REFERENCE MANUAL STEPPER MOTOR Astepper motor is a low speeed , high torque motor which characterises itself with a number of unusual features such as mentioned below 4) It moves in 200 discret steps in one revolution 2) Itis a bi-directional motor, can rotate in either direction 3) itis a self-starting motor, no external means are required for starting it 4) ts affective inertia is very low. It starts, stops and reverses practically instanta- neously. 5) Its starting, running and stalling currents are of the same order. There is no heavy inrush current at start. Its motor can be stalled forcibly without any fear of damage to windings 6) _ Its low basic shaft speed eliminate the complex gear trains in many applications When driven through a translator a stepper motor acts as a Transducer having a high gain. It generate large torques with micro watts of input control power. Its torque output is manyfold on comparison with the conventional motor of the same size and weight. A stepping motor can also be used in integrator by feeding a continuously variable signal to an anlogue to digital convertor giving a pulse frequency proportional to the amplitude of the input signal. A stepping motor when supplied with these pulses will move the load attached to its shafts through a distance proportional to the time integral of the signal.FIG. 21 PERMANENT MAGNET MOTORSome of the common applications of stepper motor are - 1) Remote control of Dimmerstats, potentiometers, camera focusing process timing etc, 2) Numerically controlled machine tools and robots 3) Punched tape drives 4) As variable speed drives 5) Paper feed drive in recorder. 6) Drives for electronic sweep generators 7) Curve tracers TYPES OF STEPPER MOTOR CONSTRUCTION Three basic type of stepper motor are there in use . They are permanent magnet, variable reluctance and hybrid Each type may vary widely in constructional details but all have a cylindrical stator with salient poles or teeth each of which carries a coil to which the pulses are sucessively applied 1) PERMANENT MAGNET MOTOR As name suggests this type of motor has a permanent megnet rotor. Rotor has two identical discs withs a permanent megnet between them. It has teeth, the number of which decides the degree of angular movement of the shaft per switching pulse Stator has two phase winding ; the coils of which produce mmf fields displaced by 90° electrical in space from each other. When supplied with two phase AC. supply; a rotating magnetic field is produced which make the permanent magnet rotor to rotate. In D.G. operation, pulses are applied to each of stator winding, sucessively creating a series of magnetic fields. The rotor with this magnetic field experiences torque. By changing the excitation sequence, the motor can be made to rotate in the clockwise or anticlockwise direction. Hence It Is a blrectional motor. BEDARE ELECTRONICS PLC APPLICATION TRAINERREFERENCE ? Permanent magnet Stepper motor can have either single winding (coil) per phase 1 or two windings per phase (bifilar wound motor). Formar is a 3-lead motor requiring two power supplies, while the later is a5 lead motor requiring only single power supply . In bifilar wound motor , to reverse the magnetie polarity, instead of reversing current in winding , current of same polarity is switched to an indentical winding wound in opposite direction. Because of rotor reaction and relatively large step angles, there is little tendency to overshoot. So damping is rarely used in this type of motors. These type of motors have therefore lower stepping rates. 2) VARIABLE RELUCTANCE MOTOR In this type of motors, It is made up of soft iron with negligible residual magnetism and has number of poles teeth differing from that for the stator. When a pulse is . applied to coils on stator, the rotor tries to seek a position of minimum reluctance and moves by a step of angle which depends on stator and rotor pole numbers. Torque is produced by electromagnetic flux as it establishes paths of least reluctance through what amounts to a variable air gap between a multipole multi phase stator and a toothed, nonretentive rotor. HYBRID MOTOR > These combines the above two types of motors. It has a rotor comprising or axially magnetized permanent magnet with two cup shape end pieces with axial teeth . The number of rotor and stator teeth governs the stepping angle. Depending on the characteristics, these motors can be compared as below. 4-LEAD TYPE : The 4 Leads Stepper Motors are useful when the isolation between the two windings is required .4 Leads Stepper Motor can be easily converted into 3 leads type by shorting terminals 2 and 4 . These require single ended power supply and double pole double through switchings. BEDARE ELECTRONICS PLC APPLICATION TRAINERREFERENCE MANUAL 5-LEADS. (BIFILAR TYPE): This type of stepper Motor is useful where applica- tion of push-pull circuitory and centre tap power supply is not possible and also more where more torque output is required at higher stepping rates. In bifilar motor each stator coil is wound in opposite directions and these are stepped by switching from one half of the winding to the other half. Permanent Variable Hybond Magnet Reluctance 1)Maximum pulse rate per second 400 1000 20.000 2)Stepping angle 40-120 18-30 09-15 3)Maximum torque N-m . 