Electronic – Cheap options for high precision distance measurement

sensor

I built a rather cheap(~€100) 3 axis CNC router for my workshop for cutting wood and aluminium in all sorts of fancy ways. It works great for most stuff but for things that require high precision, its always a little off.

For example, if I make it do 2 identical cuts, one right after another, the difference in any axis can be up to 1mm. Not too bad for wood, considering the total work area is 800x800x400mm and the size of things I make but kind of a problem for aluminium pieces that have to fit together.

It can be worse if significant amount of time/work is between the 2 cuts. I've had identical cuts made a few days apart for replacement parts differ by up to ~2.5mm on large pieces.

Now I figured I could get better rails, better bearings, engines, whatever to try and make it more consistent but I think the biggest gains could be had by having the ability to calibrate and check it in software.

TLDR: So what do people use for measuring distances of up to 1000mm with lets say 0.1mm precision?

I looked around chinese estores but all I found was laser sensors for large distances, like 100m with precision +- 0.2m and ultrasonic proximity sensors for shorter distances but pretty terrible precision.

They were pretty cheap though (<€10) which gives me hope. I also have the advantage of having complete physical control over both the points that I want to measure the distance between instead of just one.

Best Answer

I think you should get to the bottom of what is causing your errors. Either you are missing steps or your mechanical setup is too flexible or has backlash in the nuts/bearings. Your homing switches may also have poor repeatability if you are not using an edge finder to locate the tool precisely. Or perhaps it's a combination.

Things like backlash and flexibility are very difficult to compensate for with software. For example, depending on the direction of cut you may start off with the tool in the right position but as soon as it bites in kerchunk and you've dug into the work as the cutter pulls itself in. Or you may be doing climb milling and the cutter runs well outside of the desired path if the gantry and slides are too flexible.

Anyway, glass scales are a sort of mid-priced way to measure a few microns down to 1um resolution. Accuracy over the full scale might be 10-15um over 1m for a cheap one. They typically have a quadrature 5V digital output (incremental), some may have quadrature sinusoidal signals. But each axis will probably cost about as much as you've put into this so far, and there is no guarantee you will be able to do much better in part accuracy. Photo from this page

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If you win the lottery you can consider Renishaw and Heidenhain encoders, which can reach resolutions orders of magnitude less than a wavelength of light and do it with absolute measurement.