Many times its been brought up about the unreliability of using the proximity switches, that come on our machines, for limit switches. I have found a possible replacement that might even mount in the same brackets as the factory proximity switches.

Using some mechanical limit switches from Automation Direct this is what I have come up with.

Attachment 247600
On the left you have a roller/lever arm type switch. I wasn't able to easily re-position the lever arm in the 3D model but I think if you rotated it 90* and had the switch body horizontal it would be a cleaner mounting.

In the middle you have a model of the existing factory proximity switch

On the right you have a roller/plunger type switch. This type I think would work well too. Both this one and the lever arm type would require a custom mounting block to be made.

To use the roller limit switches the existing cast iron "flags" that are used to trigger the proximity switch would have to be modified with a 30* angle to the bottom of the flag. This is to give the roller an inclined plane to act against.


There is a third switch that I didn't model that I think might be able to be mounted in place of the factory proximity switch. It can be found here.
AEM2G22Z11-3 | 1 N.O./ 1 N.C. limit switch - metal plunger,metal roller w/ fixing nut


Additionally I think I found the solution to the Y axis limit switch bar from pushing out the front of the factory chip pan. By moving the bar back 100mm like the bottom picture. On my flag mounting bar there are 3 holes each 100mm from the previous. So I am just going to slide it back and re-adjust my single flag I use for homing.

Attachment 247604
Before

Attachment 247606
After