As I stated previously ...
When the Photo-Sensor sends the "STOP" signal to the Motor Controller,
the Motor Controller changes from a Precise Dispensing Velocity to a Precise Deceleration Rate down to Zero Velocity.
Zero Velocity will occur within +/-1 encoder Counts of the expected Encoder Count,
giving a very constant / fixed over-shoot distance ( in Encoder Counts ) from the Photo-Sensor Signal.
Given the Precise Dispensing velocity when the STOP signal is received and
a precise Deceleration Rate from the Dispensing Velocity down to Zero Velocity then
the motor will stop the coupon at exactly the same position every time, within +/-1 Encoder Count.
Now simply move the Photo-Sensor, as needed, to align the perforation of the Coupon.
Precise Dispensing Velocity + Stop Signal + Precise Deceleration Rate = exact repeatable stopping point after the Photo-Sensor signal
The Motor Controller works units of "Encoder Counts per Unit Time".
It is better to have controlled acceleration ramps and deceleration ramps = easy on the gears.
Full torque Hard Start and Hard Stop will cause extra wear and tear on the gears, etc.
As I stated in message #66...
A Closed-Loop Servo or a Stepper Motor makes more sense here.
When the Photo-Sensor sends the "STOP" signal to the Motor Controller,
the Motor Controller changes from a Precise Dispensing Velocity to a Precise Deceleration Rate down to Zero Velocity.
Zero Velocity will occur within +/-1 encoder Counts of the expected Encoder Count,
giving a very constant / fixed over-shoot distance ( in Encoder Counts ) from the Photo-Sensor Signal.
Given the Precise Dispensing velocity when the STOP signal is received and
a precise Deceleration Rate from the Dispensing Velocity down to Zero Velocity then
the motor will stop the coupon at exactly the same position every time, within +/-1 Encoder Count.
Now simply move the Photo-Sensor, as needed, to align the perforation of the Coupon.
Precise Dispensing Velocity + Stop Signal + Precise Deceleration Rate = exact repeatable stopping point after the Photo-Sensor signal
The Motor Controller works units of "Encoder Counts per Unit Time".
It is better to have controlled acceleration ramps and deceleration ramps = easy on the gears.
Full torque Hard Start and Hard Stop will cause extra wear and tear on the gears, etc.
As I stated in message #66...
A Closed-Loop Servo or a Stepper Motor makes more sense here.