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stkvit wrote:

I converted the bcl-amp output to a differential signal (max485), at a long length it works much more stably and reliably. You should do the same (I understand that your frequency is linear and depends only on the height). A couple more questions, your sensor have temperature stabilization?

I was thinking about differential signals and if there is such a need I will introduce them, we will see after the tests. There was only one obstacle - I wanted to leave the size of the device exactly like most BCL type sensors so that it would fit perfectly in the place designated for it. I did not find a suitable connector convenient to use to accommodate so many cables. I thought about RJ45 but it gave rise to other problems. 

Fortunately, such a converter is not a problem and it can be added even externally along with galvanic separation, which is missing here. 

Of course the temperature stabilization is needed - now introduced very basic and weak, it requires refinement. This still requires a lot of time. I have to collect a lot of measurement data and refine the algorithm but I am prepared for it. The current implementation should be completely sufficient for tests. There are other sensors apart from temperature that are more difficult to control and that spoil the measurement during cutting (dielectric parameters of the gas surrounding the nozzle).

We have built a CNC machine using open-loop stepper motors. The motor drivers are connected to a computer via a breakout board, which is linked using a DB25 cable. Most of the wiring is done using jumper wires, and we have a common ground for all electronic components. The Y-axis is driven by two stepper motors, one for each arm.To improve signal stability, we have added pull-down resistors to each Step- pin of the motor drivers. However, we have observed that the potential difference between the 5V pin and ground pin of the breakout board (powered by an 18V power supply) is only 1.6V. Additionally, when the Y-axis motor stops working, the potential difference between the 5V pin and the Y-axis direction pin drops to 0.06V.Thus, we suspect that the breakout board is damaged. The 5V pin on the breakout board should provide a stable 5V, but since it only outputs 1.6V, the board’s voltage regulator or power circuit may be faulty. The fact that the Y-axis direction pin drops to 0.06V when the motor stops further suggests a power issue or weak signal.Additionally, we suspect that electrical noise is affecting system stability, leading to random motor movements. Interestingly, noise issues only appear when the PC is connected to the breakout board. What could be the reason for the issue? Should we also connect breakout board with a usb cable to the PC for extra power. YOU can view our breakout board specifications in the file attached below.