YA-WV-V0.8

Encoder-Based Wind Vane

This wind vane achieves a directional resolution of 22.5° using optical encoder disks. The optical sensors (fork-type couplers) are reclaimed from discarded or defective inkjet printers.

The primary objective of this model is to make the operating principle of absolute encoders, as used in precision motion systems, easier to understand in an educational context.

The system implements a 4-bit absolute encoder, providing 16 discrete positions, which corresponds to an angular resolution of
360°/16=22.5°360° / 16 = 22.5°360°/16=22.5°.

The most challenging aspect of the design is the precise alignment of the encoder disks. Alignment is achieved by inserting a key through the disk keyholes; once positioned, the protruding portion of the key is removed.

A small PCB is mounted in the lower part of the vane to simplify wiring during testing and programming (note: soldering quality is not representative). Wiring is routed through the lower cap, and a PG7 cable gland is installed in the dome to provide strain relief.

3D-Printed Parts

• BearingEndCap – Lower cap holding an additional 608ZZ bearing to improve smooth rotation of the M8 shaft

• Dome – Encapsulates the electrical connections between sensors and external wiring; includes a 12.5 × 1.27 mm thread for PG7 cable glands

• BearingCap – Secures the upper 608ZZ bearing against the bearing housing

• Housing_Bearing – Upper bearing mount and protective cover

• Spacer – Required only if nut thicknesses differ

• EncoderKey – Alignment key for the encoder disks

• Encoder_diskA – Encodes π (180°)

• Encoder_diskB – Encodes π/2 (90°)

• Encoder_diskC – Encodes π/4 (45°)

• Encoder_diskD – Encodes π/8 (22.5°)

• Sens_housing – Outer shell and mounting structure for the optical sensors

• WindVane – Main vane body

• WindVane_Tip – Aerodynamic tip to improve directional alignment

• Clamp_mount – Mounting clamp compatible with standard camera mounting systems

Material

• Encoder disks and alignment key: Black PLA

• All other parts: White ABS

Printing Parameters

• Layer height: 0.2 mm

• Nozzle diameter: 0.4 mm

Hardware Components

• M8 × 100 mm hex bolt or threaded rod

• Multiple M8 nuts

• 2 × 608ZZ ball bearings

Electronics

• 4 × fork-type optical couplers (e.g., EE-SX1041; required slot size: 14 mm × 6 mm)

• 4 × 220 Ω resistors

• Wiring as required

Arduino Code

The Arduino source code will be published once it meets the desired quality and documentation standards.

Assembly 

• Install the wind vane onto the M8 bolt and align the top opening with the bolt head.

• Add an M8 hex nut and tighten it against the vane to secure it in position (counter-tighten if required).

• Install a second M8 hex nut to act as a spacer.

• Mount the upper bearing housing including the bearing onto the shaft.

• Install the bearing cap to retain the bearing within the housing.

• Add another M8 hex nut to clamp the vane assembly to the bearing.

• Attach the sensor housing. Fix the bearing housing to the sensor housing using super glue or acetone.

• Wire the optical couplers (schematics will be provided in a future revision).

• Secure the optical couplers inside the sensor housing using hot glue. The vertical position must be adjusted according to the encoder disk height.
  This step requires careful adjustment and is the most critical part of the assembly.

• Once all four sensors and encoder disks are correctly installed, route the wires through the lower bearing end cap.

• Insert the lower bearing and snap-fit the sensor housing closed.

• Connect the sensors to the supply wiring, or alternatively use a small PCB as shown in the reference images (a dedicated ESP-based PCB may be designed in a future revision).

• Close the assembly with the dome, securing it with super glue or acetone.