Connecting an encoder to S7-1200

Hello. I would like to know how to connect a two wire incremental encoder to my S71200 (1214C DC/DC/DC). The number of pitches is still not defined, I'll have to check it. But for now, let's assume that the number of pitches of the encoder is 1050. 

The encoder is connected to its driver, and has a 2 wires that are to be sent to the PLC. I wish to know how I'm supposed to connect these two wires to my PLC, and what function from inside the PLC (programically speaking) I am to use so that it can accurately perform the fast counting. 

I'm doing this simply out of curiosity, to learn more on how to use these specific type of encoders.

Now, what I considered is using the basic "CTU" count up function in the TIA. (I'm using TIA Portal v13, by the way), and somehow connect this to the encoder.

This is probably incorrect, since I have two wires and the values from what I learned have to be a limit between 0 and 27648 (ideal value). I'm not exactly sure what it  means, and how to properly use it, but I wish to learn it.

Can someone please tell me step by step what I'm supposed to do exactly programming wise, and how to connect this PLC to the encoder afterwards? ONLY DIRECT RESPONSES PLEASE! NO LINKS. I wish you guys to explain your way, step-by-step what I'm supposed to do. Thank you for reading :)

Pyrus

Hello. I would like to know how to connect a two wire incremental encoder to my S71200 (1214C DC/DC/DC). The number of pitches is still not defined, I'll have to check it. But for now, let's assume that the number of pitches of the encoder is 1050. 

The encoder is connected to its driver, and has a 2 wires that are to be sent to the PLC. I wish to know how I'm supposed to connect these two wires to my PLC, and what function from inside the PLC (programically speaking) I am to use so that it can accurately perform the fast counting. 

I'm doing this simply out of curiosity, to learn more on how to use these specific type of encoders.

Now, what I considered is using the basic "CTU" count up function in the TIA. (I'm using TIA Portal v13, by the way), and somehow connect this to the encoder.

This is probably incorrect, since I have two wires and the values from what I learned have to be a limit between 0 and 27648 (ideal value). I'm not exactly sure what it  means, and how to properly use it, but I wish to learn it.

Can someone please tell me step by step what I'm supposed to do exactly programming wise, and how to connect this PLC to the encoder afterwards? ONLY DIRECT RESPONSES PLEASE! NO LINKS. I wish you guys to explain your way, step-by-step what I'm supposed to do. Thank you for reading :)

 Assuming you're wiring of the encoder driver/interface is correct and its output meets the input requirements of your 1214C then you can connect the two encoder wires to two inputs on the PLC. Which two inputs depends on the encoder, how fast you will be counting and what else you have configured in in your CPU.

Assuming all inputs are available and you're using  AB-quadrature encoder, connect the encoder to inputs I0.0 and I0.1 and configure HSC for those two inputs (HSC1).

if you have a LINK to the encoder specs that would help answer you questions more specifically.

Edit: I was replying at the same time as others and didn't see their detailed replies. You have lots of information there.

Perhaps  I should have been clearer. I must say it is a smart way to answer, and it was quite unprecedented. So, let me try again:

In the most basic form possible, how would you connect a +5V PNP encoder, (number of pitches of your choice. I suggest 1024 just for an example) to an S7-1200 PLC (1214C DC/DC/DC) .

And by the way, I have read those forums. The thing is that they are so many, for which the reason I chose a head-on answer, because I honestly did not know where to begin. Some of these forums are quite bleak and contain indefinite answers. And, if you had noticed in my question, I did state that the encoder is connected to its driver, and that the two remaining wires are to be sent to the PLC. Now, I simply wish to know how to connect these to the PLC, and what is the function to be used inside the program to successfully perform the high speed count.

Now, if you must show me links, I would accept them. The only reason I asked for no links is not because I'm trying to be lazy. It's simply because many of the questions (not on the Siemens forum) that I have asked have almost always been answered by links, and most of the time they are quite inconsistent from what I've asked.

