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I’d just like to share this for anyone that might be interested.

I have a tool changer that I built based on the E3D tool changer. There are currently three tool heads on it all with the ToolBoard 1LC. Occasionally, a tool change will fail and I needed a way to check for that and pause the print.

I purchased and installed the TRCT1010 optical sensors as recommended by the documentation. Next, I printed a flag to trip the sensor and with the “Object Model” plug in I was able to command a tool change and verify that everything was working as intended. (0 = tool is docked, 1 = not docked). Finally, a macro will loop over all tools and check that the selected tool is not docked and that all others are. I call this macro first thing in the tpost.g for each tool.

Hope this helps someone!

var iter = 0;
var numTools = 3
var checkValue = 0; 0 = docked

if state.currentTool = -1
	; if there's no tool selected, return
	M99

while var.iter<var.numTools
	; set check value to 1 if i = current tool
	if var.iter = state.currentTool
		set var.checkValue = 1
	else
		set var.checkValue = 0
		
	if sensors.gpIn[var.iter].value != var.checkValue ; tool change failed
		M291 P"tool change failed" S2
		M98 P"pause.g"
	set var.iter = var.iter+1
M99

I’d like to update this thread in case it can help anyone out.

I went ahead and started a careful reassembly per Phaedrux a few weeks ago. In doing so I discovered that the 2020 extrusion I was using for the X gantry was basically worthless. The edges on the 2020 are chamfered which makes the channel just about as wide as the linear rail. What I think happened was the rail wasn’t exactly aligned and it ended up slightly diagonal to the long axis. Tightening the bolts forced the rail to match the ‘contour’ of the beam and that’s where the twist came from. Those chamfers weren’t captured in the solid model and even with alignment tools, it was nearly impossible to get the rail seated properly. I’ve exaggerated that in the picture below. My solution to this was to machine a new gantry beam from Al and that seems to have solved the problem. When I run a bed mesh and check with an indicator, I’m within .004” (.1 mm).

I know most people don’t have access to a Bridgeport so this route isn’t the most realistic, but my big take away is to keep an eye on the extrusion profile when dealing with smaller parts.

Thanks for the help @Phaedrux!