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Originally Posted by BurningQuestion
1) Would you recommend the use of mechanical or optical sensors?
2) What are the benefits of one over the other?
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Really, I don't have a reason for one over the other.
Pros to Mechanical
- Not affected by ambient light
Pros to Optical
- May be slightly easier to stick on the robot (less sensitive to distance between the sensor and the disk)
- Will never wear out (well, not in your life time) Mechanical switches will probably have to be replaced once in a while. Not a big deal though, they're cheap, just build it so it's easy
- Don't click at all.
Cons should be obvious with the pros, so I won't mention them.
I'd personally go with optical, but not for any reason other than the noise.

No preference really though.
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Originally Posted by BurningQuestion
7)What is the difference between all of the different output types that are listed: what is the difference between binary, gray code, BCD, and serial?
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They are different coding methods. Only a programmer will really care, but to make everything easy, I'd get a binary one.
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Originally Posted by BurningQuestion
11) how many "clicks" per revolution would you recommend? This encoder would be used for the drive train most likely, not for the angle of an arm. (meaning that the encoder doesnt need to be as accurate as one you would use for an arm)
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It depends on how fast your robot can move, wheel sizes, how accurate you want it, etc., but I'd say somewhere between 16 and 32 as a rough estimate.