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1. Cheap options for high precision distance measurement?

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 pageIf 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

2. How to Choose Press Brake Controller, NC or CNC?

With the continuous improvement of industrial automation, more and more manufacturers choose to buy sheet metal equipment (such as CNC bending machine and CNC shearing machine) with an automatic intelligent CNC system. Different CNC systems are suitable for the production of different standard products, and the price difference is also very large. Therefore, for manufacturers, the correct choice of CNC system can effectively help the mass production of products. This article will mainly take the press brake (hydraulic bending machine) as an example to briefly introduce the dedicated CNC system for the press brake machine, and help the manufacturer who needs to purchase the CNC press brake to have a preliminary understanding of the CNC system. The numerical control system can be divided into: In the CNC system of the bending machine, the digital control generally means that when the system is produced, the manufacturer has programmed the program, and the purchaser cannot modify the programmed program. Computer numerical control means that the purchaser can edit the program according to the actual operational requirements before bending, and can make any modifications to the program. In short, the NC digital control system is the first generation of the CNC system, and the CNC computer numerical control system is an upgraded version of the CNC system. As an upgraded version of the system, it has more advantages. The computer numerical control system is based on the computer operating system, which is easy to operate and does not require skilled workers to operate. In addition, the operating system is easy to learn, and after simple training, workers can get on the job quickly. The digital control system is highly demanding for the operator, requiring the worker to understand every function of the machine and to operate the machine in an accurate manner. In the CNC system of the numerical control bending machine, multiple programming can be performed, and the system has a storage function. The larger the system storage capacity, the more programs the machine can store. Take the ESA S500 series controller used on CNC bending machine as an example. 20GB of hard disk space can store at least 2 million programs, and 256M U disk can store at least 50,000 programs. Each program can contain hundreds of bending steps. If the manufacturer needs to fold a variety of different specifications or workpieces with complex manufacturing processes, it is better to choose a computer numerical control system to complete the batch production in the shortest time. Digital control systems do not have storage capabilities. The workpieces bent by the bending machine with the computer numerical control system have better quality and higher precision, which cannot be achieved by the bending machine using the digital control system. The convenient operating system of computerized numerical control system's allows workers to operate for shorter periods of time and can work 24 hours a day. In contrast, CNC bending machines with CNC controller have more advantages. However, computer numerical control systems are more expensive, so the price of CNC bending machines is generally more expensive than NC bending machines. The value of the CNC numerical control system is much higher than that of the NC digital control system if it is considered in terms of production efficiency. Moreover, with the increasingly fierce competition in the global market, shaped workpieces emerge one after another, requiring machines to produce workpieces that meet the diverse needs of customers with high efficiency, high precision, and high standards. The advantages of the computer numerical controlled press brake are also increasingly prominent, and it is increasingly able to cater to the ever-changing market demand, which is the trend of the future.

3. Very high precision zero crossing detection

You will likely want to measure the total of many zero crossings (and divide by 'many' before taking the reciprocal).. or average many measurements.. otherwise noise in the signal will unduly affect your measurement, and you do not need the answer that quickly. You can measure easily to a couple hundred nanoseconds with a typical 8-bit micro (so 200ns in a 5kHz note would give you 3 digits) but that does not translate necessarily into results anywhere near that stable or accurate.