Some weeks ago my 100w Chinese 6040 laser developed a Y-Axis limit switch problem, evident from the loud grinding noise from the stepper motor on start-up and the lack of any indication from the LED on the hall effect sensor. I planned to replace the sensor today but saw that dealing with the cable ‘raceway’ (bolted from underneath) and insufficient length of the supplied cable were going to make it difficult to fit.
I also discovered that the problem was not the sensor itself but the cable; with an open circuit on the blue wire (probably somewhere along the cable raceway). It also got me thinking about mounting the new switch & cable assembly *on the main chassis rather than the carriage assembly, thus avoiding the need to route the cable through the raceway. I would then simply add a small iron bracket on the carriage to activate the hall effect switch. It seems a simple solution to me, but there again… why are the sensors usually mounted on moving carriages anyway? Is there something I’ve forgotten?