JOYSTICKS
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PREFACE:

Joysticks are a matter of personal preference in handle, button layout, and gimbal feel.  If you are left handed, your choices are limited unless you can customize your own.  One major difference in joysticks is quality and reliability.  These two factors separate the field rather dramatically.  Do not expect the most expensive stick to be the most reliable or highest quality.  The primary considerations here being the technology used for the encoders, the gimbal design, and the materials used.  Some people will never have to worry about their joystick, others like myself are "power" users who can wear out a joystick in a couple of days of game play.  Other sources of problems are related to the computer's game port and software.

ENCODERS:

A joystick has two axes, left-to-right and forward-to-back. Two axes dictate two encoders.  The primary technology employed today for encoders is the potentiometer.  A potentiometer is a variable resistor that is made of a carbon impregnated surface and a metal wiper.  As the shaft of the potentiometer is turned, it's resistance changes thereby allowing the game port to read a value that corresponds to the position of the joystick.

Potentiometers wear out.  The rate at which they wear out depends on the gimbal design, the user, and the potentiometer.  Some potentiometers are rated in the millions of cycles.  But even these will not last if the gimbal design is incorrect or the user moves the joystick too rapidly.  Remember, the metal wiper "wipes" across the carbon impregnated surface, every time it "wipes", it removes a little bit of carbon.  Eventually, all the carbon will be "wiped" off and the potentiometer will no longer change it's value when turned or "wiped".  However, as the carbon is "wiped", the resistance in that "wiped" region is forever changed.  Some joystick manufacturers started putting a dielectric grease on the carbon surface in hopes that this would reduce wear.  All that did was hold the carbon that was "wiped" off in the grease causing even more abrasion and more resistance fluctuation.  Signs that your potentiometers are wearing out are best described as jumpiness, and the inability to maintain a center position.  Real critical when lining up a torpedo run on an Imperial Star Destroyer in XWING.

At this point, you have several choices, live with it, buy another, replace the potentiometers, modify it, or buy a joystick that does not use potentiometers.  As you can tell, I've been there, done that, got the tee shirt, and didn't like it worth a darn.

LESSONS LEARNED:

I started out with a joystick that had (and to this day still does have) the best look, grip feel, and button positions for my taste, specifically the THRUSTMASTER Flight Control System (FCS).  After about three days of XWING, I couldn't center my craft to lock onto a TIE Bomber at long range with a concussion missile because my ship kept jumping around.  Then it got to the point where if I pulled back on the stick slightly, I would take a sharp nose dive.  So, a call to tech support and they sent me a bag of replacement potentiometers and velcro…the velcro was to be used to put the stick back together instead of using the allen head screws!!!!  After about two bags of potentiometers, an improved version of the original pro version that used a geared gimbal, and two more bags of potentiometers, I decided to make a change.

At that time, the only encoder technology on the market was potentiometer based so I decided to build an optical-analog encoder that would last forever.  I printed two circles with a gray scale pattern on a sheet of plastic transparency cut out the circles, fastened them to the end of the axes shafts, and put diode & photo-transistor pairs on each.  The diodes were arranged to shine through the gray scale transparency circles onto the photo-transistors.  As the shafts rotated with stick movement, the gray scale pattern disks rotated and let more or less light through to the photo-resistors, thus changing their resistances.

I modified the joystick and rudders, tuned it, and was very happy.  It worked extremely well and the encoders would last for a very long time.   All went well until the springs in the gimbal started to break.  The velcro was no joke, it was a real good idea.  The springs were loops with straight ears sticking out.  The ears would break off.  After two or three bags of springs, I was now looking for a different gimbal design.  One that didn't have a design flaw.

Just when I was thinking of designing my own gimbal, along came the PC-OPTIX, I really liked this stick because it used optical encoders that I knew wouldn't wear out and it used coiled springs for stick tension which I knew would last longer than the loop springs of the modified THRUSTMASTER Pro FCS.  The only problem was the handle was not quite up to my standards, so a little cutting and gluing and voila, a PC-OPTIX with a TM handle, and I was in Heaven.

Then the plastic gimbal of the PC-OPTIX started wearing out.  And wires inside that connected the handle buttons to the circuit board that passed through the gimbal started pulling off.  This also happened to an unmodified stick as well…another design flaw story.   So it was either on to building my own gimbal or trying a different stick.

Then came the Microsoft Sidewinder Pro.  At this time, I am using the Microsoft Sidewinder 3D Precision Pro without a problem.  I have heard of people breaking springs in this stick, but this has not happened to me yet.  All in all it is a good stick except for the handle design, I really like the old F-4 design.  The handle on this stick is close, but not exactly the same.  But alas, the gimbal in this stick is plastic as well and is starting to wear slightly…maybe I'll still have to build a metal ball-bearing gimbal and optical encoder stick one of these days that will last.

GIMBALS:

The gimbal is the mechanical interface that translates the joystick motion into rotational motion for the encoder.  The original TM Pro FCS used the potentiometer bushings as the main load carrying bearings for the stick.  The improved TM Pro FCS (sold today) employs independent load bearing bushings and drives the potentiometers by a geared interface.  This helped reduce the potentiometer wear significantly.  However, the springs used in this design are prone to failure and the load bearing bushings wear.  The PC-OPTIX is prone to wires coming loose from the circuit card, even on my brother's whose handle was never modified, and it has a plastic gimbal mechanism that also wears.  The Microsoft Sidewinder 3D Pro has been the most reliable.  It's handle is small and uncomfortable for me and it's plastic gimbal is starting to wear as well, but it has been the best joystick I have owned including the CH Flightstick Pro which suffers from potentiometers.  The Sidewinder uses an optical-analog encoding scheme.  To me, the perfect joystick would be a TM FCS metal handle (by the way, the black plastic on this handle will wear off onto to your hand) a metal gimbal that uses ball-bearings and standard coiled compression springs, and optical encoders.

Game Ports:

The game port is a simple Analog to Digital (A/D) converter.  It takes an analog voltage and converts it to a digital number. Most game ports found on multi-Input/Output (I/O) cards and sound cards and even motherboards are not adjustable.  This can result in certain games from not recognizing the presence of your joystick.  The game port has to be adjusted to your computer's Central Processing Unit (CPU) and bus speed.  There are a few adjustable game ports on the market.  My favorite is the CH products Automatic Gamecard III.  This game card does not use a Terminate Stay Resident (TSR) program.  It uses a stand alone program that sets the game card speed and can be put in the autoexec.bat file, but it does not stay resident in memory.  The TM game card and a few others use a potentiometer to adjust the speed and you have to run joystick calibration software provided with the card to adjust it properly.  I do not like this type as the potentiometer is prone to little fingers and my cat "adjusting" it from time to time.  Plus, the CH product is automatic, it will set itself or you can override it if you are not satisfied.  The game ports on the newer sound cards seem to work well.


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