To prevent travel damage to a limit switch, what should be used?

Using a mechanical stop is the best way to prevent travel damage to a limit switch. A mechanical stop physically limits the movement of the actuator or the mechanism it is controlling, ensuring that the limit switch is not subjected to forces beyond its design capacity. This not only protects the limit switch from wear and damage caused by over-travel but also helps maintain the integrity of the system by providing a reliable reference point for the operation of the actuator.

While options such as a larger switch, a differing actuator arm, or an electronic stop may have their valid applications in certain scenarios, they do not necessarily provide the direct physical limitation that a mechanical stop offers. A larger switch could still be subject to excessive force if the actuator moves beyond its intended range. A differing actuator arm may alter the motion pattern but doesn't guarantee protection from over-travel damage. An electronic stop may involve software controls, which can be beneficial but don't provide the tangible physical barrier that ensures safety and prevents mechanical failure.