Optical Filament Sensor v2.1 with Drive Gear - for 1.75mm filament

This is version 2.1 of my previous design. It was prepared in cooperation with @dragonn
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updated January 3, 2022

Description

PDF

Comparision between versions

On the pictures you can see designed versions of sensor. All are printed in draft mode. From left V1.0, V2.0, V2.1

Bom

  • 3x 619/5 bearings
  • spring (I used one from a ballpen)
  • end stop optical sensor
  • MK8 drive gear
  • M5x16 shaft - you could cut M5 bolt
  • M3x40 - for idler tension
  • M3x20 - for mounting idler to body
  • M3x10 - for optical sensor mount
  • M3 nut
  • M5x35 (M5x30 should also fit)
  • M5 nut

 

Assembly

 

Source

https://cad.onshape.com/documents/bc431172d582a5a54b3b58ac/w/c4ffc497b40e3855d881f07f/e/8e35b674b9538da00cfbcf5f?renderMode=0&uiState=61d3477ddf0e5e300b92c53c

 

Calibration.

General good information how to calibrate this sensor is here https://duet3d.dozuki.com/Wiki/Duet3dFilamentMonitor_RotatingMagnetVersion#Section_Calibration

 

Sensor is supported by:

RepRap firmware -  https://duet3d.dozuki.com/Wiki/Duet3dFilamentMonitor_RotatingMagnetVersion

smoothieware - http://smoothieware.org/filament-detector

Marlin - find in configuration.h FILAMENT_MOTION_SENSOR

Klipper https://www.klipper3d.org/Config_Reference.html?h=filament#filament_motion_sensor - note that klipper required filament change between two high states so calculation is  value = 21mm / (tooth_no) * 3 (mm per status change) - multiple by 3 to increase accuracy and lower mean error

 

Calculation of value.

To calculate use formula

value = 21mm / (tooth_no *2) (mm per status change)

 

Example for klipper:

[filament_motion_sensor filament_sensor]
detection_length: 1.43181818182
extruder: extruder
switch_pin: ^PD10
pause_on_runout: True

Example for RRF:

For my configuration with 44T wheel I used this command:
M591 D0 P7 C"e0stop" S1 R50:800 L0.239 E2.64 A1

Example output of checks:

M98 P"0:/macros/Extruder/Check filament sensor"
Pulse-type filament monitor on pin e0stop, enabled, sensitivity 0.528mm/pulse,
allowed movement 50% to 800%, check every 6.3mm, measured sensitivity 0.566mm/pulse,
measured minimum 89%, maximum 101% over 1259.5mm

Those values have some offset due to fast printing with a lot of retraction and enabled PA. 50% is a margin when hot end get clogging. Also could be increased to get it faster.

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