I do love reading and understanding what I am supposed to do. If this was not the case, I would not even be here, since I'm a computer communications major. Neither would I know about smart relays (talking about LOGO! by the way), other brands like Delta, Omron, Mitsubishi, Allen Bradley, Crestron, etc... I wouldn't know anything about (off topic) the constitutions of stars, astrophysics, chess, music, programming on MATLAB, LabVIEW, C++, etc..., constructing panel boards, and including all the contactors that need to be used, the power cables and their needed thickness, the wiring of control cables, etc...And yes I do them ALL. Of course not all the time, but that is to be expected.

So, if you need proof of any of these, I'll gladly provide you with the photos one-by-one, then again, it would be off-topic.

Facing the music, I would like to receive the answer for this question. And yes, you may provide the needed links.

So, in response to William_B, may I please have those links? A text about the basics of these in your typing would also be helpful. Thank you :)

@William_B

Of course no hard feelings. I never hold a grudge :)

Though I must say it is a fault of my own as well for not demanding information and just went for a direct answer. The thing is that I do not know exactly what type of encoder it is, because the program that I'm doing is for a paper cutter. The person that told me to do it works on his own as a programmer in a private company, and all of the sudden PLC was included. None of them knew PLC, and since I took a course in PLC, and made a rather complex LOGO! Soft Comfort program that made their head spin, for an elevator. 

The reputation stuck, and they recognized me as a good ladder diagram drawer, etc... But as you may have guessed it, since I'm a communications major, the course wasn't really complex, and software was included only in the last two sessions, and were based on Delta, and not Siemens :(

So, due to this, the person (he's my friend from that class) asked me to help him program a paper cutter for an encoder. He didn't specify anything because he didn't know its specifications either. The paper cutter's function is simple. Just specify the size of the paper on HMI, and it will cut it in the specified size using the encoder. Of course, I realize now that far more is needed as information to work with an encoder, due to your replies, since I haven't worked much with an encoder either. I've only seen its functions from outside and how it's stopping and starting every time. So, I'm lost in software as well, hence my question. 

Viewing some of its characteristics, I'm gonna assume the worst case scenario and take (6ES7 214-1AE30-0XB0) v2.2, since it has one of the slowest instruction execution in its series (0.1ms/1000 instructions). The best in its series has an execution time of 0.04ms/1000 instructions from what I've just read, and if I understood it correctly. As in 0.1ms to execute one instruction, and may take up to 1000 instruction, provided it does not exceed the memory provided to it of course. 

I know the information remains insufficient, but if I do manage to get the specifications of the encoder, I will update this post. 

Now, if I may add this question: Don't all the two-wire encoders (both wires being the signal wires) have the same exact function block in the TIA Portal, with the only difference being the count? This is also something I would like to know.

Sorry for the long read, and thank you all for the help that you can provide.

Side note: If you are about the program I wrote on LOGO!, you may find it attached below. :)

Please reply in Serif Fonts.  Sans Serif fonts offend my aesthetic values.

William_B, I admire your persistence.

Oh, sorry :(

The last thing I wanted to do was to appear egoistic. Plus, I thought my name was hidden as a user (alias), so I thought why not just show? :P I apologize if I sent you the message incorrectly. :(

I have read the links you've sent me, as well as some other links from within the forum, and I did get an idea about it. 

This is what I've did thus far:

1. I used HSC_1 as my high speed counter
2. I put the filter on the inputs I1.0 and I1.1 as the high speed counter inputs for the encoder that is to be used. The address given are 1000 for I1.0 and 1002 for I1.1 (Since it starts from address 1000 and ends in 1003, meaning each input has 2 addresses. Please do correct me if I am mistaken). Organization block and Process Image are all left as they are "Automatic Update". Their trigger duration is set to be 20us.
3. The function is to count up, with an operating phase of A/B Fourfold (I'm uncertain about this, but based on what I read from the Siemens forum about encoders and external links, A/B meant the most precise method of counting, making the count 4x more than it actually is. Now about this, what I understood is that it counts A and B since they are 90 degrees out of phase, and for any 00, 01, 10, or 11 binary input (from A and B respectively), the counter counts up, making the final result 4 times the number of pitches the motor of which the encoder is counting. This means, if I have 1024 pitches per revolution, I'll get a count of 4048. Is this correct?
4. Reset values are all 0 and based on an internal reset input.
5. The Hardware Identifier is 257. (I do not know the meaning of this number)

