Opto Endstop v1.0

Overview

Darwin’s Cartesian axes all need a datum (also known as home position or end-stop) to reference their movements. At the start of each build each axis needs to back up until the datum point is reached. For Darwin, we use one opto-switch for each axis to define its position. This page tells you how to wire one up to a bracket used in Darwin’s design (below).

You will need 3 (three) of these for a basic RepRap machine, and 6 (six) of them for a full machine with both home and end stops.

For those using the ZD1901 opto interrupter prevalent in the Southern Hemisphere, a simple stripboard assembly is required. Details here.

• You'll need a soldering toolkit to do most of this.
• Read our Electronics Fabrication Guide if you're new.

Get It!

Full Kit

• Buy the full kit from the RRRF (PCB + components)

Raw Components

• Buy this PCB from the RRRF
• Buy the components with ease w/ parts.reprap.org

Files

You can download the electronics files from Sourceforge. This zip file contains the Kicad source files, PDF's, as well as the GERBER files you can use to build it yourself (or have it manufactured).

Schematic

Interface

Build It

Board Bugs (listed by version)

v1.0.0

• You will need to drill the mounting holes out to 3mm diameter.

v1.0.1 and beyond

• None yet!! Please report any bugs you encounter in the forums.

Printed Circuit Board

You can either buy this PCB from the RepRap Research Foundation, or you can make your own. The image above shows the professionally manufactured Opto Endstop v1.0.0 PCB ready for soldering. Its also cheap, only $0.75 USD.

Components

Soldering Instructions

R1

Resistors can be inserted in any orientation.

R2

Resistors can be inserted in any orientation.

HIL01

This is the opto switch. It will only fit in one orientation. Insert it as far as you can.

Wires

Since the Opto Endstop board essentially plugs into a stepper controller board, the easiest way is to solder the connector wires directly to the Opto Endstop PCB, and then attach a connector to the end of those wires. You will need:

• 3 wires each of different color, about 2 feet long (an old ethernet cord works well for this purpose.)
• a 3 pin, .100" pitch connector housing
• some crimp on connectors

First, strip the ends of each wire. Then you twist the ends of each wire to a point, and tin the ends with a tiny bit of solder. Insert the ends into the hole in the pcb, and solder the wire to the PCB. Take care not to have any strands of the wire cross over to the other soldering points. If this happens, use a knife or tiny screwdriver to break the connection.

Test It

Now that you've built your board, its time to test it. You can easily do so before attaching the PCB connector by plugging the wires directly into an Arduino.

Wire it up!

Connect the wires below to the specified pins on the Arduino.

Program your Arduino

Copy and paste the code below into your Arduino program. Upload the program to the Arduino, and in a few seconds it will start. Once it has uploaded, open the Serial Monitor. The program will continuously notify you of the status of the opto endstop.

Once its running, simply take a piece of paper, or other flat object and stick it between the upright parts on the endstop. Keep an eye on the terminal and if you wired everything up correctly, it will tell you whether the endstop is open or blocked.

#define ENDSTOP_PIN 2

void setup()
{
   pinMode(ENDSTOP_PIN, INPUT);

   Serial.begin(9600);
   Serial.println("Starting opto endstop exerciser.");
}

void loop()
{
   if (digitalRead(ENDSTOP_PIN))
      Serial.println("blocked.");
   else
      Serial.println("open.");

   delay(500);
}

Attach PCB Connector

Now that you've tested your endstop, you will need to crimp on a connector to the end of the wires. This can be tricky, but it is infact do-able with the proper tools (small needle nose pliers, steady hands, patience.) After you have successfully attached connectors onto each wire, insert them into the connector housing as shown below. It is important to get the order right, as the connector must be attached to the board in the proper orientation.

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