Filament monitor using HC-020K encoder

dc42 · 14 Mar 2018, 20:25

Judging by the schematic at https://sites.google.com/site/myscratchbooks/home/projects/project-11-infrared-speed-sensing-module it looks like it produces pulses as the filament wheel turns. So you may be able to connect it to a spare endstop input and use M591 with the P7 option to configure it in RRF.

Unlike the two prototype Duet3D sensors, it does not provide direction information; so although it may be able to tell you when the filament has stopped moving, it probably won't be able to correlate actual movement to commanded movement.

You may have to reduce the optical interruptor series resistor to make it work reliably on 3.3V power.

paboman · 14 Mar 2018, 20:33

You provide al information I need, thank you!
As my intention was to use it without modifications I think I will go with your solution for filament sensing.
When the sensor will be available again in the official duet online shop ?

dc42 · 14 Mar 2018, 20:45

I can't say when we will have production filament sensors, because we are still trying to see whether we can get the laser prototypes working as well as the rotating magnet prototypes. So if you already have that other sensor, try it!

paboman · 17 Mar 2018, 10:46

Ok I have wired the sensor to the E0 stop and configured as follow:
[c]; Filament Monitor HC-020K
M591 D0 P7 C3 S1 R70:130 L24.8 E3.0 ; Duet3D rotating magnet sensor for extruder drive 0 is connected to E0 endstop input, 7 = pulse-generating, sensorsensitivity 24.8mm.rev, 70% to 130% tolerance, 3mm detection length
M591 D0 ; display filament sensor parameters for extruder drive 0
[/c]

For testing purpose the encoder is temporary mounted to the estruder stepper so I can easily simulate the encoder stop reading
The L value has not been calculated yet so its 24.8mm/rev for now
https://youtu.be/skg_SJgsGZk

Sending M591 D0 I get:
[c]M591 D0
Pulse-type filament monitor on endstop input 3, sensitivity 1.00mm/pulse, check every 3.0mm, tolerance 70.0%, no data received[/c]

What should I do next to test or calibrate it ?
My idea is to run a print without filament then move away the encoder from the wheel to simulate a filament jamming, I expect it to pause the print.

dc42 · 17 Mar 2018, 14:21

To calibrate it, run a print (with filament). Send M591 D0 to get the calibration data. You can do this as it is printing, as often as you want. To restart accumulating calibration data, pause and then resume the print.

Note, the support for pulse-type filament sensor is experimental. I don't have a sensor of that type, so it is very likely that it doesn't work. If you can provide feedback on any issues you encounter, I may be able to include fixes in the 1.21 firmware release.

paboman · 17 Mar 2018, 14:53

Actually I cant run a print with filament because my test setup is like in the video I made https://youtu.be/skg_SJgsGZk
but the duet think its reading the filament so should be good for gathering data.

paboman · 17 Mar 2018, 15:09

Progress update:
I have changed the tolerance from 70 to 50%
As you can see in the new video https://youtu.be/pRrZK0OoPBg I am running a print, E0 stop led is blinking as the encoder send pulses but duet is telling me: No data received.

[c]M591 D0
Pulse-type filament monitor on endstop input 3, sensitivity 1.00mm/pulse, check every 3.0mm, tolerance 50.0%, no data received[/c]

dc42 · 17 Mar 2018, 15:50

It could be that your sensor pulls the endstop input low enough to light the LED but not low enough to register as low in the processor. Use the Machine Properties tab of DWC to check whether the detected state of that input changes as the wheel rotates and the LED turns on and off.

paboman · 17 Mar 2018, 16:14

In the DWC the E0 is triggered correctly, it change its state from NO to YES as I rotate the encoder wheel

dc42 · 17 Mar 2018, 17:20

Thanks. I found the first bug in support for pulsed filament sensors. Please try the firmware at https://www.dropbox.com/s/iq9pzfaugyfei7x/Duet2CombinedFirmware.bin?dl=0.

