Automated Vacuum Switch : 6 Steps

Automated vacuum cleaner is device which automatically turns on the cleaner when you turn on e.g. power drill, angle grinder, saw etc.

You can find automated switches inside pro vacuum cleaners but I wanted to create my own with implement more features into it and use it to switch not only cleaning devices but also other devices in many various applications.

AVC has two power outlets and one plug. After connecting Controlled device e.g. Vacuum cleaner into outlet further away from cable and Controlling device e.g. power drill into outlet closer to the cable, connect power cord to the mains power supply.

Step 1: Warning

* Please be aware that this project contains working with HIGH Voltages. Be careful while making this project and if you are not sure about what you are doing you should always ask certified electrician to help you !!!

** I do not take any responsibility for possible damages !!!

*** Be aware that any unprofessional handling with high voltage can harm your health and even kill you !!!

Step 2: BOM

Printed parts

1. Main Box
2. Box Cover
3. Logo (Can be anything. I chose kaercher log since I have kaercher vacuum cleaner and wanted it to look alike. ;))

Electronics

1. Relay (250 VAC - 5V - SPST)
2. Current Sensor (ACS 712 - 30A)
3. Control board (Arduino, ESP, Raspberry etc.) I would recommend using Arduino since it is simplest method. I have used ESP because I plan on connecting it to Wi-Fi and adding more features in future.
4. 2 PCS - power outlet. May vary depending on the type of plug you are using
5. Power cord with plug. I would recommend using flexible wire.
6. Wago terminal block 4pin or equivalent
7. 5V 1A power supply

Fasteners

1. 10 M4x15mm screws
2. 10 M4 nuts
3. 4 M3 threaded inserts - for Box Cover plate
4. 4 M3x8 mm screws
5. 2 M4x12 mm washers

Mechanical / other

1. Strain relief connector for power cable
2. Climbing webbing strip or any strip suitable for holder 20x1.5x200 mm
3. Faston crimp connectors

Step 3: Printing Parts

All parts were printed on PRUSA i3 MK3S+

I have printed all parts in PLA but other materials can be used as well. Especially if you want to use it at work it would be better idea to print from more durable filaments.

No supports nor brim are needed if you have correctly calibrated printer.

And I also experimented with ironing function for logo plate which added more clean look afterwards.

Printed at these settings:

Rafts: No
Supports: No
Resolution: 0.20 mm
Infill: 15 %
Filament brand: PlastyMladec
Filament color: Yellow and Black
Filament material: PLA

Step 4: Mechanical Assembly

1. Push M3 inserts inside the box
2. Attach holding strip using M4 screws and nuts
3. Attach power outlets.
4. Connect power cord with strain relief.
5. Connect all wires according to the schematic.
6. Make sure everything is glued and won't move around.
7. Upload SW to Arduino or your microcontroller.
8. Close the lid and test device.

* Please note that I will not upload schematic since this is very dangerous and should be done only by certified electrician and you should only make it when you are fully aware of what is going on and how it is working.

Step 5: Software

Basically our code is checking for any current rise which is indicated by current sensor. After current spike we save current time and immediately turn on the controlled device e.g. vacuum cleaner and wait for the current to drop which means that we have turned off the controlling device.

After that we will wait for 5 seconds (this value can be replaced in code) before turning off relay again. This gives us time to vacuum remaining dust after work.

I would like to thank my friend Samuel for providing us this code.

AutoShopVacSwitch.ino

/// *****        © ShopVacSwitch        ***** ///
///      Automated Vacuum Cleaner Switch      ///
///      Current sensor type: ACS 712-30      ///
///                                           ///
///         Last updated on 1/20/21           ///
///                                           ///
/// *****         Code by Jacob.        ***** ///
#defineSAMPLES300
// Change this values according to which pins ou have connected.
#defineSENSOR_Pin A0
#defineRELAY_Pin D0
// Change this value to increase or decrease delay until turning off. Value must be in millis e.g. 5000 = 5 seconds
constint delayTime = 5000;
#defineRELAY_On LOW
#defineRELAY_Off HIGH
float High_peak,Low_peak;
float Amps_Peak_Peak = 0;
unsignedlong currentMillis, lastMillis;
voidmeasureCurrent();
voidsetup() {
    Serial.begin(9600);
pinMode(SENSOR_Pin, INPUT);
pinMode(RELAY_Pin, OUTPUT);
digitalWrite(RELAY_Pin, RELAY_Off);
}
voidloop() {
measureCurrent();
if (Amps_Peak_Peak >15.00) {
digitalWrite(RELAY_Pin, RELAY_On);
        lastMillis = millis();
    } else {
        currentMillis = millis();
if (currentMillis - lastMillis > delayTime) {
digitalWrite(RELAY_Pin, RELAY_Off);
        }
    }
}
voidmeasureCurrent() {
int cnt;
    High_peak = 0;
    Low_peak = 1024;
for(cnt = 0; cnt
float ACS_Value = analogRead(SENSOR_Pin);
if(ACS_Value > High_peak)
            High_peak = ACS_Value;
if(ACS_Value < Low_peak)
            Low_peak = ACS_Value;
    }
    Amps_Peak_Peak = High_peak - Low_peak;
}

view raw AutoShopVacSwitch.ino hosted with ❤ by GitHub

AutoShopVacSwitch.ino
Download

Step 6: Finish

I have planned on making such device for a long time now and I am very satisfied with the final result. This is only first version and I will be improving it in no time.

I have found it very useful as I am also certified electrician and I use it all the time at work while drilling or cutting something.

Please do not hesitate to contact me if you want any additional information about the process.

The design files are published as-is, CC-0 / no rights reserved. Attribution when used would be nice, but is not required ;)

Happy printing and developing ;)

Jacob.

Introduction: Automated Vacuum Switch