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    Help Filament Sensor (Pulsating Type)

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    Filament Monitor
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    • Slidrundefined
      Slidr
      last edited by

      Hi ,
      i am currently building a filament sensor based on a reprap hall-e sensor.

      Personal motivation:
      I really need filament sensor due to large amounts of out of spec filaments. surface quality doesn´t matter and refilling and restarting after grinding is not a problem..but manually restarting failed prints takes just too much time.

      Let me shortly describe my setup:

      Not my picture but same components:
      alt text

      The Filament passes through 2 rubber cylinder mounted on an axle with bearing to a housing.
      One of this axles rotates a magnet which gets detected by the hall-e sensor.

      passed filament per pulse
      dr = rubber diameter = 8
      (maybe an effective diameter due to compression needs to be used, something like 7.75 or so)

      Thus the circumference (i.e. 1 revolution i.e. 1 pulse):
      1 pulse = 2*pi *dr/2 = 24.34 mm

      This is verified by running calibration mode of M591 (with S0 ).
      It reports roughtly 24.x as i have definied via L parameter (see below)

      Definition of Sensor from config.g:

      ; Hall-E Filament Sensor
      M591 D0 P7 C3 S1 R50:150 L24.0 E50.0
      ; D0=Extruder 0, P7 = Pulse (P3=MagneticDuet); C3 = Input Connection (0=X,1=Y,2=Z,3=E0...)
      ; S(0/1) = disable/enable monitoring; Raa:bb allowable error
      ; Lnn Filament movement per pulse in mm
      ; Enn Extrusion Length before comparison
      ; M591 D0 ; display filament sensor parameters for extruder drive 0

      Problem:
      The E Value needs to be pretty high in comparison to my L value.
      Meaning: to make sure i get a proper extruder length sensor reading i need multiple pulses per E-value.
      Example:
      If one pulse is 24mm (L24 ) than i could check the first time after exactly 24mm (E24). However due to different kind of errors i can not check exactly at 24 mm because the sensor reading might just not have recognized the first pulse because a very little amount of filament is missing (true extrusion is maybe 23.99).
      As a response of the M591 command i get an large error!

      This suggests that the allowable error is directly related to the number of pulse per extrusion check.
      Based on my feeling (don´t judge me here 🙂 ) this means that a somewhat tolerable error due to discretisation is reached by using more then 6 or 7 pulses per extrusion check. This would mean an maximum error of roughly 15%.

      Lets formulate this the other way around: a reliable extrusion check E is valid after 7*L. in my case: E168. (Feeling like half of my printed testcube: true measure was 25% of the model...somewhat late to check for missing extrusions 😉 )

      Possible solutions:

      1. using more magnets per revolution (costly and most like only possible with the next solution due to space requirements)
      2. gearing the system for better ratios (did i mention space requirements? besinde some slip, rattling and what so ever)
      3. getting more information from the magnetic field. as far as i know (no expert here...) the hall e sensor does not only give cut of binary signals but voltage drops (linear, sinusiodal...?) this could be incorporated in the filament sensor system.

      Is there anything else i missed?
      Every help is really appreciated 🙂

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      • dc42undefined
        dc42 administrators
        last edited by

        I agree with your analysis. You need much more than one pulse per 24mm of filament motion.

        Duet WiFi hardware designer and firmware engineer
        Please do not ask me for Duet support via PM or email, use the forum
        http://www.escher3d.com, https://miscsolutions.wordpress.com

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        • Slidrundefined
          Slidr
          last edited by

          Thanks for your response!
          I guess i can increase the resolution by roughly a factor of 30:
          3:1 via gears + 10 magnets per gear.

          Maybe that´s enought!

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          • Slidrundefined
            Slidr
            last edited by

            Just a quick update. Prototype sketching is done...let´s wait for the print.

            0_1528560713706_FilamentSensor.PNG

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