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The encoder resolution is 10000. Fortunately the problem seems to have been resolved by making small adjustments to the steps/mm value and finally it settled down, though from the symptom's it was not easy to diagnose. Thank you to every one for your suggestions. Mike

Thanks for your replies, We have checked the encoder and the rest of the electronics associated and we found nothing wrong. We tried with a new encoder and encoder module on the plc. The encoder cable is the original with no extensions (under 800mm), properly shielded, far away from any power...

The part travels at very slow speed (less than 4m/min), and start and stop regularly along the machine to be punched and finally cut to length. The acceleration and deceleration time is almost 0; 10mm before reaching the required position the speed is reduced (less than 0.5m/min) and finally...

We have a sheet metal roll forming machine that performs various operations before finally shearing to length, the component length is required to vary, however the component length should be within +/- 0.5mm max. The drive is hydraulic and the encoder is driven by a wheel (rubberized) mounted...