Hybrid stepper motors are a common type of electric motor used throughout industry thanks to its low-cost, high torque at low speed and open loop positioning capabilities. However, a closed loop control is often required for industrial applications with high precision requirements. The closed loop control can also be used to lower the power consumption of the motor and ensure that stalls are avoided. It is quite common to utilise a large and costly position encoder or resolver to feedback the position signal to the control logic. This thesis has explored the possibility of using a low-cost position sensor based on Hall elements. Additionally, a sensorless estimation algorithm, using only stator winding measurements, has been investigated both as a competitive alternative and as a possible complement to the position sensor. The thesis work summarises and discusses previous research attempts to adequately measure or estimate and control the hybrid stepper motors position and load angle without using a typical encoder or resolver. Qualitative results have been produced through simulations prior to implementation and experimental testing. The readings from the position sensor is subject to noise, owing to its resolution and construction. The position signal has been successfully filtered, improving its accuracy from 0.56° to 0.25°. The output from the sensorless estimation algorithm is subject to non-linear errors caused by errors in phase voltage measurements and processing of velocity changes. However, the dynamics are reliable at constant speeds and could be used for position control.

Thesis (PhD)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: In this dissertation a new type of electrical machine, a Radial Flux Air-Cored Permanent Magnet machine with a Double-sided Rotor and utilising concentrated, non-overlapping windings, is proposed. The concept of the Double-sided Rotor Radial Flux Air-Cored Permanent Magnet machine, or RFAPM machine for short, was derived from the Double-sided Rotor Axial Flux Air-Cored Permanent Magnet (AFAPM) machine. One of the problems that AFAPM machines experience, is the deflection of the rotor discs due to the strong magnetic pull of the permanent magnets, especially with double-sided rotor machines. The main advantage of a RFAPM machine over a AFAPM machine is that the rotor back-iron is cylindrically shaped instead of disk shaped. Due to the structural integrity of a cylinder, the attraction force between the two rotors does not come into play any more. The focus of this dissertation is on a thorough analytical analysis of the Double-Sided Rotor RFAPM machine. With the RFAPM being an air-cored machine, the feasibility to develop a linear, analytical model, to accurately predict the radial flux-density and hence the induced EMF in the stator windings, as well as the accurate calculation of the developed torque of the machine, needed to be investigated. The need for a thorough analytical examination of the Double-Sided Rotor RFAPM machine stemmed from the need to reduce the blind reliance on Finite Element Modelling (FEM) software to calculate the back-EMF and torque produced by these machines. Another problem experienced with the FEM software was to obtain accurate torque results. Excessive ripple torque oscillations were sometimes experienced which took a considerable amount of time to minimise with constant refinement to the meshing of the machine parts. Reduction in the mesh element size unfortunately also added to the simulation time. The requirement for an accurate analytical model of the RFAPM machine was also necessary in order to reduce the amount of time spent on successive FEM simulation to obtain the optimum pole arc width of the permanent magnet in order to minimise the harmonic content of the radial flux-density distribution in the the stator windings. In this dissertation, the use of single-layer and double-layer, non-overlapping, concentrated winding for the RFAPM machine is also investigated. It was decided to include a comparison of these two non-overlapping winding configurations with a “hypothetical” concentrated, overlapping winding configuration. This would allow us to gauge the effectiveness of using nonoverlapping winding with respect to the reduction in copper losses as well as in the reduction in copper volume. It would also allow us to investigate the extent of how much the developed torque is affected by using non-overlapping windings instead of overlapping windings. / AFRIKAANSE OPSOMMING: In hierdie proefskrif word ’n nuwe tipe elektriese masjien, ’n Radiale-vloed Lugkern Permanent Magneet Masjien met ’n dubbelkantige rotor en nie-oorvleuelende Windings voorgestel. Die konsep vir die Radiale-vloed Lugkern Permanent Magneet Masjien, of RVLPM vir kort, is afgelei vanaf die Dubbelkantige Rotor, Aksiale-vloed Lugkern (AVLPM) masjien. Een van die probleme wat met AVLPM masjiene ondervind word, is die defleksie van die rotorjukke as gevolg van die sterk aantrekkingskragte van die permanente magnete, veral in dubbelkantige rotor masjiene. Die hoof voordeel wat die RVLPM masjien inhou bo die AVLPM masjien, is die feit dat die RVLPM se rotorjukke silindries is in plaas van ronde skywe. As gevolg van die strukturele integriteit van ’n silinders, speel die aantrekkingskrag van die permanente magnete nie meer ’n rol nie. Die fokus van die proefskrif gaan oor die deeglike analitiese analise van die dubbelkantige RVLPM masjien. Weens die feit dat die RVLPM masjien ’n lugkern masjien is, is daar besluit om ondersoek in te stel na die moontlikheid om ’n lineêre, analitiese model vir die masjien op te stel waarmee die radiale-vloeddigtheid, teen-EMK asook die ontwikkelde draaimoment vir die masjien akkuraat bereken kan word. Die behoefde aan ’n akkurate analitiese model vir die dubbelkantige rotor RVLPM masjien is om die blinde vertroue te elimineer wat daar in Eindige-Element Modellering (EEM) sagteware gestel word om die teen-EMK en ontwikkelde draaimoment van die RVLPM masjien uit te werk. ’n Verdere probleem wat daar met EEM sagteware ondervind is, is die akkurate berekening van die ontwikkelde draaimoment. Oormatige rimpel draaimoment ossillasies is soms ondervind wat heelwat tyd geverg het om te minimeer, deur voortdurende verfyning van die EEM maas in die verskillende dele van die masjien. Soos die maas egter kleiner word, verleng dit die simulasie tyd van die EEM aansienlik. Nog ’n rede vir ’n akkurate analitiese model van die RVLPM masjien, is om vinnige metode te verkry om die optimale permanente magneet pool hoekwydte te verkry, wat die minste Totale Harmoniese Vervorming (THV) in die radiale-vloeddigtheidsdistribusie in die statorgebied sal veroorsaak, sonder om herhaaldelike EEM simulasies te loop. In die proefskrif word die gebruik van enkellaag en dubbellaag, nie- oorvleuelende, gekonsentreerde wikkelings vir die RVLPM masjien ook ondersoek. Daar is besluit om hierdie twee nie-oorvleuelende windingskonfigurasies met ’n “hipotetiese” gekonsentreerde, oorvleuelende windingskonfigurasie te vergelyk. Dit behoort ons in staat te stel om die doeltreffendheid van nie-oorvleuelende windings te bepaal, met betrekking tot die afname in koperverliese asook die afname in kopervolume. Verder sal dit ons in staat stel om ook mate waartoe die ontwikkelde draaimoment deur nie-oorvleuelende windings beïnvloed word, te ondersoek.

For positioning of linear stages in absolute coordinates, there is a general need to find a reference position since the initial one is unknown. This is commonly called homing. To reduce costs and facilitate assembly, homing can be performed without additional sensors, known as sensorless homing. This thesis delves into sensorless homing, specifically with respect to stepper motors, and develops a graphical application for control of them. The commercial technology StallGuard is applied inconjunction with exploration into how it – and sensorless load detectionin general – functions. The resulting graphical application can be used to configure the stepper motors, perform homing using StallGuard, and automatically tune StallGuard to work despite varying conditions. In addition, rudimentary sensorless load detection independent from StallGuard is developed, demonstrating how it could work in practice. Testing shows homing with StallGuard resulting in a position within a ±5μm window in 94% of cases, less than 1/7 the width of an average strand of human hair. Additionally, homing is easily performed with a single button press from the graphical interface, with optional additional configuration available.