6. Stepper Drives
STAC6 and ST Series Drives
Next Generation drives
Advanced Smoothing Features
DSP-based
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7. Stepper Drives
STAC6 Series
110 or 220 VAC input, single-phase
Advanced Smoothing Features
Encoder Feedback
CE Compliance: EMC & LVD
UL Recognized 110 VAC units
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8. Stepper Drives
ST Series
DC input
Advanced Smoothing Features
Encoder Feedback (Q and Si models only)
CE Compliance: EMC & LVD
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10. Advanced Features
Applied Motion steppers drives improve
upon two aspects of step motor system
performance
Smoothness – by eliminating resonance
Accuracy – by closing the position loop
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11. Inherent Problem
Resonance
Step motors are resonant because in short
their rotors behave much like a classic
“mass on a spring”.
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12. Inherent Problem
Resonance
When a step motor takes a step, the rotor
reacts to the changing stator field in the
same way a mass on a spring reacts to a
change in position.
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13. Inherent Problem
Resonance
Just like the mass on a spring,
the motion of the rotor settles
into position after each step.
This settling can last as long as a
second or more in worst cases!
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14. Inherent Problem
Resonance
If the settling doesn’t occur
rapidly, or the ringing of the rotor
gets worse, the motor can
become unstable and lose
position (stall).
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15. Inherent Problem
Resonance
There are two major, negative side effects
of resonance.
Rough motion
Loss of torque, which can lead to loss of
position
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16. Inherent Problem
Resonance
Rough motion
When step motors resonate they generally
vibrate excessively.
This can be bad for sensitive equipment.
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17. Inherent Problem
Resonance
Loss of torque
When step motors resonate much of the
torque available in the motor is used up in
keeping the rotor synchronized with the stator
field, and in worst cases the motor will not
have enough torque to move the load.
Loss of torque often leads to stalling.
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18. Solution
Resonance
There are three main remedies for
resonance.
Microstepping
Torque Ripple Smoothing
Electronic Damping
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19. Solution
Microstepping
Microstepping does not eliminate the
natural resonant frequency of a step
motor, but it does diminish the level of
excitation.
In other words, smaller steps mean
smaller responses.
coarse steps microsteps
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20. Solution
Microstepping
Stepper drives from Applied Motion can
microstep even when the control signal is
low resolution.
This is called Microstep Emulation.
coarse steps
from external microstep emulation
indexer performed by drive
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21. Solution
Torque Ripple Smoothing
Torque ripple smoothing reduces the
inherent torque ripple that all step motors
display at low speeds (typically well under
5 rps).
Torque ripple smoothing works by applying
a “negative” current to the motor which
offsets the torque ripple.
torque ripple
negative current
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result = smoother motion
22. Solution
Electronic Damping
Electronic damping remedies two aspects
of the motor’s resonance.
Inherent resonant frequencies of the motor.
A complex interaction between drive and
motor that happens at higher speeds, often
called “mid-band resonance”.
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23. Solution
Electronic Damping
The end result of electronic damping is to
minimize and even eliminate the resonant
response of the step motor over a wide
range of speeds.
with
without
electronic damping
electronic damping
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24. Solution
High performance stepper drives from
Applied Motion offer…
Microstep Emulation
Torque Ripple Smoothing
Electronic Damping
All of which contribute to…
Smoother motion from your step motor
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25. Inherent Problem
Accuracy – Open Loop Systems
When properly sized an open loop step
motor system can be adequately accurate
for most applications.
Keys to proper sizing are knowing the load
and knowing the move parameters ahead
of time.
However, the nature of an open loop
system is such that no built-in mechanism
exists for indicating a motor mis-position or
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stall.
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26. Solution
Accuracy – Open Loop
In situations where an extra layer of
accuracy is required, step motors from
Applied Motion can be fitted with high
resolution, incremental encoders.
The encoder is mounted to the rear shaft of
the step motor (order “D” option).
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27. Solution
Accuracy – Open Loop
The encoder is then connected to the drive
via a feedback cable.
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28. Solution
Accuracy – Open Loop
Applied Motion stepper drives can perform
two main functions when an encoder is
added to the system.
fool-proof Stall Detection
Stall Prevention w/ Position Maintenance
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29. Solution
Fool-proof Stall Detection
Stall detection works when the stepper
drive monitors encoder position relative to
commanded motor position.
As soon as a mis-position occurs the drive
stops motion and sets a fault to notify the
user.
This method is fool-proof because it works
under all conditions, regardless of motor
speed or load conditions.
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30. Solution
Stall Prevention
Like stall detection, Stall Prevention works
when the stepper drive monitors encoder
position relative to commanded motor
position.