Now for the specifications (this is as much as I could assume from what is to be used for this operation):

1. Encoder has 8 wires on it. 2 are used for power. The rest are given as A+ B+ Z+, A-, B-, Z- . (From what I understood, the Z channel is used for count of every entire rotation by "deducing" it from the out of phase channels A and B. Again, please do correct me if I am mistaken).
2. The encoder is a rotary encoder.
3. Power source is +7 to +24 V. (It's a DELTA brand)
4. Exact number of pitches is still unknown. Assuming it is 1024.
5. Since I'm going to use only the count up signals, I'm taking the A+ and B+ wires and connect them to the I1.0 and I1.1 inputs of the PLC.
6. The PLC used is S7-1200 series, (1214C DC/DC/DC, Order no. 6ES7 214-1AG40-0XB0, Version 4.0), and I'm using the TIA Portal v13 (not v13 SP1, I'm currently downloading it, because simulation for S7-1200 is not possible on the 1.0, as I saw in the Siemens forums).

Now, what I would like to know (provided if everything I did thus far is correct) is to know:

1. How can I connect my input programatically to the CTRL_HSC block?
2. How to use every parameter properly (every parameter if needed that is)? I checked the help index for CTRL_HSC and although I understood some of the parameters, some remained unclear
3. What I add "%ID1000" as input, what does the :P mean after it? Because the tag is also getting it.

The following is from a newbie:

Your encoder will have 5 wires. Vcc, 0V,A,B and Z . Your specific encoder may offer more wires for different type of output (open collector) but that doesn't mean you hook both output types. You just pick whichever one you want to use. I would pick the one with voltage output.

I believe 1214C V4 allows you to choose counter inputs so you may be good there with your plan. Not sure as I've never had one.

HSC count is in DInt meaning it uses all the four bytes for one count. It doesn't have separate counters of A and B. It's just one counter. It uses A and B for increase resolution and direction. It uses the rising and falling edges of each. The sensors , optical or hall sennosr , are placed 90 degrees out of phase.

You use ID1000 to access the counter for HS1. Not sure what ID1002 would do. I will actually try it when I have time to find out for myself.

The parameters of CTRL_HSC are explained in detail in the online help. Just give focus to it and hit F1

Edit: Late again. Just  ignore my post

 Dear William you're really doing a great effort in replying to questions in this forum. so please if you have links, documents, or any thing support the answer , don't hesitate to attach them.

someone will use them in a way or another

William_B

Pyrus

ONLY DIRECT RESPONSES PLEASE! NO LINKS. I wish you guys to explain your way, step-by-step what I'm supposed to do.

What an odd order!
This puts me under the impression that you are lazy
and insist on being spoon fed.
I encourage you to prove me wrong.

--------------

okay... the steps as follows -
1. Download the System Manual for the S7-1200.
(no link provided as per your instruction)

Thank you all for your very quick responses! :). I have read and taken into consideration all of your responses, and surprisingly the code turned out to be just two lines. (Evidently there will be other lines for low voltage contactors and relay triggers (external outputs) but they are simple process.) 

Also, thank you for clearing the idea about the direct output power to the encoder. I was wondering if I could give it directly 24 V from the PLC. (Read some other posts about the CPU 224 (S7-200 series) and it's the only PLC (although quite old and now discontinued since 2014) is the only PLC capable of handling direct input and output at +5V with encoders. 

As per what you said about the encoder having an insufficient data, I do agree 100%. At some point I'll have to go and check the data sheet personally, provided I get the exact specification of the DELTA brand that they are willing (or should I say insisting) to use.

