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Microcontroller Based Stepper Motor Drive for Variable A.C Power Supply

Research · January 2018

DOI: 10.13140/RG.2.2.28854.65602

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Sanabel Mohammed Ali

Northern Technical University
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 Jour of Adv Research in Dynamical & Control Systems, Vol. 10, 06-Special Issue, 2018

Microcontroller Based Stepper Motor Drive

for Variable A.C Power Supply
Sanabel M. M. AL hajzber, Assistant Lecturer, Department of Electrical power techniques engineering, Technical Engineering
College of Mosul, Northern Technical University, Mosul, Iraq.
Abstract--- Different application may need different voltage levels; therefore this work presents a prototype for a
stepper motor drive for variable A.C power supply. The system design is based on using a microcontroller for
driving a stepper motor to move an auto transformer slider to obtain the desired A.C supply voltage between 0 -
220V.
Keywords--- A.C Power Supply, Stepper Motor Drive, Variable A.C Supply.

I. Introduction
A precision values for A.C supply voltages extracted from the A.C main appears an important goal.one
simple solution is by using stepper motor with a fine step angle to move the auto transformer slider to give the
required value of A.C voltage.
I improved the analog device (single phase auto transformer) and used a keypad for input the value of voltage
that required the keypad transmitted the data input to microcontroller pic16f84a. Then the pic16f84a send the
signal to stepper motor during driving circuit (ULN2003A) to run the position desired. The microcontroller has a
program memory of 1 Kilobytes. The single phase auto transformer which is used at range (0-220)v ,(4A) and
stepper motor rated(24v dc , 0.22A , 1.8deg) and keypad(4x4).the complete system can be represented by the
block diagram shown in figure (1).

Figure (1): Block diagram of the complete system.

*Corresponding Author: Sanable M. M. AL hajzber

Article History: Received: 15 Apr. 2018 Revised: 1 May .2018 Accepted: 20 May 2018
724
 Microcontroller Based Stepper Motor Drive for Variable A.C Power Supply

Auto Transformer

The primary and secondary windings in the transformer have induced voltage as result of collective mutual
flux, thus they were on phase. The currents in the windings were out of the phase in 180◦. The was the equivalent
in the secondary turns for primary turns. The attached segment want to have a irritated sectional area for the coil
of transfer a current (I2 − I1). The physical arrangement of an auto transformer shown in fig (2). T1 noted to the
total turns number among C and A. On the point B the joining was booked, hence portion AB had turns T2 with
volts / turn, that was relative of the flux.

V1×T1= V2×T2
V1 / V2 = T1 / T2 -----------------(1)

The transformer magnetizing current is neglected to simplifying analysis, secondary coil carries a current on
load (I2) of the secondary ampere / turns was ( I2 T2 ). The current can be responded in I1 outflow after the main
source over (T1 ) such as :

I1×T1 = I2×T2

A current of I1 outflow between C and B The winding current between B and A was ( I2 − I1). Point B can
be slides on the arm AC as shown in fig (2), which gives variable values of the output voltage and verifies the
volt per turn equation (1).

Figure (2):physical arrangement of an auto transformer

II. Stepper motor

Fundamental of operation
Bipolar Stepper motor shown in fig (3) contains a number of teeth with an electromagnetic field which
arranged around the center of the shape of the gear of iron piece. The electromagnetic is equipped with an
external control circuit that makes the shaft of the motor rotated. This field must be equipped to make the gear
teeth synchronized with the initial field, there will be a few displacements. When the motor is operating and
another magnet field is equipped and the first is turned off, the gear will rotate slowly to be attached to the other.
The process is repeated ,each turn is called a step, these steps will be full rotation and in this way the motor is
operated at a precise angle.
Jour of Adv Research in Dynamical & Control Systems, Vol. 10, 06-Special Issue, 2018

Figure (3): Bipolar of stepper Motor winding

Stepping mode
Stepping Modes means the sequence of stator electromagnets are animated to rotate the motor. There are
three modes:
1. Wave drive mode: In this type as shown in fig(4), only one coil is activated at each time in this mode
the torque is significantly less and rarely used.
2. Full Drive mode:. In this mode which used in this paper as shown in fig (5) two coils are activated at
same time. This method is usual used for driving motor at its full torque.
3. Half drive mode: In this stepping mode as shown in fig(6), one or two coils are activated. It is
commonly used to increment the angular resolution, but the torque is less 70% at its half step position.

Figure (4): position of stepper motors coils in wave drive mode.

Figure (5): position of stepper motors coils in full drive mode.

*Corresponding Author: Sanable M. M. AL hajzber

Article History: Received: 15 Apr. 2018 Revised: 1 May .2018 Accepted: 20 May 2018
726
 Microcontroller Based Stepper Motor Drive for Variable A.C Power Supply

Figure (6): position of stepper motors coils in half drive mode.