As soon as a lag between the encoder
position and the commanded motor
position occurs the stepper drive starts to
slow the motor speed.
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31. Solution
Stall Prevention
Slowing down the motor allows the motor
to operate in a speed range where its
torque output is higher, and therefore have
a better chance of finishing the move.
Point at which torque
demand increases
Actual Move Profile
Target Move Profile with Stall Prevention
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Target Time
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32. Solution
Position Maintenance
With Stall Prevention turned on the drive
automatically corrects errors in motor
position from external forces when the
motor is at rest.
In other words, if the motor is “bumped”
out of position it automatically corrects
itself.
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33. Solution
High performance stepper drives from
Applied Motion offer…
Encoder feedback options
Which contribute to…
A more accurate motion control system
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34. Hardware
High Performance Stepper Drives from
Applied Motion
ST Series
STAC6 Series
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35. Stepper Drives
Three Model Numbers
S – basic drive
Step & Direction, Oscillator, SiNet Hub, and
SCL
Configurator software for setup
Q – programmable drive
Q Programmer for stand-alone operation
Configurator software for setup
Si – Simple Indexer drive
Si Programmer with built-in Configurator for
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setup and stand-alone operation
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36. Stepper Drives
Software
STAC6 and ST Configurators
Setup motor and drive
parameters, S and Q models
Q Programmer
Create stored programs for Q
drives
Si Programmer
Setup motor and drive
parameters and create stored
programs for Si drives
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37. ST Series
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38. ST Series at-a-glance
ST5-S ST10-S ST5-Q ST10-Q ST5-Si ST10-Si
Modes of Step&Dir Step&Dir …S plus… …S plus… …Q plus… …Q plus…
Operation Osc. Osc. Q Prog. Q Prog. Si Prog. Si Prog.
SCL SCL
Hub Hub
Inputs 3 dig in 3 dig in 8 dig in 8 dig in 8 dig in 8 dig in
Outputs 1 an in 1 an in 2 an in 2 an in 4 dig out 4 dig out
1 dig out 1 dig out 4 dig out 4 dig out
Features Basic Basic Encoder Encoder Encoder Encoder
drive drive RS485 RS485
Size Smallest Smallest Small Small Small Small
Amps per 5 10 5 10 5 10
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39. STAC6 Series
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40. STAC6 Series at-a-glance
STAC6-S STAC6-Q STAC6-Si
Modes of Step & Direction …same as S plus… …same as Q plus…
Oscillator Q Programming Si Programming
Operation SCL
SiNet Hub
Inputs 7 digital inputs 7 digital inputs 15 digital inputs
2 analog inputs 2 analog inputs 7 digital outputs
Outputs 3 digital outputs 3 digital outputs
*Option to expand
with STAC6-QE
Features Encoder Feedback Encoder Feedback Encoder Feedback
RS485 RS485
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41. Stepper Motors
Compatible Motors
ST
NEMA 17, 23, and 34 motors with flying leads
STAC6
NEMA 23 and 34 motors with integral, 10’
shielded cables
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43. STM Series Steppers
STM
Integrated motor & drive package
NEMA 23 motors
Drive based on ST5 stand-alone drive
Step & Direction
Oscillator
SCL
SiNet Hub
Q Programming
Same great Anti-Resonance and current
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control as STAC6 and ST drives
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44. Web Links
ST Series
STAC6 Series
STM Series
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53. Servo Motors
M Series
Metric Flanges
40, 60, and 80mm
N Series
NEMA Flanges
NEMA 17, 23, and 34
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54. SV and V Series
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55. SV Series servo drives
SV7
Lower cost than BLuDC
7A continuous, 14A peak
24-80 VDC input
Encoder feedback to start
Resolver feedback to come
Same base control options: S, Q, and Si
Plus CANOpen option to come
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56. V Series servo motors
NEMA 23 flange
NEMA 17 and 34 flanges to come
Medium torque-density
Low cost
Compatible planetary gearboxes
available
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57. Web Links
Servo Products
BLuDC4
BLuDC9
BLuAC5
N & M Series Motors
SV7
V Series Motors
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59. Stepper v. Servo
First, why brushless?
No maintenance – One of the best reasons
to choose brushless motors is because they
require basically no maintenance. There
are no brushes to wear out.
Cost is steadily decreasing – In the past
brushless motors were always the most
expensive, however their prices continue to
drop and make it more attractive to use
brushless motors.
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60. Stepper v. Servo
Why Steppers and Servos?
Servos and Steppers offer many
advantages in positioning applications.
Full programmability – There is no longer a
need to move limit switches and other
mechanical parts for machine setups and
changeovers.
Excellent repeatability – Because these
motors can position from digital signals, it
is easy for them to repeatedly return to the
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same position over and over.
