63 lines
3.6 KiB
Markdown
63 lines
3.6 KiB
Markdown
# CNC Water Flow Controller
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A fail-safe water flow monitoring module designed to protect CNC spindles and laser cutter tubes. It reads impulses from a ZJ-S401 water flow sensor, displays the real-time flow rate on an I2C OLED display, and triggers an active-low alarm to the CNC controller if the flow drops below a user-defined threshold.
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Designed in **KiCad v9**.
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## Table of Contents
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1. [Features](#features)
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2. [Hardware Design (KiCad)](#hardware-design-kicad)
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3. [Panel Design and GCode](#panel-design-and-gcode)
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4. [Microcontroller Pin Mapping](#microcontroller-pin-mapping)
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5. [Firmware Logic](#firmware-logic)
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6. [Firmware Build & Flashing](#firmware-build--flashing)
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## Features
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* **Microcontroller:** WCH CH32V003J4M6 (RISC-V).
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* **Display UI:** 8-pin connector for a custom OLED/Button panel (I2C SSD1315).
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* **Adjustable Threshold:** 2-button interface (Up/Down) using an analog resistor ladder (ADC) to save MCU pins.
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* **Fail-Safe Output:** N-channel MOSFET (2N7002) acting as an open-drain output. It actively pulls the CNC input to GND during normal operation. If power fails, wires break, or water stops, the connection opens and triggers the CNC alarm.
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* **EMI Protection:** Hardware RC debouncing and noise filtering on the sensor input.
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* **Direct 5V Operation:** Powered directly from the CNC controller's 5V rail.
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## Hardware Design (KiCad)
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* **Power:** 5V DC Input (via CNC connector J4).
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* **Sensor Compatibility:** ZJ-S401 Water flow sensor (plastic valve body, a water rotor and a hall-effect sensor). See [the working principle of the hall water flow sensor](https://www.seeedstudio.com/blog/2020/05/11/how-to-use-water-flow-sensor-with-arduino/).
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* **Output:** 3-pin CNC interface (+5V, GND, ALARM_CNC). Connects directly to standard CNC active-low sinking inputs.
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## Panel Design and GCode
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The [scripts](scripts) folder contains a guide to panelize the board (`Flow_Controller_Panel.kicad_pcb`) and howto generate gcode.
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## Microcontroller Pin Mapping (Per Schematic)
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| Pin | Schematic Net | Function | MCU Port (SOP8) |
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| :--- | :--- | :--- | :--- |
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| 1 | `FLOW_PULSE_MCU` | Input: Pulse counter from Flow Sensor | PD6 |
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| 2 | `GND` | System Ground (VSS) | VSS |
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| 3 | `ALARM_TRIGGER` | Output: Drives the Gate of the 2N7002 | PA2 |
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| 4 | `+5V` | System Power (VDD) | VDD |
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| 5 | `I2C_SDA` | I2C Data (OLED Display) | PC1 |
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| 6 | `I2C_SCL` | I2C Clock (OLED Display) | PC2 |
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| 7 | `BUTTON_ADC` | ADC Input: 2-Button Resistor Ladder | PC4 |
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| 8 | `SWIO` | WCH-LinkE Programming Interface | PD1 |
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## Firmware Logic (Overview)
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1. **Interrupts:** Pin 1 (PD6) counts falling edges from the flow sensor. Flow (L/min) is calculated every second.
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2. **Failsafe:** If `Current_Flow >= Threshold`, Pin 3 is driven **HIGH** (MOSFET ON, CNC OK). If `Current_Flow < Threshold`, Pin 3 is driven **LOW** (MOSFET OFF, CNC Alarm).
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3. **UI:** ADC reads Pin 7 (PC4) to detect button presses for adjusting the threshold.
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4. **Storage:** User-defined threshold is saved to MCU flash memory.
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## Firmware Build & Flashing
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The firmware is written in C using the lightweight `ch32fun` framework. All source files and toolchain documentation are located in the `firmware` folder.
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**Step-by-step Setup:**
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1. Follow the setup guide in [`firmware/Readme.md`](firmware/Readme.md) to install the RISC-V GCC toolchain and `minichlink`.
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2. Connect your **WCH-LinkE** programmer to the 3-pin SWIO header `J1` (+5V, SWIO, GND).
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3. Run `make` to compile the firmware.
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4. Run `make flash` to upload the code to the CH32V003 microcontroller. |