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22-04-2020 #5
With a fully closed loop system then you are entering into another level of complexity which I wouldn't recommend to a new user. But also I certainly wouldn't go through the painful and expensive learning process your going to have go thru learning Linux CNC (mach3/4 cannot close the loop without special hardware) just to use a stepper system.
To get the best from closed-loop you need AC or DC Servo motors which can react fast enough to the tiny fractional positional commands being fired at it and hold the position. Steppers cannot do this very well.
Also just let me point this out about a Fully closed-loop System that some new users don't realize.
If the machine goes too far and overshoots or undershoots then the Fully closed-loop system knows and the controller brings it back into the correct place which an Open-loop system doesn't.!! . . . BUT it's still lost the position and gone too far so cut into an area you probably didn't want with the same result that it's potentially damaged or ruined the workpiece..!!
This is no different to a stepper system losing steps. The main difference is that the controller's Fully closed-loop system won't let it get out of control and keep the error tiny or fault and constantly watching and adjusting the following error and when it gets too large throws a fault. A properly set up closed-loop Servo system will keep these following errors to tiny values which in the grand scheme mean nothing and you won't get faults.
But going back to steppers and not reacting fast enough then it's a lot of effort for not much gain to tune a system so it will be stable and not throw constant following errors because the steppers cannot keep up.
Whereas a properly setup and tuned Closed-loop at the drive stepper system will give you just the same protection by watching the position matches the commanded position and correcting if it doesn't, it just doesn't tell the upper controller anything about it. Also, it will throw a fault if the following error gets too great just the same.
But the bottom line is Stepper or Servo open or Closed-loop system if not correctly set up and tuned correctly will wreck the job. The only difference usually is that with a servo system you won't know until much later because it didn't stall, likewise with a poorly setup stepper system that doesn't stall but drops missed steps you won't know until later either.
My advice is to save your self a world of pain and just use a purpose-built closed-loop stepper system which is tuned conservatively because they do work more than good enough to match the limits of a stepper driven machine. After this then you enter a whole new and to be honest, expensive world of AC/DC servo motors and the related hardware needed to get the best from them.
Also just to point something out in that video that he's VERY WRONG about is that the parallel port is certainly NOT the best and most reliable way or choice.!! . . . The USB and Esp the USB Smooth stepper was or is rubbish and unreliable. Ethernet is far superior to both of them and much faster, more stable and capable of handling servos or steppers easily.
Hope this helps and if it helps any I've built well in excess of 100 stepper driven machines both open and closed-loop ranging from small to 10x5 machines and they all worked perfectly fine because it's how they are set up and the quality of components used along with build quality that matters most.
Build a sloppy machine and no closed-loop or servo system in the world will make it any better, in fact, it will make it worse, because they don't tolerate sloppily built machines.!!
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