PREDICTIVE FAILURE CONTROL Of Stepper Motors Using PID

Stepper motors are a mainstay in precision control systems, valued for their simple open-loop operation and high torque at low speeds.

- RAJESH KRISHNAN

Commonly found in CNC machines, 3D printers, and robotics, they offer reliable motion control—yet their open-loop nature leaves them vulnerable to missed steps, overheating, and mechanical wear. Introducing a closed-loop PID (proportional-integral-derivative) control system significantly improves performance, enabling real-time monitoring to predict and prevent failures.

This system integrates a PID algorithm with predictive and preventive fault detection, implemented on an Arduino microcontroller and simulated using Proteus. Before exploring the implementation, it helps to revisit the core principles of PID control and the formula used. The complete list of required components is provided in the Bill of Materials table. The prototype is shown in Fig. 1.

PID control algorithm

Once the PID formula was developed, the design, proceeded with material selection. The PID controller is a feedback loop mechanism widely used in industrial control systems. It calculates an error value as the difference between a desired setpoint (SP) and a measured process variable (PV). The controller then attempts to minimise this error by adjusting the control inputs accordingly. For further details and the PID formula, refer to standard text-books or verified online resources.