Stepper Motor Operation and Theory “IOH030 ane ‘pical Drive Circuits TYPE TYPED fis fics > From Bl Sater fore Je all Being ator Lainstons| al Bearrg / Magne Foo Lanatons ae onset, Fig. 52 Rotor Construction ‘Typical Stepping Motor Applic Foraccurate positioning of XV tables, lowers, printers, facsimile ‘machines, medical applications, robotics, barcode scanners, mage seanness, copiers, et. Construction There are three basic rypesof step motors: variable reluctance (VR), permanent magnet (PM) and hybrid. the hybrid ype step motor design ‘has the desirable features of both the VR and PM. T has high resolution, excelient holding and «dynamic torque and can operate at high stepping rate. In Fig. 5-1 construction of SKC stepping motor is shown, In Fig. 5-2 the detail of rotor construction is shown. ‘Stepping Motor Theory Using a 18 degree, unipolar, 4-phase stepping motor asan example, the following will explain the theory of operation, Referring to Fig. 61, the numberof poles om the stator is 8 spaced at 45 degree intervals. Fach pole face has 5 teeth spaced at 72 degree intervals. Each stato pole has a winding as shown in Fig. 6-1 Wine Fig. 64 Stator When applying the current tothe windings in the following sequence per Table 61, the stator can generate the rotating magnetic Feldas shown in Fig, 6-2 (steps 1 thru 4. oweruse | TL_L_1_rt_. Phase A siep2 oF Love meses | [sez PraseA | St Prase sepa Table 6-1 Step Phase Sequence (1 Phase Excited)Fig. 62 Rotational Magnetic Field Generated by Phase Sequence ‘The hybrid rotor has 2 sets (stacks) of laminations separated bya permanent magnet. Each set oflams bas 50 teeth and are offset from ‘each other by 12 tooth piteh, This gives the rotor 50 N and 50'S poles atthe rotor OD, Fig. 63 illustrates the movement ofthe rotor when the phase sequence isenergized, In step l,phase As excited so thatthe S pole ofthe rotor is attracted to pole 5 ofthe ator which is now a N pole, and the N pole ofthe rotor is aurseted to pole 37 ofthe stator which is aS pole move. At this point there isan angle difference between the rotor and stator teeth of 1/4 pitch (18 degrees). For instance, the stator teeth of poles 2,6 and 4,8 are offset 18 degrees from the rotor teeth, In step 2, there is astable position when a § pole ofthe otoris lined up ‘with pole 2,6 ofthe statorand aN pole ofthe rotor lines up with pole 48 of stator. The rotor has moved 18 degrees of rotation from step 1. ‘The switching of phases per steps 3,4 etc produces 18 degreesof rotation perstep. Pole1s Pez © Poe37 lea dab | = db db dib es er aetna HAL Jy! ae Se Oe oe Fig. 6-3 1 Phase Excitation Sequence Technical Data and Terminology 7A Holding Torque The maximum steady torque that can be applied tothe shaft of an energized motor without causing rotation, 72 Detent Torque The maximum torque that can be applied to the shaft ofa rnon-energized motor without causing rotation 73. Speed Torque Curve The speeditorque characteristics ofa stepping motor area function ofthe drive cireuit, excitation method and! load inertia, 7-4 Maximum Slew Frequency ‘The masimum rate at which the step motor will un and remain in synchronism. evi tonn OP Tome (ant spt et) Torque gem) Set Seo tne 2 yon Tnegingann ae 8 Ss ‘espe Fig. 7 Speed - Torque Curve “The maximum pulse rate (frequency) at which an unloaded step motor can start and run without missing steps or stop without missing steps 7-6 Pullout Torque ‘The maximum torque that can be applied tothe shaft ofa step motor (running at constant speed) andl nat cause it to losestep. 77 Pall-in Torque ‘The maximum torque at which a step motor can stat, stop and reverse the direction of rotation without losing step. The maxi mum torque at which an energized step motor wil stat and run, in synchronism, without losing steps at constant speed. 7-8 Slewing Range Thisis the area between the pulkin and pull-out torque ‘curves where a step motor can ran without losing step, when the speed is increased ar decreased gradually. Motor must be brought up to the slew range with acceleration and deceleration technique known as ramping, 79 StartStop Range Thisis the range where a stepping motor can start, stop and reverse the direction of rotation without losing step. 7-40 Accuracy This s defined as the difference between the theoretical and actual rotor position expressed as a percentage of the step angle. Standard is!5%, An accuracy of:3% is available on special request. This positioning error is noneurnulative. 7-44 Hysteresis Error This the maximum accumulated error from theoretical position for both forward and backward direction of rotation. See Fig 7-2. Fig. 7-2 Step Angle Accuracy 7-12 Resonance Astep motor operates on. series of input pulses, each pulse caus- ing the rotor to advance one step. In thistimethe motors rotor mustaecelerate and then decelerate 10 stop. This causes oscilla tion, overshoot and vibration. There are some speeds at which the motor willnot run, This is called its resonant frequency. The objective isto design the system so that na resonant frequencies, appear in the operating speed range. This problem canbe elimizat- cedby means of using mechanical dampers, external electronics, drive methods and step angle changes.Drive Methods. 