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FAQ: What is closed-loop stepper motor control with step-loss compensation?

By Lisa Eitel | June 27, 2016

Closed-loop stepper-motor control with step-loss compensation is a common performance-boosting algorithm for stepper systems.

In one prevalent form of step-loss compensation, an angle sensor or encoder tracks the motor-rotor position and any missed steps. Then the controller records its commands and the actual motor position from the encoder … converting position data to the equivalent number of steps. When the controller detects missed steps, it triggers position correction with makeup steps.

This form of step-loss compensation is useful when a stepper motor must deliver full speed or run near its maximum load (or where the output shaft is at risk of jamming).

Control in context: Preventing motors from missing steps

In another sensorless setup of step-loss compensation, the controller detects stalls through use back-EMF measurements for feedback.

Here, the controller uses a position loop to avoid lost steps from external disturbances through a current loop that modifies input to the motor … and keep the motor going, even under variable load.

Sensorless step-motor stall detection uses tracking of back EMF induced by rotor motion — leveraging the fact that back-EMF voltage proportional motor-rotor speed.

Sensorless step-motor stall detection uses tracking of back EMF induced by rotor motion — leveraging the fact that back-EMF voltage proportional motor-rotor speed.

Stepper motors have the advantage of running in an open loop configuration, as explained in FAQ: What is closed-loop control with load-position control? But closed-loop systems such as step-loss or load-position control require system feedback. Even so, these setups are less complicated and need less feedback than systems based on servomotors.

Note that some manufacturers define closed-loop stepper control as sinusoidal commutation using encoder feedback — to track rotor position and enable true field-oriented control. They argue that encoder-fitted stepper motors without field-oriented control (or sinusoidally commutated current control) are not true closed-loop options. The logic here is that such systems can only track step position and can’t correct for lost step during operation.

In contrast, true closed-loop stepper setups can correct for step losses. Here, the motor windings carry sinusoidal phase currents and the drive ensures the stator and rotor magnetic fields are complementary — so field strength delivers the target torque level. Such well-metered current in the windings lets the motor output consistent force with minimal noise and heat waste.

In contrast with load-position controls, step-loss controls don’t continuously compensate for errors throughout the movement profile.

Rather, only if the system detects lost steps does it take any corrective action.

Step-loss compensation is simpler than load-position control. Still, when considering whether to use closed-loop stepper motor control with step-loss compensation, think about what a particular system needs. Lost steps can throw off the entire operation of a stepper-motor-driven system. However, the degree to which a particular setup is sensitive to such failures will dictate whether it’s worthwhile to include step-loss compensation.

Another caveat: Step-loss compensation can correct errors and act as insurance. However, it shouldn’t serve as a first line of defense to make a stepper-control system foolproof. Take steps to ensure as few steps as possible are missed in the first place:

1) Select an appropriately sized motor. Here, use safety factors and ensure external causes don’t cause stalls.

2) Always test systems to make sure they won’t skip steps. Usually when a motion design misses steps, it loses multiple steps and not just one at a time. Careful checking and testing along with step-loss compensation can lead to more stable, reliable systems.

Edited by Zak Khan.

For more information on closed-loop stepper motor control with step-loss compensation:

ElectroCraft: Integrated Motor DC (IMDC) Closed-Loop Stepper FAQs

PDF Download: Mircomo Solutions — How to prevent step losses with stepper motors?

Motion Control Tips


Filed Under: Motors • stepper, Motion Control Tips

 

About The Author

Lisa Eitel

Lisa Eitel has worked in the automation industry since 2001. Her areas of focus include motors, drives, motion control, power transmission, linear motion, and sensing and feedback technologies. She has a B.S. in Mechanical Engineering and is an inductee of Tau Beta Pi engineering honor society; a member of the Society of Women Engineers; and a judge for the FIRST Robotics Buckeye Regionals. Besides her motioncontroltips.com contributions, she also leads the production of the quarterly motion issues of Design World.

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