0.3 -20 30-40 0.158 4)inertia Kg-m™40 4-20 2-200 - 3 -4000 TERMINOLOGY USED IN STEPPER MOTORS - 1) STEP ANGLE The motor shaft rotateis its specific angular increment each time the winding polarity is changed . This specific degree of rotation on increment is called the step angle . Itis specified in degrees . Now a days motors with step angle as small as 0.9° are available 2) STEPS PER REVOLUTION : This term describes the total number of steps required for the output shaft to rotate through 360° or one complete revolution . Steps per revolution are calculated by dividing 360° by step angle 3) STEPS PER SECOND :-The number of angular moments (steps) accomplished by the motor in one second of time . It corresponds to pulse rate.REFERENCE MANUAL m 04)3TEP ACCURANCY : It is defined as a positionai accurancy tolerance . This figure is generally expressed in percent and indicate the total error Introduced by the stepping motor in a single step movement . The error is non cumulative Le. , it does not increase as additional steps are taken. 05)HOLDING TORQUE : With the motor shaft at standtUt or zero r.p.m. condition , the amount of torque from an external source , required to break away the shaft from its holding position . This is measured with rated voltage and current applied to the motor and is the basic characteristic of stepping motor. Q6)RESIDUAL TORQUE: The torque present at standstill under power -off condition is a result of the permanent magnetic flux acting on the stator poles. Residual torque is present under power off condition only with a motor of permanent magnet rotor design 7) TORQUE TO INERTIA RATIO :Thts ratio is determined try dividing the rased holding torque of the motor by its inertia. The better the torque to inertia ratio, the better the response. When dealing with step response problems, it is important to know the torque to inertia ratio of the motor. 8) STEP RESPONSE >When given a command to move a step, the mater will respond within a specific time period . This “time for a single stepper step response is a fuction of the torque to inertia ratio of the motor and the characteristics of electronics drive system. Ratings are given for ncload ccrtti- tions with time generally expressed in miViseconds. Q9)RESONANCE .-Stepper motors cart be simulated as a spring mass system, and 33 3ucn have certain ‘natural * frequency chractenstics :When motor's natural frequency or‘resGoance* is reached, an increase in toe audible \evei of toe BEDARE ELECTRONICS PLC APPLICATIONmotors operation can be detected . In case of severe resonant condition ffi may loose steps and or oscillate about a point. The frequency at which this resonance occurs varies, depending on the motor and the load 10) DRIVES > This is a broad term used to describe the circuitary which controls the stepping motors and usually consist of a power supply, sequencing logic and power output switching components. 11) RAMPING The process of controlling pulse frequency to acceleate the rotor from zero speed to maximum speed as well as to deaccelerate the rotor from maximum speed to zero speed . Ramping increases the capability of driving motor and load to higher speed levels, particularly with large intertial loads. 12) START/ STOP ERROR --An additional curve found on some speed torque curves which indicates the maximum step rate to which the particular motor can start and stop without loosing steps or falling out of synchronism. This condition assumes no acceleration /deceleration time. These are usually the result of actual testing with negligible external load inertia 13) SLEW RATE An area of high speed operation where the motor can run unidirectionaly in synchronism. However, it cannot instantaneously start, stop or reverse. A stepper motor is brought up to slewing rate using acceleration and is then decelerated to stop under conditions where no step loss can be tolerated Now a days motors with slewing speeds of from 10,000 steps/sec to 20,000 steps/sec are available . The secret lies in the electronics control 14) DAMPING =The reduction or elimination of step overshoot is defined as damping It is used in applications where settling down time is important. Damping methods used include mechanical, electronic and viscous (fluid)TRANSLATOR. ‘Stepper Motor translator Is a versatile electronic control,capable of producing the proper pulse trains for driving the stepper motor . It is designed for controlling 5-lead type ie. bifilar motor only . The complete circuit diagram Is shown in figure . It basically consists of a CMOS dual D-type Flip-Flop CD 4013. The Q and Q outputs of 1st D-flip-flop are directly connected to windings