paboman · 17 Mar 2018, 18:05

Installed the firmware 1.21RC5+ (2018-03-17 build 1) apparently nothing has changed.
Still [c]M591 D0
Pulse-type filament monitor on endstop input 3, sensitivity 1.00mm/pulse, check every 3.0mm, tolerance 50.0%, no data received[/c]
https://youtu.be/nitZGkwWn7s

Maybe something wrong with my conf.g ?

dc42 · 17 Mar 2018, 18:18

Did you get that report after the wheel had spun a few times and the LED flashed off and on?

paboman · 17 Mar 2018, 18:34

yes, after 30 min of printing the report is the same

dc42 · 17 Mar 2018, 22:17

I've rewritten the pulsed filament monitor support based on the code for the rotating magnet sensor, which is know to be working. Also I have changed the configuration parameters to be the same as for the rotating magnet sensor. You are welcome to try it (it's at https://www.dropbox.com/s/iq9pzfaugyfei7x/Duet2CombinedFirmware.bin?dl=0)), but as I haven't had time to test it yet I don't expect it to work.

paboman · 17 Mar 2018, 22:30

I have just upgraded the firmware, should I change something in my config.g ?
Right now i have :
[c]; Filament Monitor HC-020K
M591 D0 P7 C3 S1 R70:130 L24.8 E3.0 ; Duet3D rotating magnet sensor for extruder drive 0 is connected to E0 endstop input, 7 = pulse-generating, sensorsensitivity 24.8mm.rev, 50% to 130% tolerance, 3mm detection length
M591 D0 ; display filament sensor parameters for extruder drive 0[/c]

paboman · 17 Mar 2018, 22:32

now after the prints begins i get : [c]Extruder 0 reports too little movement[/c]

paboman · 17 Mar 2018, 22:50

Upgraded to:
1.21RC5+ (2018-03-17 build 2)

I have changed my settings in config.g to:

[c]; Filament Monitor HC-020K
M591 D0 P7 S23.5 C3 R50 E3.0 ; Duet3d sensor for extruder drive 0 is connected to endstop input 3 (E0), S=23.5mm/rev, R=50% error detection tolerance, C=3mm comparison length

M591 D0 ; display filament sensor parameters for extruder drive 0[/c]

Still getting [c]Extruder 0 reports too little movement[/c]

the strange thing is that The S parameters is set to 23.5 while after M591 D0 I get :
[c]M591 D0
Pulse-type filament monitor on endstop input 3, enabled, sensitivity 28.80mm/pulse, allowed movement 50% to 160%, check every 3.0mm, current position 0.0, no calibration data[/c]
the S parameter is 28.8 instead of 23.5

I will be more than happy to send you one HC-020K encoder, just send me the adress to info@3dbnz.com and on Monday UPS will collect the parcel.

in the mean time, thank you

paboman · 17 Mar 2018, 23:15

setting the sensitivity very low to 0.2 makes the print goes thru
then issuing M591 D0
I get [c]Pulse-type filament monitor on endstop input 3, disabled, sensitivity 28.80mm/pulse, allowed movement 20% to 160%, check every 3.0mm, current position 0.0, measured sensitivity 160.73mm/pulse, measured minimum 0%, maximum 2877% over 63648.7mm [/c]
so i set S value to 160 but then i get again:
[c]Extruder 0 reports too little movement[/c]
and the printer go to pause

PS
while the S is 0.2 there is no difference if I remove the sensor from the wheel, the print does not go to pause

Why M591 D0 is telling me [c]disabled[/c] ?

dc42 · 18 Mar 2018, 07:17

As I said, I brought the parameters into line with the other filament monitors. So S now enables or disables filament monitoring, and L sets the sensitivity. See https://duet3d.dozuki.com/Wiki/Gcode#Section_M591_Configure_filament_sensing.

You will probably need to increase the E parameter.

160mm/pulse sounds far too high. Can you measure it?

paboman · 18 Mar 2018, 08:08

what P parameter should I use?
still P7 for pulse-generating sensor or P3 for rotating magnet sensor ?

One complete rotation of the wheel is 20 pulses
Encoder wheel diameter is 26mm
E0 stepes per mm is 1166 ( 13to1 gearbox ratio)