Dust Collection System Monitor

Description

I'm setting up a wood shop in my basement and in an effort to contain the fine particles I've purchased an Oneida V-system with a 0.5 micron filter. I want to create something simple that alerts me to take action when either of two criteria is met.

1. The dust collection bin fills to within X inches of the top.
2. The pressure going to the filter exceeds X kPa above ambient.
I'm going to prototype with an Arduino and deploy it with an Adafruit Trinket.

Since the dust collector makes a large amount of noise when it is running I am going to use some sort of visual means of notification like little woot lights.

Files

i2cIR.ino

Sketch I used to test the function of the Sharp GP2Y0E03 IR sensor. It appears to work successfully and uses the I2C connection which I've never done before.

x-arduino - 1.32 kB - 12/21/2016 at 21:26

Download

pressureInput.ino

Simple Sketch Used to test pressure sensor function.

x-arduino - 1.10 kB - 12/21/2016 at 03:25

Download

gp2y0e03_e.pdf

Datasheet for distance measurement sensor.

Adobe Portable Document Format - 747.25 kB - 12/20/2016 at 14:22

Preview

Components

1 × MPVZ5004GW7U Sensors / Pressure, Force

1 × GP2Y0E03 Optical Sensor 4 ~ 50cm I²C, Analog Output - Using this to determine height of dust inside of the colleciton drum at the bottom of the cyclone.

1 × 07SR-3S Connectors and Accessories / Board-to-Board and Card Edge Connectors - Needed to connect to GP2Y0E03

1 × RCER71H103K0K1H03B 10000pF ±10% 50V Ceramic Capacitor X7R Radial - Used for MPVZ5004GW7U as reccomended on Datasheet

1 × RCER71H105K2A2H03B 1µF ±10% 50V Ceramic Capacitor X7R Radial - Used for MPVZ5004GW7U as reccomended on Datasheet

Project Logs

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Ordered the PCB
EcPc • 07/21/2017 at 17:04 • 0 comments

After futzing around in eagle at work, and then getting a new laptop, a new job and a new kitchen. I returned to this project. I used Eagle to design the PCB and sent the gerbers to BasicPCB. I should have them soon and look forward to my first pass at a board

I decided to use the Arduino Duemilanove I've had forever as Rev1 of this project but it's completely unecessary. I also decided to add a 16x2 LCD screen i've had around.

Before even obtaining the PCB, i'm thinking about shrinking it down but I would like to get the code up and working first.
Learning Eagle: First PCB
EcPc • 01/16/2017 at 14:28 • 0 comments

I'm making headway learning eagle. It's actually quite a pleasant program to use and logically laid out. I've learned to make components. Next is to get the nets stubbed so i don't have a rats nest on the schematic. If anyone can point me toward something that tells me guidelines or steps for that, I would be grateful.

I started in fritzing until Benchoff soundly beat that out of me with his create a pcb in everything series. I have to say that the breadboard -> schematic features of fritzing is nice but perhaps unnecessary as I get more experience laying boards and circuits out.
Engineer wife buys engineer gifts. Dust Particle Sensor
EcPc • 01/13/2017 at 02:09 • 0 comments

I had a Shinyei PPD42 on my Amazon wishlist thinking it could play a part. Looks like I own one now thanks to the gal.

Not sure if should expand the scope to include the auxiliary air filter for the shop or not. I'm moving some wiring around downstairs to get the shop ready for prime time so hopefully there will be more progress over the next month.
Automated Startup and Sleep - Ideas?
EcPc • 01/04/2017 at 03:22 • 0 comments

Over the holiday break I started to think about a way to activate and deactivate the monitoring system I'm making when the dust collector is turned on or off. I may end up running the whole thing on battery power and having the Arduino sleep would help extend the life.
I thought initially about tapping into the power line going to the blower motor and sensing the current but that is a bit of a pain in the ass.
I thought about looking at the pressure across the blower, it should tell me without a doubt if the system is on and reduce the risk of running with a dirty filter. If I have high pressure differential but low flow, there would not be much pressure generated at the filter pressure sensor. It would take some calibration but the chart below indicates that I should have some measurable level of pressure at even the highest flow rates.

I am thinking of another freescale/nxp pressure sensor for this measurement. I am going to put it on the cyclone drum as that is exposed to the same vaccuum as the inlet. I am cutting into that for the dust bin height measurement anyway.
GP2Y0E03 + i2c + Arduino
EcPc • 12/21/2016 at 21:37 • 1 comment

I got the distance measurement sensor up and running successfully without much trouble. The reference page below in Japanese did not translate very cleanly but the code was able to be cleaned up with some careful inspect.
I attached the simple sketch. I live mostly in Matlab in my day job so Arduino is a nice way for me to learn C without knowing it.