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61. Stepper v. Servo
Why Steppers and Servos?
High accuracy – Because these motors
have high resolutions and excellent torque
characteristics, they can accurately
position to a fine resolution.
Software and Controls are becoming easier
to integrate – Icon-based programming
and more user-friendly interfaces allow for
even non-programmers to integrate motion
controllers into their machines and
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applications.
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62. Stepper Systems
Stepper Systems are
Open Loop
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63. Servo Systems
Servo Systems are
Closed Loop
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64. Stepper Systems
Open Loop means…
Current in the motor is the same,
regardless of load
Step motors run hot
Natural Resonance frequencies occur
Applied Motion drives take care of this!
Speed v. Torque curves represent peak
torque under ideal conditions
Torque margins are necessary
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65. Stepper Systems
The advantages are…
Lower cost
Simplicity
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66. Servo Systems
Closed loop means…
Current in motor is directly related to the
load requirements
No load means no current
Servo motors generally run cooler than
steppers
Both peak and continuous torque ratings
are available
Tuning is required
System is generally more complex
ELECTROMATE Cost is generally higher than stepper
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67. Servo Systems
The advantages are…
Higher speeds
Higher peak torques
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71. Stepper v. Servo
Generally speaking, in a linear
application with an actuator, the most
prudent path to success is to pick the
system that best balances cost and
performance.
Determine the speed and torque
requirements and look at the
curves.
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73. Sizing
There are a few key application
elements you need to determine before
choosing a proper motor and drive
combination:
Total System Inertia (load + motor)
Peak Speed Requirement
Peak Torque Requirement (cont + accel)
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74. Sizing
A primer on sizing…
The Smart Motion Cheat Sheet
From Minarik
From Electromate Industrial Sales
This PDF has all the equations you need to
calculate inertia, speed, and torque for
your linear actuator application.
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75. Sizing
VisualSizer sizing software
Free stand-alone sizing software
Manufacturer-independent (generic) so it
works with anyone’s system
Able to size motors and drives for linear
actuators and many other kinds of loads
Download from www.copperhilltech.com
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77. Si Programmer Software
We are well-known in industry for our
easy-to-use, icon-based programming
environment
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“Si” stands for “Simple Indexer”
ELECTROMATE
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78. Si Features & Benefits
So easy-to-use
A non-programmer’s
program
Icon-based
Intuitive graphical
interface
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79. Si Features & Benefits
So easy-to-use Very little support
A non-programmer’s
program
Customers are up
Icon-based
and running quickly
Intuitive graphical
interface
“Sell it and Forget it”
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80. Si Features & Benefits
Same software
regardless of which
drive you choose
Works with Steppers
and Servos
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81. Si Features & Benefits
Same software Customers can
regardless of which switch between
drive you choose stepper and servo
Works with Steppers without rewriting
and Servos their program
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82. Si Features & Benefits
Runs on Windows
All programming
cables and software
included with each
drive – for free
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83. Si Features & Benefits
Runs on Windows Anyone with a PC
can use it
All programming
cables and software
included with each
drive – for free
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84. Si Features & Benefits
Runs on Windows Anyone with a PC
can use it
All programming Free software!
cables and software Download from our
included with each website today
drive – for free
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85. Advanced Functions in Si
For All Si™ Drive Models
Subroutines
Branch On Limit
Branch On Fault
Interrupt
Multiple, programmable jog speeds
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86. Si Drives
Drive model numbers that contain
either an “Si” or “i’ designate a drive or
control with the Si Indexer built-in
STAC6-Si
STAC6-220-Si
ST5-Si
ST10-Si
BLuDC4-Si
BLuDC9-Si
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87. Si Drives
Drive model numbers that contain
either an “Si” or “i’ designate a drive or
control with the Si Indexer built-in
STAC6-Si
STAC6-220-Si
ST5-Si
ST10-Si
BLuDC4-Si
BLuDC9-Si
old & Serviced By: BLuAC5-Si
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88. Si Programmer Screen
Download Si Programmer
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90. Q Programmer Software
Our latest motion control software adds
much more power and flexibility to our
drives
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“Q” stands for “Queue”
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91. Q Features & Benefits
Large set of
commands
Motion control
I/O manipulation and
sensing
Register manipulation
Math functions
Multi-tasking
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92. Q Features & Benefits
Large set of Solve complicated
commands applications
Motion control
I/O manipulation and
Machine and motion
sensing
control in one drive
Register manipulation
Math functions
Multi-tasking
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93. Q Features & Benefits
Runs on Windows
All programming
cables and software
included with each
drive – for free
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94. Q Features & Benefits
Runs on Windows Anyone with a PC
can use it
All programming Free software!
cables and software Download from our
included with each website today
drive – for free
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