Aland A2 of stepper motor through power Amplifiers . Whereas other two inputs to B1 & B2 are controlled by 2nd D-FLIP-FLOP and a CMOS DEMULTIRLEXER CD 4053 The functionn of DEMULTIPLEXER is to change the direction of stepper motor . This is done by either grounding pin 10 and 11 or connecting them to +Vcc .The truth table for logic signals for forward and reverse direction is given along with timing diagram. CLOCK GENERATOR Thie clock pulses are generated by using 555 Timer \C The clock frequency can be selected in two modes, High or Low . This is done by selecting different values of capacitors . Fine adjustments of the ciock frequency can be done by varying the potentiometer provided on the front pannei POWER AMPLIFIERS Since the output of the translator cannot drive the stepper Motors windings directly hence the use of power Ampifiers. \t consists of a driver stages SL100 and power transistors 2N3055 . The Stepper Motor windings are connected in series with the power transistor. Four such stages of power Amplifiers are used TRANSIENT VOLTAGE SUPPERESSION:- During D.C. stepping transient voltages are generated as the voltage is swithced across the windings . if these voltages are not removed or limited to a safe value, they can cause fauity operation or damage to Motor and other circuit components. Hence Shunt diodes an connected across each windings as shown in circuit digram.BEDARE ELECTRONICS PLC APPLICATION TRAIN Stepper motor requires an electronic controller to energise its windings in the proper sequence, there by causing It to step. Block diagram of stepper motor controller Is as under Stator windings of the PM stepper motor must be excited in a pedicular se- quence to cause the motor to move from the exciting step to the next step. Logic circuit is to be designed OR tn case of Microprocessor based system , program is to be prepared to provide the proper sequential output to power driver. Excitation sequence for bifilar wound PM motor is shown in Table,. The signal fom the To increase fie power level of these signal sufficiently, to energies the motor wmdtcg ‘power drivers vsmgpomer transistor or fiyrators are usedPROCEDURE : Stepper motor with dial & pointerls provided on main unit Operating voltage : 12 volt DC Torque 3.5 Kg-om Step Angle : 1.8° Motor driver and controller is provided in control unit Variable Clock Generator is provided with potmeter (Speed Adjust) for applying clock to the controller. Mode Input sets the direction of motor.( Mode = 1 - FW & Mode = 0 - REV). A) AUTO OPERATION 1) Connect clock CLK from Clock Generator to the clock input (CLK) of synchro- nous up/down counter. 2) Connect MODE input to synchronous up/down counter. Keep FWIREV switch for FW position: 3) Connect output from code converter and driver stage A11 to base of Q1, B11 to base of Q2 , A21 to base of Q3 , and B21 to base of Q4 4) Make powe on to the unit 5) Keep Speed Adjust potmeter for minimum clock speed) 6) Note the output pulse pattern as observed on LED D1 D2 D3 D4 7) Change the MODE switch to REV position: Note the output pulse pattern as observed on LED D1 D2 D3 D4. 8) Count total number of steps for one complete rotation No. of Steps for one rotation = Step Angle =- AUTO OPERATION: No. of Steps for one rotationConnect output from code converter and driver stage A11 to base of Q1, B11 to base of Q2, A21 to base of 3, and B21 to base of a4 Connect CLK and MODE input to synchronous up/down counter.ftemumec mmm 1) Connect 8255 from Benlx 8085 Microprocessor kHto stepper mivfunit using fiat cable cord provided with system, (28 pin FRC connector to 8255 port of Mcroproc™$6f tot and 9 pin D- connector(male) to 9 pin Oconnector(fermie) on stopper ewtor control unit.) Connect output from BUFFER At to base of Qt; B1 to base of 02, A2 to base of 03, and B2 to base of 04. 2) Connect power supply to Microprocessor kit. . Make power ON to both Microprocessor kit and Stepper motor confrof unit 3) Hard copy of the program is provided on EPROM at location 4300W Execute the program stored at location 4300H GO4300EXEC 4) Direction of motoris controlfed by FW/REV switch on Stepper motor control unit STEPPER MOTOR ™2VOLT asTORFA-OilITWJT ant FOPTH--NFUT PLC AAPPUCATICN TRACER.82S5 a* PORT Define NPur . BEOARE $ Pvt im ELECTRON ADDRES OPCODE MNEMONI COMMENT 1000 3E 82 IVM82 SET 8275 CONTROL REGISTOR 1002 D303 OUT03 PORTA-O/P PORTB 4 1004L1 06 = 04 MVI604_ SETCOUNTER CHECK FWREV MOTOR 1006 DB oot INB CHECK FW 1008 E6 ANI 01 yo CA 13 10 JzL2 ie 24 50 10 LX1H1050 LOAD HL POINTER (FW) 1010 C3 46 190 ©6YMPL3 1013L2 21. «60-10 LXIH1060 LOAD HL POINTER (REV) 1016L3 23 INXH 1017 7E MOVA,M GETDATA VALUE 1018 D300 OUTA — OUTDATAONPORTA HO1A 11 FF 3F_—_—LXID 3FFF LOAD DELAY COUNT CALL 01D cp 98 609) GALL 1020 05 DCRB DECREMENT COUNTER ho24 c2 16 10 wnzig_F,COUNTERNOTZERO GOTO 024 (en FORWARD SEQUENCE REVERSE SEQUENCE 1051 5 1061 1062 9 1062 1053 A 1063 1054 6 1064 Enter the above programme in RAM from location 1000H. Execute: 001000 EXEC