Variable torque control of a stepper motor

• US 8,975,854 B1
• Filed: 04/05/2013
• Issued: 03/10/2015
• Est. Priority Date: 04/05/2013
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Rawles, LLC (Amazon.com, Inc.)
• Inventors: Coley, Christopher D., Poulad, Navid, Xu, Jijie
• Primary Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US13/857,948
• Time in Patent Office: 704 Days
• Field of Search: 318/2, 318/685
• US Class Current: 318/685
• CPC Class Codes: H02P 3/025 holding the rotor in a fixed position after deceleration
• CPC Class Codes: H02P 8/12 Control or stabilisation of current
• CPC Class Codes: H02P 8/14 Arrangements for controlling speed or speed and torque H02P8/12, H02P8/22 take precedence
• CPC Class Codes: H02P 8/30 Holding position when stopped

Abstract

A stepper motor may be controlled by a controller to provide extended revolution of a motor shaft while operating in a first mode and to allow a user to manually intervene with an intended position or rotation of the motor shaft while operating in a second mode. In some embodiments, the controller may adjust a torque applied to the stepper mode during operation of the stepper motor. The controller may reduce a torque applied by the stepper motor to a lower torque while the user intervenes with the intended position or rotation of the motor and increase the torque to a holding torque after the user intervention has ended. Thus, the controller may dynamically adjust a torque of the stepper motor in response to detection of the user intervention.

Claims

1. A stepper motor assembly comprising:

a stepper motor having a first coil, a second coil, a stator and a motor shaft, the motor shaft coupled to a first part of a device and the stator coupled to a second part of the device that moves relative to the first part, the stepper motor to rotate the first part to a control position or maintain the first part in the control position with respect to the second part;

an encoder to detect rotation of the motor shaft and output position feedback in response to the detected rotation, the position feedback corresponding to an actual position of the motor shaft relative to the stator;

a driver to receive a vector control signal and to generate a vector control current to be output to the stepper motor to cause the stepper motor, when unhindered, to rotate to the control position or maintain the control position, the vector control current having a first current applied to the first coil and a second current applied to the second coil; and

a controller to receive the position feedback, to generate the vector control signal for the driver to cause the stepper motor to rotate to the control position or to maintain the control position, and to adjust a torque applied by the stepper motor by;

determining an occurrence of user intervention with the motor shaft based at least in part on the control position being different than the actual position based at least in part on the position feedback;

decreasing the torque during at least a portion of the occurrence of the user interaction;

determining an end of the occurrence of the user interaction; and

increasing the torque to at least a holding torque to maintain a new position of the first part relative to the second part, the new position resulting at least partly from the user intervention.

2. The stepper motor assembly as recited in claim 1, wherein the driver detects current feedback from the stepper motor in response to the actual position of the stepper motor being different than the control position, wherein the controller receives the current feedback from the driver, and wherein, prior to decreasing the torque, the controller increases the torque to a maximum torque in response to the current feedback indicating that the actual position is different than the control position.

3. The stepper motor assembly as recited in claim 1, further comprising a proximity sensor to transmit a signal to the controller, and wherein the determining the end of the occurrence of the user interaction by the controller is based at least in part on receipt of the signal.

4. The stepper motor assembly as recited in claim 1, wherein the driver generates a new vector control current that corresponds to the new position of the first part relative to the second part, the new vector control current to maintain the new position.

5. A method comprising:

determining an occurrence of user intervention of rotation of a motor shaft of a stepper motor based on one or more of a control position of the motor shaft being different than an actual position of the motor shaft or a current feedback received by a controller indicating that the actual position is different than the control position;

decreasing a torque applied by the stepper motor to the motor shaft during at least a portion of the user interaction;

determining an end of the occurrence of the user interaction; and

increasing the torque applied to the motor shaft to at least a holding torque to maintain a new position of the motor shaft.

6. The method as recited in claim 5, further comprising, prior to the decreasing the torque, increasing the torque to a maximum torque in response to the current feedback indicating that the actual position is different than the control position, and wherein the decreasing the torque occurs immediately after the torque is increased to the maximum torque.

7. The method as recited in claim 5, wherein the control position is based on a vector control current that specifies an amount of current for each coil of the stepper motor.

8. The method as recited in claim 7, wherein the vector control current causes the stepper motor to rotate to the control position or to maintain the control position.

9. The method as recited in claim 8, further comprising generating a new vector control current, different than the vector control current, that corresponds to the new position, the new vector control current to maintain the new position of the motor shaft.

10. The method as recited in claim 5, wherein the determining an occurrence of user intervention comprises receiving a signal form a proximity sensor, the proximity sensor is at least one of a capacitance touch sensor or a resistive touch sensor.

11. The method as recited in claim 5, wherein the determining the end of the occurrence of the user interaction is performed based at least in part on at least one of the control position indicating no movement of the motor shaft during a first threshold amount of time or no current feedback being received by the controller during a second threshold amount of time.

12. The method as recited in claim 5, wherein the increasing the torque to at least the holding torque includes:

increasing the torque to a maximum torque immediately after the determining the end of the occurrence of the user interaction; and

decreasing the torque to a minimum torque that maintains a position of the motor shaft to determine the holding torque.

13. The method as recited in claim 5, further comprising, prior to the determining the occurrence of the user intervention, controlling the stepper motor to cause a constant rotation of the motor shaft.

14. The method as recited in claim 5, further comprising, after the increasing the torque to the at least the holding torque, controlling the stepper motor to cause a constant rotation of the motor shaft.

15. A system comprising:

a stepper motor to rotate a motor shaft to a control position or maintain the motor shaft in the control position; and

a controller to receive at least one of position feedback or a signal from a proximity sensor, and to generate a control to cause the stepper motor to rotate to the control position or to maintain the control position, the controller to determine a torque to be applied by the stepper motor, the torque determined by;

determining an occurrence of user intervention with the motor shaft based at least in part on the position feedback or the signal from the proximity sensor;

decreasing the torque during at least a portion of the occurrence of the user interaction;

determining an end of the occurrence of the user interaction; and

increasing the torque to maintain a new position of the motor shaft.

16. The system as recited in claim 15, further comprising an encoder to detect rotation of the motor shaft and output the position feedback to the controller in response to the detected rotation.

17. The system as recited in claim 15, further comprising the proximity sensor to transmit a signal that indicates the occurrence of the user interaction.

18. The system as recited in claim 15, further comprising a driver to receive the control from the controller and to generate a vector control current to be output to the stepper motor to cause the stepper motor, when unhindered, to rotate the motor shaft to the control position or maintain the motor shaft in the control position, the vector control current having a first current applied to a first coil of the stepper motor and a second current applied to a second coil of the stepper motor.

19. The system as recited in claim 18, wherein the driver detects current feedback from the stepper motor in response to an actual position of the motor shaft being different than the control position, wherein the controller receives the current feedback from the driver, and wherein, prior to decreasing the torque, the controller increases the torque to a maximum torque in response to the current feedback indicating that the actual position is different than the control position.

20. The system as recited in claim 19, wherein the driver generates a new vector control current that corresponds to the new position of the motor shaft, the new vector control current to maintain the new position.