Back to the code, I have uploaded the encoder part of the code, and used the input as an arithmetic operator used for comparison. I gave the limit a variable (Data_Block_1.Size), and got it from a global data block, so that I may use it to link it from an HMI. Worked on some designs for it, and KTP600 or even TP600 seemed the ideal dimension for it in color, since I only own a TP177A to test on. (Both are 5.7 inches, as it occurred). 

I have uploaded a picture of the code I wrote for the encoder as requested. As stated previously in the current post, it is just two network lines. One for the encoder count, and the other for the control of the high speed counter. Now, for this case, I would like to know if the count will reach 1024 or 4096. (I have mistakenly said 1024*4=4048, when it's actually 4096. My bad :P). And if the count reaches only 1024, how can I make it reach 4096 for better precision, given the current assumptions by William_B and me?

For the TIA Portal v13 SP1, I'm afraid I'll have to wait. Although I am currently downloading all the files SP1.001 through SP1.011, I'm on hold for the trigger of the installer (the .exe file), due to software export restrictions. I have filled an extended registration form (as per given), and will have to wait for a granted request. I'm not worried though (Patience is a virtue XD). At least this way, I'll only have to download the .exe file since I have all the remaining ones.

I completely agree. That is what I'm to reach in the end, and what I'm aiming to do. The size is actually in meters. What I am aiming to do personally is the following:

Determine how many meters I get after exactly 1 revolution. Depending on that, I'll use a math operator as a multiplier or divider,etc... (Whatever the case calls for), and depending on the PPR of the encoder, just do the math and get the desired value from the HMI to the Data block value multiplied by a constant which was predetermined. 

Once this step is complete, I'm adding a break to the system drive motor to nullify any possible inertia that may remain. Once the breaks trigger (and to avoid complications), I'll trigger a 1 second timer from within the PLC to "cut" the paper. Once the cutter reaches back its initial position (I'm going to use the negative transition instruction on the proximity switch that indicates the cutter in its initial position), the system reactivates, and continues to perform the same operation over and over. An operation during constant movement specially with a cutter is far more complex, and is not required by the client (which is actually good news hehe).

Oh, and another good news, I have pictures of the motor that is to be used as well as the encoder attached to it. The picture was blurry, however, I was able to make out what the brand and the serial number of the DELTA brand encoder actually is:

It's an ES5-10CN8942 Incremental Rotary Encoder

Here is the description after I found it online:

Surprisingly, the encoder has 5 wires only, and was quite identical to the picture I saw.

Yet again surprisingly, there were no NPN or PNP specifications. All I saw was "ungated". I tried to look it up, by writing the part no and adding to it "PNP" and then "NPN" and "ungated", but instead, I got something in Japanese, and it was barely even related to the part number that was referred! LOL!

Now, "Ungated" probably has its own meaning, but I'm afraid I do not know its definition. I'll keep looking.

In any case, I hope the information provided is enough this time.

The link: http://www.starautomations.com/ACEncoder.aspx?p=Encoder

If you're not using the Z output don't worry about gated or ungated. That just describes the relationship between Z and A&B pulses.

If it's an open collector then it's NPN and you will need to do as William mentioned in his post, add a pull-up resistor.

Ah! I see... This puts things on a different angle. I honestly wasn't expecting an NPN encoder. 

Nevertheless, I'll have to use a pull-up resistor, indeed as William_B aformentioned. For this type of signal input, I'm guessing the resistance should be around 0.5 W, 1k or 2.2 kohms. Some sources proposed 3.3 khoms even. Because I checked some forums, and they were usually referring to pull down, and not pull-up resistors. Which makes me wonder about the admittance and how easily it would be affected by outside noise, stray capacitance, and electromagnetic compatibility. 

Another thing that came to mind is about a interesting read I made some time ago. It's about using NEGATIVE resistance. It does completely oppose ohm's law, but there are diodes that are used for negative resistance, such as the Tunnel diode, and the Gunn diode, which are used for high speed microwave oscillations. Could reach about 100 GHz transition frequency if need be, though I'm not certain it would help my application. 