The sensor needs a larger target as you get farther away which is fine for the bottom of a dust filled drum.
Pressure Sensor Test
EcPc • 12/21/2016 at 03:24 • 0 comments

Tested the pressure sensor with the an Arduino Leonardo and the recommended decoupling circuit. I have no means of verifying calibration but it really doesn't matter as I won't need accurate absolute measurements. So long as the pressure trends correctly as the filter clogs, I will be able to get the functionality I need. I'm attaching my demo sketch. It's just a modified version of the standard Analog In / Serial Out.
Notes on GP2Y0E03 usage
EcPc • 12/20/2016 at 14:32 • 0 comments

Translated from Japanese : GP2Y0E03 being used with Arduino.
This page clears up a bit of confusion I had. On the datasheet for the GP2Y0E03, there is a schematic with a various components on the exterior of a black bounding box. I initially assumed that I needed to add these components myself. It appears that I do not.

It does show that i have to use a logic level converter in order to shift the level from 3.3 to 5V and back for the I2C connection to work. I've never used I2C before so I'm glad I discovered this now. I've ordered a logic level converter from adafruit which I will add to the components list.

View all 7 project logs

Discussions

Michel wrote 12/21/2016 at 23:32

I saw somewhere a simple solution to detect a full dust bin. It was a simple DC motor with a little rod (wire?) on the shaft mounted perpendicular and a resistor in series high enough like 100R. When the dust level bring the rotor to a complete stop the voltage across the resistor rise but the current is low enough to not burn the motor.

Are you sure? yes | no

EcPc wrote 12/22/2016 at 03:37

I never thought about that it's a good idea. I think that would work perfectly. Frankly, I went in the direction of things i didn't know how to do. Using i2c and digital communication at a very low level was one of them so perhaps I'm over complicating it. I'm a mech guy by degree so even using the arduino library gets me lower than i typically would.
Where I work we use motor current draw to determine various different states of an electromechanical actuator and it's a very reliable, solid method. Motors are easily modeled too so that helps.

Are you sure? yes | no

zakqwy wrote 12/20/2016 at 18:10

Interested to see how the optical sensor works in a dusty environment; dust is often the downfall of laser-based measurement systems, hence most of industry resorting to radar-based solutions.

One thought -- have you considered piezoelectric sensing in the actual dust lines? iRobot does something like this with some Roomba models to detect heavy dirt areas; essentially, you plop a piezo disk at a sharp angle in the dust path, and then run the output through some fancy signal processing system to figure out when the dust isn't present.

Are you sure? yes | no

EcPc wrote 12/20/2016 at 19:52

The dust hopper I'm hoping to detect debris in is at the bottom of a cyclone system and sort of "dead headed" There isn't a large quantity of flow in it, so my hope is that the dust just falls and my sensor being set on the lid shouldn't collect much. We'll see what happens. I saw a commercial solution doing a similar thing with an optical sensor so I'm fairly confident it should work. Instead of buying the turnkey solution I'm hoping to improve upon it by adding the filter monitoring and get some coding/arduino experience in the process.
Check this link out.
http://www.oneida-air.com/pdf/dust-sentry-installation-sheet-2016.pdf

Sensing in the dust lines is not something I've considered mostly because its not something I would be able to easily take action on. The startup current on the impeller is so large they indicate that you should not exceed a certain amount of starts per hour.

I could do something like that via actively controlling blast gates but they're not installed or built yet. It is something to consider though and perhaps it could operate as such.

1. Turn on system. Wait for impeller to reach speed.

2. All blast gates open by some predetermined amount to allow some fixed amount of flow through the system. Start monitoring dust sensors.

3. Dust count is driven up at certain station. That blast gate is opened 100% and others are trimmed back.

This would be good as a sort of reactive system that would help circulate air and accommodate stations without a specific power tool such as downdraft tables and floor sweeps. The stationary tool stations such as disk sanders and table saws probably should be actively triggered for maximum capture.

Are you sure? yes | no

zakqwy wrote 12/21/2016 at 16:35

Makes sense -- I hadn't heard of the Dust Sentry, seems like a good call to follow that design concept. Looking forward to seeing how this works!

Are you sure? yes | no

PointyOintment wrote 01/22/2017 at 05:07

> essentially, you plop a piezo disk at a sharp angle in the dust path, and then run the output through some fancy signal processing system to figure out when the dust isn't present.

Similar to a QCM?

Are you sure? yes | no

Dust Collection System Monitor

Description

Files

i2cIR.ino

pressureInput.ino

gp2y0e03_e.pdf

Components

Project Logs

Collapse

Ordered the PCB

Learning Eagle: First PCB

Engineer wife buys engineer gifts. Dust Particle Sensor

Automated Startup and Sleep - Ideas?

GP2Y0E03 + i2c + Arduino

Pressure Sensor Test

Notes on GP2Y0E03 usage

Discussions

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Description

Files

i2cIR.ino

pressureInput.ino

gp2y0e03_e.pdf

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