I am currently using a Japan Servo and Dy adic controller. The Nema 23 has a 10:1 gearbox on it. The application is not CNC, but a single motor in a linear motion application, moving a 100lb load horizontally on a rail and slide via timing belt and pulley. The speeds are slow, and require an ultra smooth ramp in and out of the curve. The servos provides no vibration, smooth as silk motion.
The system I am using including Nema 23 servo, gear box and controller is running around $800 per system, which is cheaper by far than anything comparable as far as servos. Automation direct is way higher for less torque, and far less options on the controller.
Is there a way to get ultra smooth motion out of a stepper(not using gearing--the cost is too high), plus very low noise? The servo I am using is dead quite, but the steppers I have on my CNC mill(closed loop Lin enginerring nema 23's) are very loud, even at stand still they ring so loud people can't stand to be around when they are sitting idle.
The bottom line is I am looking to cut costs, but don't want to sacrifice power, noise levels, ease of use with a controller with 16 programmable positions, each with independently programmed speeds, accel/decel, torque.
Does something exist in the stepper world that compares to what I am describing, but at a lost less cost?
I have been talking to Lin design, they have some options, but cant guarantee the power I need in Nema 23 without using a gearbox. By the time they add the gearbox, motor and controller I am back at the servo price range.
Thanks for any ideas.