Another question: If I am to use the pull up resistor, should I connect them to both pins? (In this case it's I1.0 and I1.1, but I am reconsidering after what you guys told me.) For now the inputs are still the same. How many ohm resistance should I add, and how may I determine it in case it is highly variable? 

Note that I'm still using 20 us speed for the pulse detection on input. Since it is starting from IB1000, I'm assuming both inputs are actively working between addresses 1000 and 1003. 

I may need the CTRL_HSC, because it seems that the high speed counter MAY change its value during the operation automatically. Basically, instead of a user coming in and putting the new addressed value, the high speed counter will automatically change it into a predetermined value, and the process goes into an endless loop until stopped by the user.

These values will be of course converted from distance to pulse, depending on the application, and will automatically be applied as the new value for the high speed counter.

So, my questions:

1. What is the value of the pull up resistor?
2. Should I put a pull-up resistor to each wire? 
3. The operating phase is still A/B fourfold. Should it be kept this way due to the new information provided about the encoder, or irrelevant?
4. The program that I have uploaded as picture in my previous post, is it correct? Am I on the right track if I am to continue afterwards?
5. Side note: Would the diodes mentioned above in the current post help? 

(Thank you note: Thank you all for the information that you are all providing me. It is helping me immeasurably, and the links are indeed helpful (but I'm just stating the obvious here XD)

Sorry, it's a Saturday and it's sunny out.

The idea of using an open collector output is to source more current than a sourcing output can. The question is, did they choose it for that reason and  the encoder is going to be placed a considerable distance from the CPU or is it just what was available.
The resistor value will depend  on the power supply, length of wire connecting the encoder to the PLC and the current requirement of the you CPU inputs, check the specs of your particular unit.
The higher the value of the resistor the slower the response but in general a value between 1K and 10K is where it will be.

Resistors will need to be placed on both lines A and B.

Are you doing the wiring of programming only?

And with regard cycle time and math functions. How fast will your encoder be rotating? calculate that and you may find that by the time you FBs do their math work the count has changed. Hardware Interrupt block is more appropriate.

Oh hey. I'm only responsible for the programming wiring, but I would still like to know how to wire it from outside. Now, William_B said that using the comparison arithmetic operator is a bad choice, and left it for others to answer for its reason. Now, I'm assuming that it is possible that the comparison may not occur on time, and the high speed counter is too fast, and the condition may become bypassed, and will continue counting, reach the highest possible value, restart from the lowest possible value until it reaches the desired value once again and MAYBE stop this time. This is what I deduced. The programming part is most important for me however, which is why my focus is tending towards it. But again, it doesn't mean I should not know how to connect it on my own.

So, here is basically how I want this program to work, and hopefully, I'll be able to draw the optimized and correct form of the ladder diagram I'm trying to get:

1. The machine is a paper cutter.
2. Multiple papers stacked upon each other will be placed to be ran on a conveyor. 
3. The knife (paper cutter) has been tested, and it is able to perform its job by successfully cutting through the stacks of paper.
4. The motor is the same for both encoder and conveyor (Asynchronous motor)
5. The encoder specs are given in previous post. (It's NPN incremental rotary encoder, 7-24 VDC).

Programming part:

1.  Motor must have a break on it, to cancel out all inertia moment left after power interrupt.
2. When the "Start" button is pressed, the encoder will read the input from the HMI, convert the unit from distance to pulse (depending on the system, calculations will be performed for it of course).
3. The encoder will count the number of pulses, until it reaches the desired amount. Once reached, the break will deactivate (meaning it will grip the motor), and the motor's power will stop.
4. The cutter will be activated, slicing down through the papers, and will return to its original position, will it will trigger through a negative transition the restart of the motor.
5. The process repeats itself.

Hi pyurus,

My apologies for not remembering  all the details of you project and I will go back to read it thoroughly.
It appears to me that the kind accuracy you detailed in your last post requires more motion control than adding an encoder.
I thought you were adding code to an existing program to include the encoder. My bad, I will review your previous posts.

