Sensor Wiring Setup
Thought for 3 sec
Work done
- Integrated the two native PC817 homing sensor channels with labeled X/Y sensor terminals, 10kΩ pullups, 100nF filters, 4.7kΩ status LED resistors, Nano D9/D10 outputs, and a single 0Ω star link between
GND_24VandGND_LOGIC. - Preserved the 100 mm × 152 mm, 2-layer board and placed the new/updated sensor parts in the connector area with no placement overlap or out-of-bounds issues.
- Applied the required 1.6 mm copper spacing rule conservatively and documented the implementation in Homing Sensor Integration Audit.
- ✅ Native X/Y sensor circuitry integrated and connected to
+24V_SENSOR/GND_24V. - ✅
LIMIT_X_NETconnects to Nano D9;LIMIT_Y_NETconnects to Nano D10. - ✅ Sensor terminals are documented as BRN/BLU/BLK and filters/status LEDs are included.
- ✅ Board size and 2-layer stackup are preserved.
- ❌ Final layout DRC is not clean: airwires and overlapping copper remain after the stricter spacing rule, so the board is not fabrication-ready yet.
Run routing cleanup/autoroute for the updated board, then re-check DRC until the airwire and copper-clearance issues are cleared. I can continue with PCB routing/cleanup guidance next.
Route sensor nets
Review DRC violations
Verify clearance rule
Prepare Gerbers
Update audit doc
Refine this doc
Ask about this doc
Connector Cleanup Validation
Completed updates
- Removed redundant
RELAY_OUTPUT_CONN1111relay dry-contact output connector. No separateRELAY_OUTPUT_CONNcomponent is present in the verified connector set. - Standardized external screw-terminal connectors to a pluggable male PCB header plus removable female plug style:
X_SENSOR_CONN— Phoenix Contact 1757242, 2 positions, 5.08 mm pitchY_SENSOR_CONN— Phoenix Contact 1757242, 2 positions, 5.08 mm pitch24V_RAIL— Phoenix Contact 1757242, 2 positions, 5.08 mm pitch5V_RAIL— Phoenix Contact 1757242, 2 positions, 5.08 mm pitchX_MOTOR_CONNECTOR— Phoenix Contact 1757284, 6 positions, 5.08 mm pitchY_MOTOR_CONNECTOR— Phoenix Contact 1757284, 6 positions, 5.08 mm pitchRELAY_MODULE_CONN— Phoenix Contact 1757255, 3 positions, 5.08 mm pitch
- Replaced
BUTTON_BOX_CONNterminal block with Stewart ConnectorSS-60400-021, an 8P8C shielded Cat6 RJ45 female PCB jack.
Verified net preservation
Power rails
5V_RAIL:Pin_1→+5V5V_RAIL:Pin_2→GND24V_RAIL:Pin_1→+24V24V_RAIL:Pin_2→GND
Button box RJ45 mapping
- RJ45 pin 1 →
ESTOP_NC - RJ45 pin 2 →
BTN_RESUME - RJ45 pin 3 →
BTN_PAUSE - RJ45 pin 4 →
BTN_START - RJ45 pin 5 →
BTN_ABORT - RJ45 pin 6 →
GND - RJ45 pin 7 →
GND - RJ45 pin 8 →
+5V - RJ45 shield/mechanical pins 9/10/11/12 →
GND
Existing connector mappings preserved
X_SENSOR_CONN: pin 1+24V, pin 2X_SENSOR_RAWY_SENSOR_CONN: pin 1+24V, pin 2Y_SENSOR_RAWX_MOTOR_CONNECTOR: pins 1/3/5+5V, pin 2X_PUL, pin 4X_DIR, pin 6ENAY_MOTOR_CONNECTOR: pins 1/3/5+5V, pin 2Y_PUL, pin 4Y_DIR, pin 6ENARELAY_MODULE_CONN: pin 1+5V, pin 2RELAY_IN, pin 3GND
Layout result
- External connectors were reorganized into a right-edge service row for cable management.
5V_RAIL,24V_RAIL,X_SENSOR_CONN,Y_SENSOR_CONN,X_MOTOR_CONNECTOR,Y_MOTOR_CONNECTOR,RELAY_MODULE_CONN, andBUTTON_BOX_CONNare placed on the top layer and accessible from the board edge.- ESP32 and Nano remain near accessible edges for USB troubleshooting.
Remaining validation items
- Electrical checks for floating pins and single-pin nets pass.
- Footprints and layer validity pass.
- Routing is not complete: the board still has airwires, so final routed-board DRC cannot be clean yet.
- A few copper-overlap issues remain after placement and should be resolved during/after routing cleanup.
Recommended next step
Run/complete PCB routing, then rerun layout checks and resolve any remaining copper clearance issues before manufacturing export.
Completed updates
Verified net preservation
Power rails
Button box RJ45 mapping
Existing connector mappings preserved
Layout result
Remaining validation items
Recommended next step
