's gotta be touchy to keep down the false positives.
I used a infared distance module. I measure the height of the dust in the can and hold the light on based on the distance from the top of the can to the dust. If the dust is at the top, i don't run the dust collector and keep the red light flashing. I have to run the check before i run the dust collector, it is crazy values when it is running.
Thanks,
Jim

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