As to HSC:

Go to hardware configuration and properties.
Go the the HSC you enabled
Scroll down to event configuration  and enable "generate interrupt for counter value.....bla, bla bla"
It will assign a hardware interrupt block. May be OB40.
Put the necessary HSC code that you want to execute.

Basically there are various types of OBs and there's a priority list of which OB type gets executed first. A hardware interrupt allows you  immediate access to an event. That event in your case will be reaching a specific count that you assign to HSC's NEW_RV

Pyrus

The encoder is connected to its driver, and has a 2 wires that are to be sent to the PLC. I wish to know how I'm supposed to connect these two wires to my PLC, and what function from inside the PLC (programically speaking) I am to use so that it can accurately perform the fast counting. 

 What are the details of the driver you mentioned? You may not need resistors at all.

William_B

4.
Bad news. Your code will not "cut" it.

Think physics and timings.
When you reach your position target it will already be too late to start the cutting.
The blade should have make contact with the paper already.
The reaction speed of the blade. travel speed of the blade
and the speed of the paper feed needs to be brought under consideration.

Probably you would want to synch the lateral movement
to be in synch with the paper feed.

If you are doing an in-motion cutting application, you are in big trouble.
In this case you need a motion controller running
an electronic cam application.

As I said before...   the high speed counter is the piece of the tip
that did not sink the Titanic.

5.
Converting the pulse measurement to a distance would be a good idea.
The user understands inches / mm.. not pulses.

Your thoughts?
w

William_B

engma

<snip>
because my problem is with software not hardware.

</snip>

{Set :: Mentor tone}
My dear brother...
If this is your thinking, then you are already lost.

We program because of the hardware and to compliment it.
If you do not understand how the hardware works,
then your program may very easily not do the right thing.

Case in point...  PWM vs PTO when using the H-bridge.
It is because of the hardware that I interfered.

Step0 - understand what is asked by the project and what the aims are.

Step1 - get to know the hardware and what is required. It does not need to be experimentally proven but it must be 99.5% sure from research at least. - - - in the actual hardware you are using.

Step2 - configure the hardware on the PLC.

Step3 - create a model (design) of rule based or mathematical formula to give control.

Step4 - coding

Step5 - test, evaluate, adapt.

w

 Project management 

Yikes, looks like you are doing Feed Roll Control/Cut to Length using start/Stop.  What are you using to drive your feed roll?  As William_B alluded to, your cut command must be issued when your product is stopped at the proper place, which means you need a proper position control.  If you trigger your stop solely on length, then there is additional distance traveled during the deceleration.  Whether your are stopping by brake or by using a drive on your motor, you can't change this. 

Cut-to-Length applications are not trivial.  You may want to give this a little bit more thought as to how it is executed.  Trust me, 90% of what I do is cut-to-length is some form.

Wow... This really isn't as simple (in system design) as I thought it would be. The problems are slowly being revealed like moths to a flame, and it worries me. I don't even know what the speed of the motor is, o consider if the breaking system would indeed be safe or not. Exactly as you guys mentioned: "Crash test dummies". Specially if there are stacks of paper, they will definitely fall in given at a high speed.

What I'm thinking about is motion control. I do hope this works though. I will have to define an offset to the counter so that the motor stops on its own, due to the weight of the papers. Let's say (depending on the size) it should be 1500 pulses, I'll give it an offset of 100 pulses, so that it reaches 1400 (and due to some inertia, may cross a bit a more, but that is to be expected). Now, the next step that I'm thinking is always using comparison instructions so that the motor slowly and with many triggers and stops covers the last pulses it's supposed to cover.

For example: Let's say it reached 1462 pulses. 38 pulses remaining. I use comparison instruction to give immediate start and stop responses to the motor so that it covers the needed pulses. I'll put multiple stops for most possible accuracy, and the data to compare will always be updated ones from a global data block in which the counter value is. So, 10 + 10 +10 +5 + 2 +1... Meaning I'll need a comparison instruction for 10 pulses, 5 pulses, 2 pulses and 1 pulse, each triggering the next if condition is true, otherwise it will keep on repeating. After all steps are complete, manual or automatic input may be executed to trigger the negative transition of the blade (when it cuts and goes back to its place) that indicates the cut is complete and the system is ready for another sequence. 

