Early Warning Filament Low Sensor
thingiverse
<body>This sensor gives you an early warning when your filament reel is starting to run low. It can be used on its own or with a filament runout sensor and does not require any modifications to the printer. It avoids aborted prints or having to change a spool mid print. Some cardboard and most big plastic reels have closed sidewalls making it difficult to see how much filament is left over, sometimes we just get distracted and don’t pay attention…</body> ##Design Features## - Stand-alone, battery powered audible alarm - Adjustable sensor does not tangle filament - Multiple mounting options - On/off switch and separate test button - Very simple circuit - Uses common mechanical and electronic parts - Simple prints with few supports and easy clean-up ##Print and Assembly## - Uses a 608 bearing that’s open or shielded (ZZ), but not sealed (RS/2RS) - Feed the wire through the arm’s slot before adding the end protectors - You MUST attach the arrow and protector to the ends of the wire for eye protection - Use a washer on the M3 screw in front and behind the test button and make sure it moves freely - The arm can be L or U-shaped, the latter makes it easier to set up - Make the arm from coat hanger wire or 2.0-2.5mm brass, etc.; bend squarely and with small corner radius for long (sensor finger) to be 160mm, cross-member 60mm, and whatever is left for the front arrow indicator side - some of this will depend on your particular printer so use your judgement to optimize it - There are three versions of the arm holder: with an M3 threaded insert (strongest), with a drop in M3 nut, or a tapped M3 hole (weakest) - The buzzer has polarity, so test it before soldering - Leave enough wire on the battery contacts so you can replace the battery - Wiring is one big happy loop going from the battery to the on/off switch, to the micro switch, to the buzzer, and back to battery. ##Use## - Bolt the sensor to the printer where the arm can swing all the way to the filament reel’s hub (using M4 x 10 or 12 cap screws with drop-in/T-nut) - Adjust the forward/backward position of the arm so the front arm clears any mounts, and the back arm is comfortably inboard the reel - Adjust the arm to about a centimeter above the hub – it’s okay to just eyeball it, we’re not looking for great precision, just a “change this reel before the next print” warning - Don’t forget to switch it on and test the battery every time. <br /> <hr /> <body> Check out more designs from <a href="https://www.thingiverse.com/department_nine/designs/" title="D9"> Department_Nine</a>!</body> <hr /> <br /> <br /> ##NOTES## <body>This was one of those ideas that's been floating in my head for a long time and I finally got around to doing it. Sometimes in the heat of the moment, rushing through some prints, the filament-out sensor would go off and then it's always a bit ticklish replacing the spool mid-print and there is always an artefact on the print. This early-warning sensor let's me know in plenty of time - before starting the next print - if the reel needs replacing or I've got to buy more. The look of it is very functional, no-fuss utilitarian, but still has a bit of personality.</body>
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