Chris,
Thanks for the detailed reply. Responding by group:
• Sensorless for RPM, accel/decel: Got it.
• Hold, count steps, single step with Hall sensors and encoder: I'm hoping that all of this can be done without an encoder at the resolution(!) of a single BLDC step, i.e., coarse, but made much finer effectively by the gearbox.
• Similarly, for "micro stepping", presuming a delta UVW wiring for the motor stator, couldn't I position the motor at a "half step" with U positive, and V and W negative with equivalent currents? And move within that single step be varying the average current through V and W via PWM?
• Re force, I'm presuming I can vary the torque generated by the motor at fixed voltage by varying the drive current (via PWM again). Correct? Conversely, (as I've noted with a simple speed control coupled to the motor), I can estimate the resisting torque of the mechanical load by the average current (useful up to stall torque).
Yes, there are advantages with stepper motors. But in high-end robotics, I understand it's much more common to use DC servo motors to get a wider range of speeds and force feedback. I'm just trying to bring those advantages down to small, low-cost platforms, especially taking advantage of the plethora of cheap, powerful BLDC motors (e.g., for helicopter drones).
Thanks again,
Mike