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I finally found the real cause.

Today i got the amplifier fault on another joint (joint 0) and I found that it the problem happened whenever I turned on the spindle.

After several attempts to measure the ground connections the machine stopped in a position where I found the machine frame was not grounded.

The reason: The spindle connector got loose. The machine frame was grounded through the spindle cable, and that cable had become loose.

All I had to do was tighten the screw of the connector. Ground connection works reliably again and the machine runs well. Phew.

So, has there been any progress on getting this sensor to market? 

I'm trying to get a laser machine built, but, this is one of the toughest issues I'm facing.  I have a MESA 7i76EU that I have been trying to interface a BCL-AMP output to.  I have the BCL-AMP connected to a Raytools BT210S002A cutting head sitting on the bench with a chunk of steel in front of it and grounded to the case of the Raytools cutting head.  Between the BCL-AMP and the 7i76EU, I have a TI SN74HCS74DR dual Schmidt Trigger Flip Flop that I'm using to divide the BCL-AMP output frequency by 2 and "clean it up" at the same time.  However, it's just not very stable.  The velocity measured by the 7i76EU jumps around about 600-700 hz.  The velocity range only seems to be around 6500 hz from 0-10mm (3/8") sensing distance, so, my positional sensitivity sucks at around 0.1 inches.  Just for giggles, I ran the signal through 4 Flip Flops to see if the 'jumping around' would decrease.  It didn't.  Which leads me to believe the instability is introduced somewhere in my circuitry or wiring.  I even tried connecting Q and Q not outputs into the MESA card as differential signals and twisted the wires.  No help.

Anyhow, This CV2 height sensing device sounds very promising.  

Based on what im reading, it does seem ill need a larger card to handle all the limit switches and 3 encoders, one for each hand-wheel. I will prob go RJ45 as the parallel ports are less and less these days.

Thinking this guy, not cheap but one stop shop correct?
store.mesanet.com/index.php?route=produc...id=399&search=7I76EU