4112d8653c
When winding short lengths e.g. 5m it does not make sense
to use the entire winding width thus getting unnecessary
wide cable ring.
Determined some thresholds while testing and implemented
those to be applied at target length change automatically:
control:
- update winding width each time target length changes
guide-stepper:
- add function that returns dynamic winding width depending
on passed target length according to fixed thresholds
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
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
Variable Frequency Drive T13-400W-12-H
See docs/vfd/
Stepper-driver TB6600
See docs/stepper-driver_TB6600-Manual.pdf
Linear Axis with Nema-12 28HB40 Stepper
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