j/cable-length-cutter

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Firmware for a custom built machine which winds and cuts cable to a specific length using an esp32 controller on a custom pcb

C++ 73.4%
C 25.4%
CMake 1.1%

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jonny_l480 f2dc43d7cd Merge branch 'dev' - dynamic winding width		2024-04-04 22:34:14 +02:00
cad	CAD: Add assembly of all parts (for website)	2024-03-23 22:26:14 +01:00
components	Revert 8 commits (approach with stepper lib dropped)	2023-04-25 19:16:38 +02:00
docs	Add control-pcb schematic, Add screenshots modbus tests	2024-03-13 16:40:47 +01:00
img	Rework README, Minor changes to function-diagram	2024-03-14 14:01:24 +01:00
main	Add dynamic-winding-length depending on targetLength	2024-03-17 09:41:24 +01:00
pcb	Add filter-pcb for denoising stepper signals	2023-03-02 23:12:52 +01:00
testing/cnc-guide	Add C-project for simulating axis in commandline	2023-03-02 23:35:24 +01:00
.gitattributes	Add CAD-files, wire-labels, docs/datasheets	2022-09-29 19:39:56 +02:00
.gitignore	Outsource global variables, Optimize comments	2024-03-10 12:55:13 +01:00
CMakeLists.txt	Rework README, Minor changes to function-diagram	2024-03-14 14:01:24 +01:00
connection-plan.drawio	Update Connection-plan: Measure voltage, Details, Color	2024-03-13 16:31:07 +01:00
connection-plan.drawio.pdf	Update Connection-plan: Measure voltage, Details, Color	2024-03-13 16:31:07 +01:00
function-diagram.drawio	Rework README, Minor changes to function-diagram	2024-03-14 14:01:24 +01:00
function-diagram.drawio.pdf	Rework README, Minor changes to function-diagram	2024-03-14 14:01:24 +01:00
README.md	Merge branch 'dev' - cable-guide functional	2024-03-14 14:09:32 +01:00
sdkconfig	Adjust parameters cable-guide	2024-03-09 22:26:26 +01:00
wire-labels.fods	Add CAD-files, wire-labels, docs/datasheets	2022-09-29 19:39:56 +02:00

README.md

Overview

Firmware and documentation of a custom built machine that winds and cuts cable to certain lengths.
Extensive details about this project can be found on the website: pfusch.zone/cable-length-cutter

Photo of the built machine

Current Features

Measure length using rotary encoder
Wind to set length while start-button is pressed
Automatic wire cutter
Control interface:
- 2x 7-Segment display showing lengths and notifications
- Buzzer for acoustic notifications
- 4 Buttons and Potentiometer for setting the target length
- Reset and Cut Button
Stepper motor controlling a linear axis guiding the cable while winding
Store last axis position at shutdown

Usage

Electrical Details

For detailed documentation of all electrical aspects, see connection-plan.pdf.

Printed Parts

All designed and 3D-printed parts can be found in the cad/ folder. These parts were designed using FreeCAD.

Components

Custom pcb with ESP-32 microcontroller

See connection-plan.pdf

Rotary encoder LPD3806-600BM-G5-24C

- Pulses: 600 p/r (Single-phase 600 pulses /R,Two phase 4 frequency doubling to 2400 pulses)
- Power source: DC5-24V
- Shaft: 6*13mm/0.23*0.51"
- Size: 38*35.5mm/1.49*1.39"
- Output :AB 2phase output rectangular orthogonal pulse circuit, the output for the NPN open collector output type
- Maximum mechanical speed: 5000 R / min
- Response frequency: 0-20KHz
- Cable length: 1.5 meter
- size: http://domoticx.com/wp-content/uploads/2020/05/LPD3806-afmetingen.jpg
- Wires: Green = A phase, white = B phase, red = Vcc power +, black = V0

Installation

For this project ESP-IDF v4.4.4 is required (with other versions it might not compile)

#download esp-idf
yay -S esp-idf 
#alternatively clone the esp-idf repository from github and do `git checkout release/4.4`

#run installation script in installed folder
/opt/esp-idf/install.sh

Build

Set up environment

source /opt/esp-idf/export.sh

(run once per terminal)

Compile

cd board_single
idf.py build

Flash

connect FTDI programmer to board (VCC to VCC; TX to RX; RX to TX)
press REST and BOOT button
release RESET button (keep pressing boot)
run flash command:

idf.py flash