Performance Comparison Between Microstepping and Field-Oriented Control for Hybrid Stepper Motors

With their cost-effective manufacturing process, hybrid stepper motors (HSMs) are a popular choice for position control in low-power industrial applications. These versatile motors offer a compelling solution for reducing system costs and size since at standstill/low speeds, HSMs typically have higher torque density with respect to low-power permanent magnet (PM) motors. This higher torque density determines a reduced use of rare-earth PMs and, therefore, a lower environmental footprint. In practical applications, the commonly used microstepping control faces low efficiency, low dynamic performance, vibrations, and a variable maximum continuous torque depending on the working point. In this paper, the operating region of an HSM is extended in the field-weakening (FW) region, showing how field-oriented control (FOC) with FW allows one to strongly increase the drive performance with a slight cost increase thanks to the availability of low-cost magnetic encoders. Due to the fact that FOC provides only the requested current, the HSM faces lower temperatures, lower insulation degradation, and lower permanent magnet demagnetization issues. An experimental evaluation comparing the commonly used microstepping and the proposed FOC with FW is performed on four commercial HSMs with different DC voltage power supplies using an industrial test bench. In particular, the experimental campaign has a focus on steady-state conditions in the case of the maximum continuous torque, showing the advantages of FOC with FW because the advantages in transient conditions are well known.