firmware-base/docs/Extruder.md

title	description	keywords
Extruder Component	Documentation for the Extruder component which manages VFD-controlled extrusion with joystick and potentiometer control	extruder, VFD, joystick, potentiometer, torque monitoring, jam detection

Extruder

Path: src/components/Extruder.h

Revision History: Initial documentation

The Extruder component provides control over a SAKO VFD-driven extruder motor. It supports both manual and automatic extrusion modes, with configurable speed and overload protection via potentiometers. The component integrates with a joystick for manual control and features jam detection based on motor torque feedback.

Requirements

Hardware

• SAKO VFD (Variable Frequency Drive) for motor control
• Joystick for manual control (optional)
• Potentiometer for speed control (optional)
• Potentiometer for overload threshold control (optional)

Pins

• No direct pin requirements (manages components that have their own pin requirements)

Features

• Dual operating modes: manual (joystick-controlled) and auto (timed operation)
• Configurable extrusion speed via potentiometer
• Adjustable overload/jam detection threshold
• Automatic jam detection based on motor torque feedback
• Modbus TCP interface for remote control and monitoring
• Safety features including maximum runtime limits
• Auto-mode activation via joystick hold

Dependencies

• Component - Base component class
• SAKO_VFD - VFD motor controller
• Pos3Analog - 3-position analog input (joystick)
• POT - Potentiometer interface
• ModbusTCP - Modbus interface

graph TD
    Extruder --> Component
    Extruder --> SAKO_VFD
    Extruder --> Pos3Analog
    Extruder --> POT
    Extruder --> ModbusTCP

Behaviour

The Extruder component implements a state machine with the following states:

stateDiagram-v2
    [*] --> IDLE
    IDLE --> EXTRUDING_MANUAL: Joystick UP
    EXTRUDING_MANUAL --> EXTRUDING_AUTO: Hold joystick UP for set duration
    EXTRUDING_MANUAL --> IDLE: Release joystick
    EXTRUDING_AUTO --> STOPPING: Auto time complete or manual stop
    EXTRUDING_MANUAL --> JAMMED: Torque exceeds threshold
    EXTRUDING_AUTO --> JAMMED: Torque exceeds threshold
    STOPPING --> IDLE: VFD stopped
    JAMMED --> RESETTING_JAM: Reset command
    RESETTING_JAM --> IDLE: Reset complete

TODOs

Performance

• Consider implementing acceleration/deceleration ramps for smoother operation
• Optimize VFD polling frequency based on system requirements
• Evaluate the potential for predictive jam detection using torque trend analysis

Security

• Implement authentication for Modbus commands that control the extruder
• Consider adding physical emergency stop integration
• Validate input values from potentiometers to prevent unexpected behavior

Compliance

• Ensure conformance with industrial safety standards for automated machinery
• Implement proper error handling and logging for diagnostic purposes
• Consider adding UL/CE compliance features if required for deployment environment

Recommendations

• Add temperature monitoring to prevent motor overheating
• Consider implementing a material feed sensor to detect material availability
• Implement a maintenance tracking system based on operation hours
• Add visual feedback (e.g., LED indicators) for different states, especially jammed condition

Example

The following example shows how to create and configure an Extruder component:

#ifdef ENABLE_EXTRUDER
  // First ensure required components exist
  if (sakoVFD && joystick && speedPot && overloadPot) {
    extruder = new Extruder(
      this,             // owner
      sakoVFD,          // VFD controller
      joystick,         // joystick for manual control
      speedPot,         // potentiometer for speed control
      overloadPot       // potentiometer for overload threshold
    );
    
    if (extruder) {
      components.push_back(extruder);
      Log.infoln(F("Extruder initialized"));
    } else {
      Log.errorln(F("Extruder initialization failed"));
    }
  } else {
    Log.warningln(F("Extruder not initialized - missing dependencies"));
  }
#endif

References