8-1 Drive Circuits ‘The operation ofa step motor is dependent upon an indexer (pulse source) and driver. The indexer feeds pulses to the driver ‘which applies power to the appropriate motor windings. The number and rate of pulses determines the speed, direction of rota tion and the amount of rotation of the motor ouput shaft. The selection of the proper drivers critical to the optimum perform: ance ofa step motor. Fig, 81 shows some typical drive circuits. These circuits also illustrate some of the methods used to protect the power switches against reverse voltage transients 8-1. Damping Methods These circuits can also be used to improve the damping and noise characteristics of a step motor. However, the torque at higher pulse rates (frequency) can be recuced so careful consid tration must be exercised when selecting one ofthese methods. Examples: 1 Diode Method Fig 84 (2) 2. Diode+Resistance Method Fig 8-1 (5) 3. Diode Zener Diode Method Fig 8-1 (e) 4. Capacitor Method ig 8-1 (@) 6 + + t i hs Thy mn @ © Fig.84 @ © Fg.8a 8-4.2 Stepping Rate ‘Astep motor operated ata fixed voltage has a decreasing torque ceurve as the [requency or step rate increases. This is due tothe rise time of the motor winding which limits the value of the coil cur- rent, This s determined by the ratio of inductance to resistance (L/R) of the motorand driver as illustrated in Fig 8-2 (2), (Compensation forthe L/R ofa circuit can be accomplished as follows: ced ey o te Fig. 81 ) Increase the supply voliage and add a series resistor, Fig 82 (b), to maintain rated motor eurrent and reduce the L/R of the arcu, ) Increase the supply voliage, Fig 82 (c), improving the time ‘constant (L/R) ofthe circuit. However, it ismecessary to mit the motar current witha bilevel or chopped supply voltage Examples: 1. Constant Voliage Drive Fig. 81(@) 2. DualVoltage @Brlevel) Drive Fig. 81(1) 3. Chopper Drive Fig. 8168) @:suR supply Vonage-2 Fig. 8.2 8-2 Excitation Methods In Table 81 are descriptions and features of each method. Exatation Method Sraie ase | Dual Pras Tae canna | ann | _nanannnan) ots runing | Mah trays | Por stp aecuacy, Save ne ood sep | od sonance posed ia: Seracr | thats S| read ser. ier pubes. rap a sepsing 8:3 Bipolar and Unipolar Operation Bipolar Winding the stator flux is reversed by reversing the ‘currentin the winding, Itrequires a push-pull bipolar drive as shown in Fig. 83. Care must be taken to design the circuit so that the transistors in series do not shor the power supply by ‘coming on atthe same time. Properly operated, the bipolar wind ing gives the optimum performance tlow'to melt step ratesFig. 84 Unipolar Method Unipolar Winding - has two coils wound on the same bobbin perstator half, Fluxcs reversed by energizing one coil or the ‘other coll froma single power supply. The use of unipolar ‘winding, sometimes called a bifilar winding, allows the drive ‘ireuit 9 be simplified. Not only are one-half as many power ‘switches required (4 vs. 8), but th timing is not as ertical to prevent acurent short through two transistors as is possible vith bipolar drive. Unipolar motors have approxi mately 30% less torque at low step rates. However, at higher rates the torque outputs are equivalent, Step Motor Load Calculations and Selection To select the proper step motor, the following rust be determined: 1 Load Conditions ‘ra, Friction Load 1b. Load Inertia 2. DynamicLoad Conditions 2a, Drive Circuit 2-b. Maximum Speed (PPS/Frequency) 2e. Acceleration /Deceleration Pattern ‘Wit the above load information the proper step motor can be selected. 94 Load Inertia “The following is an example for ealeulating the inertia of a hollow cylinder. DD Fig. 9 Jee Me (DE+D2) (kgem) Where -M mass of pulley (kg) DiI: outside diameter (em) D2: inside diameter (cm) 92 Linear systems can be related to rotational systems by utilizing the kkineticenergy equations for the xo systems. For linear transls- tions: Energy 2M v= 12 w Where M> mass vs velocity Je inertia ww: angular velocity 1) Geardrive system ‘When gears are used to drive a load, the inertia reflected to the ‘motor s expressed by th following equation: J=(Z1/22y-(2+J3)+JL Where 21,22: No.of gearteeth J1LJ2,]3: inertia (kgyem) Load 2 a “> (oHS)||) 2 2) Pulley & belt system. A motor and bel drive arrangement is, used for linear load translation je2yielamp2 Where J: Total inertia reflected to motor Ji: inertia of pulley (keer) D: diameter of pulley (mm!) M: weight of load (kg) Fig.93 93. Determination of load acceleration, deceleration pattern 931 Load Caleulation To determine the torque required to drive the load the following equation should be satstied Tm TT) Where; Tm: Pullout torque (keem) TE. Friction torque (kgf-em) Tj Inertia load (kgfcrm) T= GR+JLY/g°(p-q-s)/180- df/a JR: Rotorinertiakg-cm'] JL: Load inertia [kgeem’) ‘Step angle [deg] Gravity acceleration 980 [em/see!) E Drive frequency [PPS] Example: A 18 degree step motor is tobe aceelerated from 100 10 1,000 pulses per second (PPS) in 50 ms,JR* 100 grem®,J1= 1 ken ‘The necessary pullout torque is T)= (01+ 1)/980-(p- 18)/180 -(1000- 100/005 = 0.635 (kg-em) 932 Linear acceleration For linear acceleration as shown in Fig. 94 frequency ft), inertial system frequency f(t) and inertia load T} are cexpressedas follows:fq) -(L-fOy/eL +10 T GRID /g-(p-4-s)/180- (0 -fOy/tL t Tine Fig. 94 Linear Acceleration 933 Exponential acceleration Forexponential as shown in Fig. 95, drive frequency f(t) and inertia load Tj ae expressedas follows: f-f1--e-qyoyel0 T= GRJLY/B"(p-4"5)/180-f1/t-e-() Tine Fig 95 Exponential Acceleration Dm Dynetics DYNAMIC IN MECHATRONICS