Stepper motor drive circuits

The drive circuit used is of an L/R kind. Voltage of negative or positive was supplied to any winding for
arrange position. When applied torque in shaft of the stepper motor, a current ( I ) of the winding was
concerning for the supplied voltage V in the inductance L winding of and the resistance R winding., the
resistance R limits by Ohm's law. The inductance L find by the big change of rate of the current / time ( dI/dt =
V/L). The maximum stepper motor speed is limited by its inductance. The rate for a current changing is a
function to the L / R .Forget max torque through max speed needs a high voltage by a low value of inductance
and resistance in this control drive.
The ULN2003 used in this paper shows in fig (7),it is a high voltage and current consist from seven open
collector Darlington pairs with common emitters. Every channel rated with 500mA and a peak current 600mA.
ULN2003A, 5V, TTL, CMOS is a versatile device, it is useful for driving a wide range of loads. The ULN2003a
is supplied in 16 pin plastic DIP packages.

Figure (7): The control circuit of stepper motor

Jour of Adv Research in Dynamical & Control Systems, Vol. 10, 06-Special Issue, 2018

III. PIC16F84 microcontroller

Fig (8) representing the general structure map of PIC16F84 to a class of 8-bit microcontrollers of RISC
architecture.[3]. PIC16F84 has an 18 pins, it is most frequently found in a DIP (for Dual In Package) there are 18
types of case but can also be found in SMD (Surface Mount Devices) case which is smaller from a DIP.

Figure (8): General structure of PIC16F84 Microcontroller

IV. Flowchart diagram and power supply

Figure (9) shows the flow char t the steps for microcontroller programing which used in process circuit[4].
The two voltage levels are obtained from A220 A.C mains after using step down transformers. Full-wave
bridge rectifier is used to obtained D.C voltage, and this voltage is fed to smoothing capacitors for suppressing
the D.C ripples then the output voltage as shown in the block diagram given in figure (10) [5]. In this study the
electrical working circuit connection is shown in figure (11) and the practical connection is shown in figure (12).
Table (1): presents the percentage error for practical designed in this study, it can seen that good agreement is
observed for the designed result compared with key bad result [6].
Table (1): percentage error for practical designed.
No Theoretical voltage Practical voltage Percentage Error
1 25 25.2 0.8%
2 50 50 0%
3 75 74.7 0.4%
4 100 99.3 0.7%
5 123 123.5 0.4%
6 144 144.6 0.4%
7 189 189.7 0.37%
8 220 220.3 0.14%

*Corresponding Author: Sanable M. M. AL hajzber

Article History: Received: 15 Apr. 2018 Revised: 1 May .2018 Accepted: 20 May 2018
728
 Microcontroller Based Stepper Motor Drive for Variable A.C Power Supply

Figure (9): Flow chart of steps for microcontroller programing

220v AC Transformer Full-wave rectifier Out-put

220v to 24 Rectifier 24v dc

A- Stepper motor (power supply)

220v AC Transformer Full-wave rectifier Regulator

220v to 10 Rectifier 5v dc

B-Microcontroller (power supply)

Figure (10): Connection of power circuit
Jour of Adv Research in Dynamical & Control Systems, Vol. 10, 06-Special Issue, 2018

Figure (11): Electrical circuit conection

Figure (12): Practical connection

*Corresponding Author: Sanable M. M. AL hajzber

Article History: Received: 15 Apr. 2018 Revised: 1 May .2018 Accepted: 20 May 2018 730
 Microcontroller Based Stepper Motor Drive for Variable A.C Power Supply

V. Conclusion
In this paper, a microcontroller based stepper motor drive for variable A.C power supply is designed. The
concept of this power supply has been utilized in different areas in the real world. This designed can easily be
extended to any voltage we needs from 0 to 220 by using the key bad and with small error approximately 0.4%.
The protocol designed of this power supply can be used as follows:
 Give any voltage from 0-220 in the laboratory easily.
 The students were able to take their knowledge and apply it to real world application problem.
 The boxing of this power supply is smaller size and simple it used.
 PIC16F84A can be used instead of many fixed functions [ICs] because it more efficient and easy to
programming and more fixable for voltage higher than 5v.
 The error percentage is increase when stepper motor runs in two directions.
 ULN2003A is high current, high voltage driver that could be used instead of using (relay) which have to
driving by a transistor and get rid of the problems caused by relay contact which are ripples, sparks and
noises.

References
[1] Colone WM.T.”Transformer and inductor design hand book “by Marcel Dekker Inc., California
2004..
[2] S.G Abeyratne and U.I.Dayaratne “Anew power conversion strategy for a unipolar stepper motor
drive”IEEE transaction on Industrial electronics, pp213-217,2010..
[3] Dr.Tarek A.Tutunji”mechatronics microcontrollers PIC16F84 control of stepper motor” Engineering
Department philadelphia Universityb ,Jorden, 2004..
[4] www.stepping motors.com.
[5] www.pic list .com.
[6] www.microchip.com.
.

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