Predictive Failure Control of Stepper Motors using PID Controller

Abstract

Stepper motors are commonly used in applications that require accurate position control such as robotics, automation, and industrial systems. However, their performance can be affected by issues like overheating, load variations, and mechanical stress, which may lead to failure. In this project, a predictive failure control system is designed using a Proportional-Integral-Derivative (PID) controller. The system continuously monitors parameters such as speed, position, and load conditions to identify abnormal behaviour at an early stage. Based on this analysis, corrective actions are applied before failure occurs. The PID controller helps in maintaining system stability by reducing error and improving response time.

Experimental results show that the system minimizes overshoot and enhances reliability. This approach is suitable for real­time applications where consistent performance is required.