There is still a possibility of loss of step in permanent magnet stepper motors, mainly for the following reasons:

1.Load mutation. When the load on the motor changes suddenly, such as a sudden switch from no-load state to high-load state, the motor may lose step. This is because the motor needs to readjust the output torque to adapt to the new load, and the adjustment process may cause the relative offset between the rotor and the rotating magnetic field.

2.Saturation effect. Under high load conditions, the magnetic circuit of the motor may be saturated, resulting in uneven magnetic field distribution. This will cause a relative offset between the rotor and the rotating magnetic field of the motor, causing loss of step.

3.Control system errors may also cause permanent magnet stepper motors to lose step. Sensors, encoders and other components in the control system have certain measurement errors. If the error is too large or accumulates to a certain extent, it may cause the motor to lose step.

In order to solve the problem of permanent magnet stepper motors losing step, the following measures can be taken:

1.Optimize control strategy. Use advanced control algorithms and technologies to improve the operating stability and anti-interference ability of the motor. For example, use vector control, model predictive control and other methods to monitor the state of the motor in real time and make dynamic adjustments to keep the rotor and the rotating magnetic field synchronized.

2.Improve the structural design of the motor. By optimizing the magnetic circuit structure of the motor and reducing the saturation effect of the magnetic circuit, the stability and anti-stepping ability of the motor can be improved. For example, increase the number of windings in the magnetic circuit, change the shape of the permanent magnet, etc.

3.Improve the accuracy of sensors and encoders. Improve the accuracy and stability of the measuring equipment and reduce the impact of measurement errors on the control system.

Although the probability of permanent magnet stepper motors losing steps is low, it is still possible under certain working conditions. By optimizing the control strategy, improving the motor structure design and improving the accuracy of the measuring equipment, the risk of permanent magnet stepper motors losing steps can be effectively reduced to ensure their stable and reliable operation. With the continuous advancement of technology, it is believed that the problem of permanent magnet stepper motors losing steps will be better solved.

Source: https://stepperlink.over-blog.com/2024/06/permanent-magnet-stepper-motor-loss-of-step-and-solution.html