when you are applying 99% of rated motor torque - - you are asking for stalls - - - any little thing - - will cause a stall - -
that is why we run out steppers quite a bit away from this point
you are right that the more out of position the higher torque is present to cause the stepper rotor to move
it would be interesting to have someone actually measure the amount of movement with micro steps.
there are other factors in play - - a you comment friction, stickion (starting friction to be over come) and acceleration loads - - and required torque
my feeling is if you have so much friction that the rotor can not move you have a problem - - -
if the motor has no load - - free shaft - - how much will it move per micro step - - - the right amount or take a couple of micro steps before it moves.
I am willing to bet it will move the proper amount
that is why we run out steppers quite a bit away from this point
you are right that the more out of position the higher torque is present to cause the stepper rotor to move
it would be interesting to have someone actually measure the amount of movement with micro steps.
there are other factors in play - - a you comment friction, stickion (starting friction to be over come) and acceleration loads - - and required torque
my feeling is if you have so much friction that the rotor can not move you have a problem - - -
if the motor has no load - - free shaft - - how much will it move per micro step - - - the right amount or take a couple of micro steps before it moves.
I am willing to bet it will move the proper amount