Now, I really am hoping that the motor is slow, in which case the breaking system may not be of much affect in shock or sudden stop forces.

I hope I am understanding you guys well, and taking the correct methods to solve this issue. The only thing I'm worried about is about an entire system change (should the client desires)... I do hope it does not come to that though

Pyrus

Wow... This really isn't as simple (in system design) as I thought it would be. The problems are slowly being revealed like moths to a flame, and it worries me. I don't even know what the speed of the motor is, o consider if the breaking system would indeed be safe or not. Exactly as you guys mentioned: "Crash test dummies". Specially if there are stacks of paper, they will definitely fall in given at a high speed.

What I'm thinking about is motion control. I do hope this works though. I will have to define an offset to the counter so that the motor stops on its own, due to the weight of the papers. Let's say (depending on the size) it should be 1500 pulses, I'll give it an offset of 100 pulses, so that it reaches 1400 (and due to some inertia, may cross a bit a more, but that is to be expected). Now, the next step that I'm thinking is always using comparison instructions so that the motor slowly and with many triggers and stops covers the last pulses it's supposed to cover.

For example: Let's say it reached 1462 pulses. 38 pulses remaining. I use comparison instruction to give immediate start and stop responses to the motor so that it covers the needed pulses. I'll put multiple stops for most possible accuracy, and the data to compare will always be updated ones from a global data block in which the counter value is. So, 10 + 10 +10 +5 + 2 +1... Meaning I'll need a comparison instruction for 10 pulses, 5 pulses, 2 pulses and 1 pulse, each triggering the next if condition is true, otherwise it will keep on repeating. After all steps are complete, manual or automatic input may be executed to trigger the negative transition of the blade (when it cuts and goes back to its place) that indicates the cut is complete and the system is ready for another sequence. 

Now, I really am hoping that the motor is slow, in which case the breaking system may not be of much affect in shock or sudden stop forces.

I hope I am understanding you guys well, and taking the correct methods to solve this issue. The only thing I'm worried about is about an entire system change (should the client desires)... I do hope it does not come to that though

 I think you need to focus a little more on the system design at this point and a little less on how to process encoder signals.  That will turn out to be the simple part.

You need to know how you are moving the product.  If you have a drive system, and if you have an encoder on the motor, then the built in Motion functions should work fine for what you are doing.  Depending on your tolerance and dynamic requirements, a standard AC should work fine.  Use your other encoder to measure the actual length and close your position loop.  Use In_Position and 0_Speed signals to control your shear.  Brake really is not needed except for holding with no power.

Hello again! I just wanted to log in to tell you that the encoder with the program worked! Believe it or not, I STILL didn't see the client's machine to take the proper measurements to know the factor to multiply with (or divide) depending on the high speed counter. I put a suggestive constant (x100 multiply) and making it the goal of the high speed counter. (Basically, if I need 25 (units), the encoder has to count 2500 pulses to reach). I have also manually created an automatic position control to control those extra counts the motor includes due to inertia when the power should be off. The HMI and PLC code both are working perfectly. 

Thank you all for your help!

Strangely enough, when I did the online simulation, there was no need for a cable shield or anything. It worked out on its own. Dunno how exactly. I just used 2 wires for power, and 2 wires for the A/B quadrature phase.

You will only need to hook up the following provided that the inputs are open, and using HSC 1 enabled.

A+ to I0.0

B+ to I0.1

Then monitor ID1000 under the HSC,

Dont forget to change your input channel 0 and 1 filters to the respected rate of your encoder.

this is an perfect example why I hate FBD ;-)

it looks like a web and I think after a year you will not be able to understand what the thing is about!

you need write code in a way others can understand and follow it EASILY

for your own benefit and for benefit of your service / maintenance staff!