Systems and methods to perform limited-motion alignment of brushless dc motors in welding wire feeders

A welding system, comprising:

• a welding-type power supply configured to convert input power to welding-type power, and output the welding-type power to a welding-type torch;
• and
• a welding wire feeder configured to deliver welding wire to the welding-type torch, the welding wire feeder comprising:
• a drive roll configured to feed the welding wire via rotation of the drive roll;
• a brushless DC motor configured to rotate the drive roll, the brushless DC motor comprising:
• a rotor having a permanent magnet;
• a stator comprising a plurality of coils;
• and
• a position sensor configured to determine at least one of an angular position of the rotor or a change in angular position of the rotor;
• and
• control circuitry configured to:
• determine the angular position of the rotor, while limiting movement of the rotor during the determination, by changing a direction of a magnetic force vector applied by the stator in response to detecting a direction of movement of the rotor using the position sensor;
• and
• in response to initiation of a wire feeding operation, control the stator to start actuating the drive roll by applying the magnetic force vector in a direction based on the determined angular position of the rotor.