|Another option I have considered, is to use Hall sensors which would
|work okay without an enclosure, but I seem to recall that Hall sensors
|are not very fast, though engine crankshaft sensors seem to work well
|enough.

Here is a new encoder option on the market that looks very attractive, the:


   AS5040
   10Bit 360° Programmable Magnetic Rotary Encoder

These are chips with hall sensing of a single magnet positioned over the 
chip. this one gives 10 bit resolution and in the quadrature mode has 
this to say about speed: The incremental outputs are not affected by 
rotational speed restrictions due to the implemented interpolator. The 
incremental output signals may be used for high-speed applications with 
rotational speeds of up to 30,000 rpm without missing pulses. There is a 
delay from the actual position change to the time it is reported, but it 
looks like it could follow a 1500 RPM motor without interpolating, and 
if used with a spindle at constant speed, since you're looking for the 
index pulse to line up at the same spot every time for threading, it 
might work for that application too, as long as you didn't have to sync 
up the thread start with some feature cut at low speeds. Some of the 
chips in this series are available from component distributors for 
around $10 each in onesies, and I remember seeing the magnet specific to 
this application for sale also. There is a company that has put out an 
encoder using the AS5040 at this link: 
http://nubotics.com/products/me110/index.html



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