Hi Kirk

 > I want a 3" encoder to go on the end of a ballscrew like this one:
 > http://www.wallacecompany.com/machine_shop/bridgeport/00047-1a.jpg

I recently replaced a worn-out encoder disk with about 4" diameter and 
most likely more than 1000 lines in a Canon IPF750 large format printer. 
I guess you could get one of these as a replacement part. This disk had 
an index mark to be read by a second sensor.

For any DIY solutions, please keep in mind that you don't only need the 
resolution to create the fine details required, but also a very high 
absolute accuracy. And you need to find a way to centre the encoder on a 
mount. If it's not centred properly you will get linearity errors in the 
movement you want to control.

On the plotter this problem  is solved in software. After replacing the 
encoder a calibration routine prints thin lines and the plotter scans 
back these lines and obviously calculates the date need to linearise the 
encoder readout in software.

See you
Flo

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