Filament Counter with Warning Lights and Buzzer

Description

This is a Remix of Bin Sun's Filament Bot. When I first made this I thought it was great to see how much filament my CR10S-Pro was using per project. Until the first time I used PETG in my printer and it jammed causing me a couple hours of frustration. Which resulted in wasted project time as it was a 32 hour print. :( So I started to think.... Could I turn this into some kind of jam sensor? The answer is yes.... yes you can. So I set out on my quest to upgrade the Filament Bot. First let me say, my Arduino skills are led on..... led off *giggle like I made magic.* But I have excellent build and schematic skills. So I drew up a diagram in Fritzing, and enlisted the help of a mad Arduino genius. With her sketch and my build, we created the Filament Bot WITH warning Lights! The warning light is from Adafruit, it is 12v powered with a common hot, and switched grounds. It has a low amp draw, but I decided to use N channel mosfets in my build. I added a 25mm fan to the box, just because.... Well not really, I noticed that when my original filament bot got too hot on a hot day it would start acting funny. So I figured with mosfets sharing the same box... Put a small fan in it. I included a pic of my amazing rats nest of wire and bread board, you ask "how in the hell does it even work?" Welp I'll tell ya. The Filament Bot gets a signal from the modified PS/2 mouse filament sensor. It displays that info in two ways. Top line is filament currently used. Second line is total filament used. The first button on the bot is the reset button. This functions just as it did in the original design by Bin Sun. One press of the reset button resets the top line, two presses both lines are cleared. The second button turns the tree on and off. One press turns the whole tree on, two presses turns only the red light function on, and three presses turns the tree off. The third button is the buzzer which is directly linked to the red light. The buzzer is loud.... but a cotton ball fixed that . Basic function is this. Turn on the counter and it will ask you if you want to change the direction of the counter. Press the button if you need to do this. This same button also resets the the read out of filament. 1 press clears the top "Used" line, 2 presses or a long press will clear both "Used and Total" line. Now if you press the middle button and turn the tree on, the green light will flash. As long as filament is moving it will be happy and flash green. If it stops feeding for 3 seconds it will start to flash yellow, Might want to check it. At 10 seconds of no movement it is defcon 5, the red light will come on solid, and so will the buzzer if on. To build this wonderful Filament Bot you will need some stuff! 1 × PS/2 Mouse Logitech 2-Button PS/2 Ball Mouse M-SAW34 1 × Arduino UNO 1 × Serial LCD 1602 16x2 Module With IIC/I2C Adapter Blue or green 3 × 12x12x7.3mm Momentary Tactile Push Button Switch with key cap 1 × 625zz 5x16x5 Shielded Miniature Ball Bearing 3 x PS/2 socket 1 x PS/2 extension cord (for the light tree) 1 x 3 tier light tree with buzzer from Adafruit 4 x N channel IRLB8721 Mosfets 1 x prototyping board 1 x 25 mm fan 1 x 12v power supply 3 x 5x15mm bolts with nuts 8 x 3x6mm sheet metal screws (or something close) 1 x glue... I love Bondic from Amazon, but regular super glue will work The filament sensor is really easy to build, I highly recommend checking out Bin Sun's Instructibles on how to make it. You basically take apart the mouse, discard the ball and shell. Clip one of the sensor wheels and stick it in the filament roller. Tweak the mouse sensors a little if needed and done. In my downloads I have included Bin Sun's modified mouse file. You need this file to make it work! When I first made this it took me forever to find a LCD driver that worked! So I will save you the trouble, and include it! Some optional items that I have included are my filament sensor mount. And door hanger for the light tree. The light tree and the hanger both use 6mm bolts.... but I didn't quite get the diameter of the bolt circle right. So 5mm bolts work well, I may fix this later. The door hanger is 2.5mm thick, so make sure you have enough gap between your door and frame. There is a little 1mm thick wire protector, a little scotch tape keeps the wires in place and safe from rubbing on the door frame. The socket for the tree hangs downward, I use a rubber band around the cord to keep it secure. Some other build hints. I used Molex 90 degree stands so that the back cover is easier to remove. 90 degree stands are the only way you will get the clearance for everything. Keep the wires as short as possible in there. It's packed in there!. I mounted my mosfets to a prototyping board, this is optional. But it fits nicely in the bottom of the case. The glue is for the switches and the PS/2 plugs. The fit is snug, but one good push and they will pop out. Here are some links! You need the light! https://www.adafruit.com/product/2993 And definitely power https://www.adafruit.com/product/352 All the other items can be found on ebay for pretty reasonable. ONE NOTE! the LED light tree should have it's own 12v power. Two ways to do this. First tee the power from the power supply, remember the Arduino and the tree MUST share the same power supply or it will not light. Second way which is how I did it. Solder a black and red power tap from the bottom of the Arduino's 5mm power jack. This keeps it all internal to the box, and tidy.... Well tidyish :p

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