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​Stepper motors​ may encounter a variety of common faults during use, including lost steps, stalling, inaccurate positioning, etc. The causes of these faults are diverse, but these problems can be effectively solved through proper troubleshooting and solutions.

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Causes:

The acceleration of the rotor is slower than the rotating magnetic field of the stepper motor, causing the motor to be unable to follow the changes in the magnetic field.

The stepper motor and the load it carries have inertia, which prevents the motor from starting and stopping immediately during operation. The stepper motor resonates, causing the motor to vibrate more. Insufficient power or unstable drive voltage causes the effective current inside the motor to be too low. The driver signal is disturbed, causing errors in the pulse signal.

Solution:

Increase the drive current of the stepper motor, increase the output torque, and reduce the phenomenon of lost steps.

Increase the drive voltage of the drive circuit and increase the electromagnetic torque of the motor.

Use a stepper motor with large torque to better overcome the inertia and friction resistance of the load.

Set a longer acceleration time so that the stepper motor can obtain enough energy during the start-up and acceleration process.

Causes: The starting speed is too high or the acceleration is too large, causing lost steps; the working torque of the stepper motor itself is insufficient and does not have enough capacity to drive the load; the controller or driver is disturbed and causes malfunction.

Solution: Appropriately reduce the starting speed and acceleration to ensure that the working torque of the stepper motor can drive the load; check and eliminate the interference source of the controller or driver to improve the anti-interference ability of the system.

Causes: Lost pulses when changing direction; Lost steps due to too high starting speed or too large acceleration; Improper setting of synchronous belt compensation parameters; False operation of the controller or driver caused by system interference.

Solution: Adjust the logic of pulse transmission or add delay to solve the problem of lost pulses when changing direction; Appropriately reduce the starting speed and acceleration; Adjust the compensation parameters of the synchronous belt according to the actual situation; Find and reduce the interference ability of the interference source and improve the anti-interference ability of the system.

Through the above methods, common faults encountered by stepper motors during use can be effectively solved to ensure the normal operation of the motor and the stable operation of the system.

Source:​https://the-dots.com/projects/common-faults-and-troubleshooting-methods-of-stepper-motors-1097908​