For some time we have just been setting the Z-axis height by touch or using the old "piece of paper" trick. So we decided to upgrade and buy one of these cheap ebay tool touch sensors with the idea of connecting it to the mach4 software to perform z-height calibration automatically.
Although we found a problem. The touch block had no give or spring in the design so a simple push of the z-axis too far would drive the tool down into the device and destroy the tips.
So I can up with the concept below. Essential to use the lathe to make a few simple parts that allowed a touch sensor with a pre-loaded spring to allow for some movement during tool contact.
After turning and installing the electrical contact below.
First test run with a 9v battery and an LED strip light.
A slight refinement by packaging the unit together. This is now a stand alone unit that can be placed at the opposite end of the table to the computer, while I calibrate the z-axis and just watch for it to light up. So far it has been repeatable to within ±0.04mm in the same setup.
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