Using stepping motor with IONI

Using stepping motor with IONI drive is possible in three ways:

Mode1 - Open loop (no encoder)

This is the traditional stepping motor drive method. Will achieve highest speed and is easily configurable but there is no feedback, so if motor stalls/loses synchronism, the absolute position will be unknown before referencing/homing.

Mode 2 - Closed loop (with encoder feedback)

This is open loop mode combined with encoder feedback. The advantages are that drive can detect loss of synchronism and restore to commanded position with clear faults command. May be used also with linear encoder to enhance system accuracy.

Mode 3 - Servo (with encoder feedback)

In this mode, a stepping motor is used as high pole count brushless servo motor. In this mode, motor efficiency is high (no current if no load) and motor do not lose synchronism. However, motor speed is limited by back EMF of motor and typically can achieve lower top speed than the other modes. In this mode stepper can be also safely driven over it's rated current to get higher peak torque than it's rated torque (like a servo motor).

In the modes 1 and 2 stepper is driven with constant current drive and the motion produced by adjusting phase angle (traditional stepper drive method). In the mode 1 phase angle is controlled directly by setpoint trajectory and in mode 2 it is controlled by encoder based feedback loop. In the mode 3 motor current is controlled by torque controller (from zero to peak current limit) while phase angle is synchronized to rotor angle by the help of encoder. Mode 3 is similar to servo motor control (more details).

Setting up open loop mode 1

In this mode, drive emulates encoder internally and some tuning parameters need to be set to allow operation:

Using stepping motor with IONI/param\ Motor type

Stepping motor

Using stepping motor with IONI/param\ Feedback device

None

Using stepping motor with IONI/param\ Invert feedback direction

Unticked

Using stepping motor with IONI/param\ Feedback device resolution

6400 (this is the emulated encoder resolution, 6400 PPR = 25600 steps/rev)

Using stepping motor with IONI/param\ Motor continuous current

This is the resting current when motor stands still. Drive will switch to this after 0.5 seconds of standing still.

Using stepping motor with IONI/param\ Motor peak current limit

This is the motor rated current that is used when motor is rotating.

Using stepping motor with IONI/param\ Motor coil resistance

See motor datasheet or if not known, start with low values such as 1 ohm

Using stepping motor with IONI/param\ Motor coil inductance

See motor datasheet or if not known, start with low values such as 1 mH

Using stepping motor with IONI/param\ Control mode

Set to Position control (typical) or Velocity control mode

Using stepping motor with IONI/param\ Velocity P gain

0

Using stepping motor with IONI/param\ Velocity I gain

900

Using stepping motor with IONI/param\ and Using stepping motor with IONI/param\

0

Using stepping motor with IONI/param\ Position P gain

150

Using stepping motor with IONI/param\ Position feed-forward gain

100%

Using stepping motor with IONI/param\ Over speed fault

1000

Using stepping motor with IONI/param\ and Using stepping motor with IONI/param\ fault limits

1000

Other settings are not critical and can be configured as desired (such as acceleration and velocity limits). If setpoint scaling is 1:1 (Using stepping motor with IONI/param\=Using stepping motor with IONI/param\), then this mode yields resolution of 25600 steps/revolution. If reduction of resolution is required, then adjust scaling accordingly (if scaling is set above 4:1, then try also Setpoint smoothing Using stepping motor with IONI/param\).

NOTE: these values and settings apply from firmware version 1.2.1 (1064). For older firmware version, check out earlier version of this page here.

Seting up closed loop mode 2

In this mode, follow parameterization of closed loop mode except:

Using stepping motor with IONI/param\ Feedback device

Choose your feedback device (other than None)

Using stepping motor with IONI/param\ Invert feedback direction

Try both settings and choose the one with stability

Using stepping motor with IONI/param\ Feedback device resolution

Set your feedback device resolution

Using stepping motor with IONI/param\ and Using stepping motor with IONI/param\

Tune KVI and KPP values (and possibly other gains if non-zero) to have nice response

Using stepping motor with IONI/param\ Motion fault limit

Set non-zero value (perhaps 100-1000) to cause a fault state when motor stalls

Setting up servo mode 3

To set-up stepper as servo motor, just follow the IONI & IONICUBE user guide and consider the stepper motor as servo motor. For a typical 1.8 degree/step two-phase stepping motor the correct motor type parameters are:

Using stepping motor with IONI/param\ Motor type

2 Phase AC or BLDC

Using stepping motor with IONI/param\ Pole count

100

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