Nippon Pulse America unraveling the mystery of stepper motor technology presentation

NPM
Unraveling The Mystery of
Stepper Motor Technology

Jeramé Chamberlain
Nippon Pulse America, Inc., USA
Sold & Serviced By:

Toll Free Phone: 877-378-0240
Toll Free Fax: 877-378-0249
sales@servo2go.com
www.servo2go.com

NPM What is a Open Loop
Stepper Motor System?

What Are Stepper Motors?

How Do Stepper Motors Work?

Troubleshoot & Test Stepper Motors
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NPM Basic Stepper Application

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NPM Stepper Motor Coil
PHASE A

S
N
● PHASE B
PHASE B
S

N

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PHASE A
sales@servo2go.com
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NPM PHASE A
One Phase
PHASE A

Step Sequence
S
N

PHASE B
●
PHASE B PHASE B N S PHASE B

N
S
●
●
S

N
STEP 1 STEP 2

PHASE A
Two Phase PHASE A

PHASE A
Stepper Motor PHASE A

N
S

PHASE B
●
●
PHASE B PHASE B S N PHASE B

N
●
S
N
N

S
STEP 4
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STEP 3

PHASE A PHASE A
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NPM Types of Stepper Motors

Permanent-Magnet (PM)
• PM rotor & electromagnetic coil
Variable Reluctance (VR)
• No PM, no residual torque
Hybrid – NEMA Sizing
• Combined PM & VR Technology
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Cross Section of A Two
NPM Phase Hybrid Motor

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NPM PM & Hybrid Stepper Motors

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NPM Bipolar Coil Winding

Each phase
is a single
winding

Current flow and electromagnetic
polarity is reverses in the windings
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NPM Unipolar Coil Winding

Sometimes
called
four-phase
steppers

Current flow and electromagnetic polarity is
NOT reversed in the windings. Polarity
comes from alternately energized windings
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NPM Motors Need Maintenance
Steppers – Not So Much
Stalled motors burn up
• Steppers operate in stall condition
Most brushes go bad
• Steppers are brushless
All bearings go bad
• Quality Stepper bearings are
rated from 90-100K hours
People break them Sold & Serviced By:

• Hammers don’t fix Steppers Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Ohmmeter Test With Steppers
Bipolar
Always 4 leads
Resistance is
the same in
both windings
and both
directions

Some 8 lead motors can be connected
as bipolar Sold & Serviced By:

sales@servo2go.com
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NPM Ohmmeter Test With Steppers
Unipolar
5 or 6 leads
Resistance from
each phase to
Common is the
same in both
directions

If 5 leads, two commons connected
Some 8 lead motors can be Unipolar
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NPM Unipolar Windings & Wire Colors

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NPM Bipolar Windings & Wire Colors

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NPM Stepper Motor Electronic System

CPU, Controller, Sequencer, Driver
One or more parts can be combined,
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based on motion complexity Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Controller Receives & Coordinates

A dedicated controller generates
motion profiles that produce smoother
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motor operation than just with a CPU. Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Controller Manages & Interpolates

Some controllers provide interpolation
between motors to produce smooth
XYZ motions – CNC Machines
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NPM Two Outputs Types to Sequencer

Pulse & Direction – Speed & Rotation
CW/CCW – Speed & Rotation Sold & Serviced By:

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NPM One Controller – Two Output Types

Pulse & Direction –
Speed & Rotation
CW/CCW – Speed &
Rotation

Pulse & Direction is the most
common format used in the USA
PCL6045B can output both formats
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NPM Stepper Motor Sequencers

Sequencers read speed and direction
from controller and deliver excitation
sequence to the driver
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NPM Bipolar Stepper Drivers
When Q1a and
Q4a (green)
are on, current
flows in one
direction
When Q2a and
Q3a (red) are
turned on,
current flow is
reversed Sold & Serviced By:

sales@servo2go.com
www.servo2go.com

NPM Unipolar Stepper Drivers

Half the drive
electronics of
bipolar, and
30% less torque
However,
unipolar coils
allow a higher
pulse rate than
bipolar, before
becoming Sold & Serviced By:

saturated. Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Constant Current - Constant Voltage

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NPM Current Lags Voltage in an Inductor
Torque from stepper
motors is generated by
current, not voltage
PWM or Chopper drive
manages current
through a switch,
applied at higher
voltages to induce
more winding current
Chopper delivers more
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torque at higher speeds Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Half Stepping A Stepper Motor

Easiest way to accomplish half stepping
is by using 1-2 phase excitation
Divides a stepper’s full step angle by
two 7.5°/2 = 3.25° per half step
30% loss of torque depending on step
rate when compared to full step
Winding is not energized during each
alternating half step
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NPM PHASE A
Half Stepping
PHASE A

Sequence
S
N

PHASE B
●
PHASE B PHASE B N S PHASE B

N
S
●
●
S

N
STEP 1 STEP 3

PHASE A
Two Phase PHASE A

PHASE A
Stepper Motor PHASE A

N N
N

N N

S
PHASE B S PHASE B PHASE B S PHASE B
●

●
S

N
S S
STEP 4
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STEP 2

PHASE A PHASE A
sales@servo2go.com
www.servo2go.com

NPM Microstepping A Stepper Motor

Full step can be broken into as many as
512 parts
Current is limited through each winding.
Unequal pull on the magnet means it
moves toward the weaker winding
Torque falls rapidly as speed increases
Steps are not constant for positioning
Microstepping should only be used for
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smooth movement. Toll Free Phone: 877-378-0240
sales@servo2go.com
www.servo2go.com

NPM Combined Sequencer & Translator

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sales@servo2go.com
www.servo2go.com

Nippon Pulse America unraveling the mystery of stepper motor technology presentation

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Nippon Pulse America unraveling the mystery of stepper motor technology presentation