Answered your PM but to put it out for others to see:
1) "Gentle steps" - microstepping makes it gentle but I would be surprised if full steps would actually damage gears. I usually use microstepping on my horizontal stages and have never run out of power. For a controller it is just as happy to make 8x 1/8th microsteps as 1 full step. You will nearly always get smoother motion when microstepping and, as long as the power is enough, should get more repeatable positioning. The first ustep should take care of the stiction / inertia. I've tested it myself on a system with a shaft encoder - much more random and systematic positioning errors with big steps than little steps.
2) Acceleration: you can't accelerate into a single step, you accelerate by progressively reducing the delay between steps. This is done if you want to move a stage from rest to high speed. Actually, you could "accelerate" into a step by gradually ramping the applied voltage. The commonly available bipolar chopper drivers (see below) tend to give it a big whack and then back off. The only driver I have personal experience of that gives very smooth motion by using a ramped voltage is a Linistepper
http://www.piclist.com/techref/io/stepp ... /index.htm but that only works on unipolar motors and most commonly available motors are 4 wire bipolar.
3) Torque holding power: pretty much a suck it and see - it depends on the mass you are lifting, pitch and stiction of the leadscrew, etc, etc. Of course a reduction gear head helps but I don't think it is really necessary and they are hard to find. You will typically find that a linear drive with a 5mm pitch or less will easily hold and move a couple of kgs vertically when coupled to pretty much any NEMA23 stepper. If it does drift just buy stepper motor with more power. to put it in context, I can't rotate any of my NEMA23 motors by hand when powered up and just gripping the shaft bare handed. They do have a high holding torque
IMO the biggest hurdles with steppers are:
- mechanical interface: easy when connecting to a conventional linear bearing with worm drive / leadscrew with mounting points, but more interesting if you want to drive a microscope focus knob shaft with no pre-existing mounting points. You will normally connect with some kind of flex coupling that has zero backlash but reduces the need for exact shaft alignment - unless the rotation axis for motor and shaft are exactly aligned you need some kind of flexible coupling to soak up the difference
- control signals for the stepper driver: you need a way of sending the correct number of step and associated direction pulses. Can be done from a PC or a dedicated microcontroller. Can't be done with a push button switch unless you debounce it.
- stepper driver: converts "step and direction" into the actual current sent to the motor coils. These are easy to purchase. I have personal experience of JAFmotion or routoutcnc but there are many more.
http://routoutcnc.com/singlesmall.html
http://www.jafmotion.co.uk/index.php?op ... &Itemid=50
A vertical lift is very much the same as a CNC Z-axis. Search the web for CNC drives and z-axis, you'll find lots of relevant info out there.
Specific questions are easy to answer: if you link to some specific hardware or electronics you've found it will be easier to discuss.
hope that helps
Andrew
Now I've got to go the hospital and get some positron emission imaging of my spine - what fun
