Dust collection automation

[GPowers]

Finally got back to my Dust Collection Automation project.  I wanted to be able to turn on any of my woodworking equipment, that is connected to the dust collection cyclone and have the following happen:

When turning on equipment:
1. Automatically open the blast gate
2. turn on the dust collector, If it is not already on

When turning off equipment
1. Automatically close the blast gate
2. wait 15 seconds and turn off the dust collector if all blast gates are closed

To do this I decided to use:

1.  Arduino Mega
2.  Prototype Screw/Terminal Block Shield Board Kit for Arduino MEGA
3.  LCD color touch screen
4.  Current sensing relays
5.  12 volt Relay board with 16 relays
6.  Pneumatic cylinders to open/close the blast gates
7.  3 Position Solenoid Valve 1/8 Air Outlet Connector 12V 2.5W
8.  IDC20 2x10 Pins Male Header Breakout Board
9.  Terminal block connectors on DIN rail
10. 12 volt power supply

Below is the electronics on a test bed and a photo of The pneumatically controlled blast gate as I fabricate all the required aluminum brackets.

I plan on automating 6 blast gate the first go round more later.

[attachimg=1]
[attachimg=2]

 

[ERG]

I'm interested...

 

[Bob D.]

Interesting, how do you plan to connect the actuator to the gate?
Looks like a two-way actuator, are you concerned that the shaft will flex when opening/closing.
Will you be using solenoid valves to operate the actuators. Might be easier to use a spring to close the gate and air to open only. Then just energize the solenoid for air to open and when you de-energize the solenoid the actuator would be vented to atmosphere and the spring would close the gate.

 

[GPowers]

Interesting, how do you plan to connect the actuator to the gate?

Either way you still need a pneumatic solenoid. I chose to use a dual action cylinder and an  A/B ported solenoid I found on Amazon for under ten dollars. The previous one I was testing with, were similar and over $30.

The pneumatic cylinder is attached to the gate with a piece of all thread that is bolted on to the gate and a short length of aluminum angle that is then bolted to the cylinder. see photo below. 

[attachimg=1]

 

[Peter_C]

It would be interesting to see the cost savings vs purchasing an automated system.

Pretty dang cool the OP built it themselves!

 

[GPowers]

It would be interesting to see the cost savings vs purchasing an automated system.

Pretty dang cool the OP built it themselves!

Here is my best guess

Each blast gate need:
Air solenoid .............. 9.00
Pneumatic Cylinder....15.00
Current sensor .........17.00
Misc hardware ..........15.00

Total    $56.00 per blast gate

The System control center
Arduino mega ...............14.00
Relay board (16 relays)...15.00
Touch screen ................16.00
Misc hardware ...............20.00

Total $65.00 for control unit

Dust collector
Current sensor ............17.00
Misc hardware .............20.00

Total $37.00 for dust collector

6 blast gates      141.00
Control center        65.00
Dust Collector        37.00

Total $243.00 for a 6 tool system

Commercial product
6 Blast gates (Plastic)  ................ 606.00
Dust collector box .......................  70.00
6 Power sensors  ........................ 360.00

Total  $1,036.00 for a 6 tool system

 

[Svar]

Total  $1,036.00 for a 6 tool system

Have you considered iVac Auto Dust Collection Pack? It's wireless and is cheaper.

 

[GPowers]

Total  $1,036.00 for a 6 tool system

Have you considered iVac Auto Dust Collection Pack? It's wireless and is cheaper.

The $1000 system above is the iVac system.

Besides I'am all in with my system. All the parts have been purchased and the brackets have been fabricated.

Version two might be a system using the ESP8266 WiFi module at each blast gate.

 

[junk731]

Good job on the design Greg. Whether going with your solution Greg or the IVac system a couple of price points were missed. Having power available at every station and in Greg's scenario having air available at every station is also a heavy cost consideration not factored into the price comparison. Also the cost to manufacture the homemade solution is not factored in. I've considered both systems in the past and will probably go for the IVac solution in my situation for the simplicity and speed on install. Sometimes what appears to be a less expensive option turns into the same cost when all the factors are put together especially in a production shop. The hobby guy can write the time off not so much for those of us making a living and spending too time in the shop already.

 

[GPowers]

In my case I’m a hobbyist and enjoy the project of building and programming the automation. Getting compressed air to each location is very easy using a 6 mm tube and inexpensive. My tubing cost only 20 dollars for entire system. This  assumes you already have a compressor of some type. And the cost of 6mm tubing is included in my estimate above.

 

[Russty]

i looked at doing something like this when i set up my new workshop last May, all seemed a bit too complicated, expensive and pointless to have automatic blast gates. i ended up just putting a micro switch on each blast gate which closes a 12v loop to a breaker which turns the extractor on. takes all of one second to open a blast gate every time i turn a machine on, ok i have to go looking for rogue open blast gates when im hopping between machines but it isnt a huge shop (about 110 square meters). i guess it starts to make sense to have auto blast gates in larger shops with multiple people using machines. I appreciate its an interesting project though, i never thought of using pneumatic actuators, good idea that.

 

[Midnight Man]

Each blast gate need:
Air solenoid .............. 9.00
Pneumatic Cylinder....15.00
Current sensor .........17.00
Misc hardware ..........15.00

Total    $56.00 per blast gate

6 blast gates      141.00
Control center        65.00
Dust Collector        37.00

Total $243.00 for a 6 tool system

Commercial product
6 Blast gates (Plastic)  ................ 606.00
Dust collector box .......................  70.00
6 Power sensors  ........................ 360.00

Total  $1,036.00 for a 6 tool system

I think I found a small math error in your cost listings?

If each blast gate is $56, then 6 of them come to $366.

$366 + $65 + $37 = $468.

Still a large saving off the commercial product, and you have me very interested, thank you for posting this!

 

[mattbyington]

How'd this turn out?

Matt

 

[GPowers]

How'd this turn out?

Matt

I have been using the Arduino based system for a few weeks. So far is has been working great. It is very convenient too just turn on a machine and have the blast gate open and the dust collector turn on.  I had to add a few tweeks to the software, but that is part of the fun.

 

[Jaco77]

Hey Creg,

I am looking to do the same system with servo motors on blast gates...Do you have any wiring drawing that you can share/provide I have to see a drawing in order to stay focus... and try to make the wiring , have you installed your Relay Modules in the different outlet boxes?

Would you be kind enough to have a look , if I suggest to you a wiring drawing for my installation I am a bit in the dark here.

Many thanks

Ray 

 

[askorcal]

Awesome work! I have been designing my own system with an Arduino - and you have made me re-consider my choice of Electronic. I had no idea the pneumatic set up could be so affordable. I think I even have a relay board laying around somewhere. Do you share your code anywhere? If not that's ok, but if so let me know!

 

[askorcal]

Sorry - that was reconsider electronic *servos. Your pneumatic system seems much more robust. 

 

[GPowers]

Here are three more photos of the installation.

The first picture is the blast gate and solenoid assembly.

The second photo shows the plumbing of the solenoid that is bolted to the blast-gate. The brass fittings are the exhaust brake. They are used to control the closing speed of the blast gate.

The third picture is the system electronics mounted to a back board.

[attachimg=1]

 

[GPowers]

Below are some screen shots of the very simple LCD screens:
[attachimg=1][attachimg=2][attachimg=3][attachimg=4]

 

[Cheese]

Very interesting Greg…I like the system feedback from the LCD.