My team is trying to build a mechanical cannon for a final project for a course and we are running into some problems with our motor stalling.
Our motor stalls when the plate hits either side of this railing (as shown with circles below) because, I think, it creates infinite tension that the motor can’t overcome. Once our DC motor is fully stalled and refuses to move in the direction of infinite tension, we try to move the motor in the opposite direction to free it up, but it stays stuck. We need to physically intervene to “unjam” the motor. Sometimes we can also press our button to move the motor backwards quickly and consecutively and it will unwind.
We don’t want to use a limit switch since we have to stay within a “required budget”, so we are wondering if there would be any other way to prevent this motor from becoming jammed. We were thinking that the jamming of the motor occurs because there is too high of a current draw when it stalls, so a solution would be to put a resistor in series with the motor driver + DC motor interface to reduce the amount of current that is drawn when the motor stalls. We have no idea if this is a robust solution that would allow the motor to easily unjam. Any ideas would be really appreciated !
Some specs for context:
DC motor that moves plate:
Motor has a 6V rating and a stall current of 1A