The Gecko stepper drives, if the rumour is correct, does exactly that.? Microstepping a stepper motor does not give better positioning accuracy unless it's close looped with an encoder.? ?That's because certain positions have far less torque because there is far less current so the load on the motor prevents it from turning.
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Take one your motors and couple it to some load.? Then step it in micro-steps and track it with a dial indicator. Not the 18 micro-steps it takes to move 0.001" but one micro-step at a time.
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What micro-stepping does, and it's primary reason for being isto keep the torque constant through the resonance spot of the motor.
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Above that point micro-stepping isn't needed and I believe the Gecko switches over from Micro to full steps. The result is higher speed with more torque.?
From what I can understand, very little, it seems that being able to switch microsteps on the fly changes the practabilty of stepper motors.
Of course you still need a suitably sized motor that's up to the forces needed with the chosen gearing. But it does open up new possibilities by making a given set up more versatile.
I'm not sure how at the moment but it seems that if you had some kind of feedback you could write the control software to dynamically alter steps to respond to how easily the material cuts; automatically optimising speed, precision and torque as best as possible with a given rig.
But...I know nothing. I just like interesting things.