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Arduino Forum Turning on a machine automatically when another machine is turned on - using ad hoc ESP8266 network
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  • wifi
  • esp8266
  • relays
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Related

Turning on a machine automatically when another machine is turned on - using ad hoc ESP8266 network

donnybahama
donnybahama over 3 years ago

I’m very new to microcontrollers and programming. I probably know just enough to be dangerous. I’m trying to devise a reasonably simple system for turning on the dust collector in my wood shop and positioning the sliding carriage (output side) of a blast gate manifold over the appropriate inlet for the tool that was just turned on. (The first 10 seconds of this video will clarify how the manifold works.)

The way I think I want to do this is using an ad hoc network of ESP8266 modules - 6 “sender” modules which send "Power ON” and [Machine ID] to the “receiver” module (mounted near the dust collector and blast gate manifold) when current is detected for the dust producing machine’s motor. The receiver module then triggers a relay which turns on a motor which turns a threaded rod which moves the manifold’s sliding carriage to position it over the inlet for the tool that was just turned on. Six reed switches - one each attached to the blast gate inlets - are connected to GPIO pins on the receiver module. A magnet mounted to the sliding carriage closes each reed switch as it travels. When the ESP8266 sees that the reed switch for the desired GPIO pin has been closed, it 1) deactivates the relay that’s supplying power (or ground) to the positioner motor, 2) activates a relay that turns on the dust collector, and 3) Turns on a green indicator that can be seen throughout the shop, indicating that the dust collector is on and the proper blast gate is open.

If that’s not the right way to do things, please let me know what the right way is.

Things I need guidance on:

  1. Because I have zero experience with microcontrollers and GPIO pins, I’m not exactly sure what the microcontroller expects to see on a GPIO pin in order to know that some trigger just occurred and some action must be taken. Does it want to see voltage? Ground? A particular frequency?
  2. The “sender modules send “Power ON” ad the machine ID to the receiver module when current is sensed. What’s the simplest/cheapest way to detect the current from a motor turning on and use that to trigger the GPIO pin?
  3. Again, because I have no experience programming a microcontroller, how do I tell the microcontroller to ignore the (momentarily) closed reed switches from the other manifold inlets as the carriage/magnet travels by reed switches 1, 2, and 3 to get to the desired (#4) position?
  4. Anything else I’m overlooking?

Thank you for your time and consideration.

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Top Replies

  • fmilburn
    fmilburn over 3 years ago +5
    Hello donnybahama That is a relatively complex project for someone new to microcontrollers but doable with effort. The best advice I can give is to break it into pieces and prototype each step before…
  • beacon_dave
    beacon_dave over 3 years ago +5
    Perhaps best to start with Question 4... - Safety. Power tools, mains power and "new to microcontrollers and programming" can quickly result in injury. - Your 5th port (free hose) doesn't have a power…
  • dougw
    dougw over 3 years ago +4
    Nice manifold design. It might be better to use a pulley than a lead screw. A leadscrew wouldn't allow the magnets to align the ports.
  • fmilburn
    fmilburn over 3 years ago in reply to donnybahama

    Yes, it is an analog output.  There may be a sensor out there with digital high/low output but I've not looked.  However, it is easy to put a threshold value in your code and turn the analog output into high/low with an if statement.

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  • Jan Cumps
    Jan Cumps over 3 years ago in reply to fmilburn

    The Arduino has a Comparator that you can use to trigger on level over/underrun.

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  • fmilburn
    fmilburn over 3 years ago in reply to Jan Cumps

    True - I don't know if the ESP8266 does though.  He could add an external comparator in any event.

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  • donnybahama
    donnybahama over 3 years ago in reply to beacon_dave

    I’m really having trouble picturing that. Would there be something like a dust hood that covers the manifold and goes between the manifold and the dust collector port?

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  • dougw
    dougw over 3 years ago in reply to donnybahama

    A pulley system would work exactly like the belt drive on most 3D printers that moves the print head across the bed. They use a stepper motor to drive one end of the belt while the other end just runs around an idler gear. It should be much faster than a leadscrew.

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  • Jan Cumps
    Jan Cumps over 3 years ago in reply to fmilburn

    It has: arduino.stackexchange.com/.../17967

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  • donnybahama
    donnybahama over 3 years ago in reply to dougw

    Got it. Cool! Thanks for the clarification. I’m leaning more and more toward a stepper motor. Seems like it solves a lot of problems. And if I’m going to use a stepper motor, it seems logical to use a belt/pulley system. Seems like it would stand up better to the fine sawdust that will inevitably gum up the works over time, too. Now I just need to figure out a way to enclose the stepper motor, controller, and maybe even the belt (to keep sawdust off it entirely) without the motor or controller overheating.

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  • dougw
    dougw over 3 years ago in reply to donnybahama

    All ports, including the vacuum go into a plenum chamber. The source hoses are all blocked by a rotating plate with a hole in it  which allows only one source access to the plenum which is evacuated by the vacuum. 

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  • dougw
    dougw over 3 years ago in reply to donnybahama

    Your drill idea could still work - they really have a lot more torque than a stepper motor, which you might need if you want to maintain a good seal. The vacuum side could use a funnel to reduce the need for accurate positioning - as long as you have a plate around the source hoses to seal the whole funnel mouth.

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  • donnybahama
    donnybahama over 3 years ago

    The thread display format for this forum is awkward to me. When I’m notified that there’s a reply, I struggle to find it. Is there a setting somewhere where I can choose to have posts displayed in simple, chronological order? Or is the nested display my only option?

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