OUTCOME

BASED LAB
TASK REPORT

TO IDENTIFY THE SUITABLE MOTOR TO CONTROL

HARD DISK DRIVE

Submitted by

SUSEENDRAN V

1
 BANNARI AMMAN INSTITUTE OF TECHNOLOGY
(An Autonomous Institution Affiliated to Anna University, Chennai)
SATHYAMANGALAM-638401

JULY 2021

DECLARATION

I affirm that the lab task work titled “ANALYSE THE TORQUE
CHARACTERISTICS OF STEPPER AND SERVO MOTOR AND IDENTIFY
THE SUITABLE MOTOR TO CONTROL HARD DISK DRIVE” being submitted
as the record of original work done by us under the guidance of C.R.SUGANYA
DEVI, Assistant Professor,Department Of ECE.
.

( Signature of candidate )
SUSEENDRAN V
( 202IT243 )

I certify that the declaration made above by the candidates is true.

( Signature of the Guide )

C.R.SUGANYA DEVI
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 TABLE OF CONTENTS

S.NO TITLE PAGE

NO.
1. Objective of task
4

2. Overall
block diagram of 4
task
3. Methodology proposed
5

4. Experimental procedure
6

5. Expected outcome
13

6.
Conclusion 13

7. REFERENCES
13

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 ANALYSE THE TORQUE CHARACTERISTICS OF STEPPER AND
SERVO MOTOR AND IDENTIFY THE SUITABLE MOTOR TO CONTROL
HARD DISK DRIVE

OBJECTIVE OF THE TASK

To analyse the torque characteristics of stepper and servo
motor and identifythe suitable motor to control hard disk drive.

OVERALL BLOCK DIAGRAM OF TASK

Stepper Servo
motor motor

characteristics

Suitable
motor for
hard drive

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 METHODOLOGY PROPOSED
STEPPER MOTOR :

A stepper motor, also known as step motor or stepping motor, isa brushless DC
electric motor that divides a full rotation into a number of equal steps. The motor's
position can be commanded to move and hold at one of these steps without any
position sensor for feedback (an open-loop controller), as long as the motor is
correctly sized to the application in respect to torque and speed.Switched reluctance
motors are very large stepping motors with a reduced polecount, and generally are
closed-loop commutated.

SERVO MOTOR :

A servomotor is a rotary actuator or linear actuator that allows for precise

control of angular or linear position, velocity and acceleration. It consists of a suitable
motor coupled to a sensor for position feedback. It also requires a relatively
sophisticated controller, often a dedicated module designed specifically for use with
servomotors.Servomotors are not a specific class of motor, although the term
servomotor is often used to refer to a motor suitable for use in a closed-loop control
system.Servomotors are used in applications such as robotics, CNC machinery or
automatedmanufacturing.

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Experimental procedure:
\

Stepper motor torque and speed characteristics:

Stepper motors have different torque-speed characteristics
depending on whether the motor is starting/stopping or already running. These
characteristics are depicted in two curves on the motor’s torque-speed chart, and it’s
important to understand the differences between these curves and what each one
means for the motor’s operation. But a stepper motor can also produce torque when
it is not moving, and these stationary torque values — referred to as holding torque
and detent torque — are also important factors to consider when sizing and selecting
a stepper motor.

Pull-in torque curve :

The pull-in torque curve shows the range of conditions (maximum torques at given
speeds) under which the motor can start and stop in synchronism with the input
pulses — in other words, without losing steps. At any point on or below this curve
— referred to as the “start/stop” or “self-start” region — the motor can start or
stopinstantly (that is, without accelerating or decelerating) without losing steps.

Pull-out torque curve :

Also referred to as “running torque” or “dynamic torque,” pull-out torque is the
maximum load (torque) a stepper motor can produce while it’s rotating, without
losing steps. If operated at a point beyond the pull-out torque curve, the motor
canstall.
The area between the pull-in and pull-out curves is often referred to as the “slew
range.” In this range, the motor cannot be immediately stopped or started — it
mustbe started in the start/stop region and accelerated to the slew range, or it must
be decelerated from the slew range to the start/stop region and then stopped.
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 Holding torque :
One of the beneficial features of a stepper motor is its ability to hold a load in place
when the motor coils are energized, due to the attraction between the rotor and stator.
This is referred to as the motor’s holding torque and is the torque required to move the
motor one full step when the coils are energized but the rotor is stationary. A stepper
motor’s holding torque is higher than its running torque and is limited primarily by the
amount of current the motor can withstand.

Stepper motors are able to hold a load in

place, even against an external force, when the motor is stationary.

Detent torque:
Detent torque occurs when the motor is not energized — that is, no current is
flowingthrough the motor windings. It occurs because of the attractive forces
between the magnets in the motor’s rotor and the stator. Both permanent magnet and
hybrid stepper motors experience detent torque, but variable reluctance designs do
not. (Recall that variable reluctance steppers use a non-magnetized rotor, so there is
no attraction between the rotor and the stator when the motor is not energized.)

Detent torque reduces both the ideal power and ideal torque that the motor could
produce, with the effect becoming larger as speed increases.
Image credit: Geckodrive Motor Controls
Detent torque is often given in the motor’s data sheet and is an important factor in
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 stepper motor sizing and selection because it must be overcome before the motor
willmove. The amount of power required to overcome detent torque is proportional
to the motor’s speed — the faster the motor is rotating, the more significant the
effect detent torque will have on the motor’s actual torque output. But detent torque
can be beneficial when the motor is stopping because it counters the momentum of
the moving rotor, so higher detent torque will help the motor stop more quickly.

Servo motor torque curves :

A servo motor, when coupled with a feedback device, servo amplifier, and error-
correcting control loops, can maintain a tightly controlled position, torque, or
speedin applications that require closed-loop operation and the ability to respond to
disturbances.
But another benefit of servo motors is their ability to produce significant torque over
a wide range of speeds.
So the servo motor torque curve, which depicts the amount of torque a motor
can produce over its range of operating speeds, is one of the most useful tools in
servo motor sizing and selection.

The servo motor torque curve shows two operating zones — continuous and
intermittent. The continuous operating zone encompasses the combinations of torque
and speed that the motor can produce indefinitely.

When evaluating whether an application lies within the continuous duty zone, the
motor’s root mean square (RMS) torque is used. RMS torque takes into account the
varying torque requirements during the motor’s full duty cycle — including
acceleration, constant velocity, deceleration, and dwell — as well as the amount of
time that each level of torque must be produced. The purpose of RMS torque is to
determine the torque value that, if it was produced continuously by the motor,
wouldresult in the same level of motor heating as all the various torques and
durations the motor experiences during its duty cycle.

Ambient temperature also affects how quickly the motor will reach its thermal limit,
and therefore, its continuous torque rating. If the motor will be operated in an area
with an ambient temperature greater than that specified by the manufacturer, the
servo motor torque curve will need to be adjusted (derated) accordingly. Conversely,
if the ambient temperature around the motor is well below the ambient temperature
specified by the manufacturer, the motor’s continuous torque rating may be
increased.
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 Servo motors have two operating zones:
continuous duty and intermittent (peak) duty.
Servo motor torque curves are relatively flat up to
the motor’s maximum speed, unlike stepper
motors, whose torque drops sharply beyond
a certain operating speed.

The maximum torque required by the motor is typically the sum of torque during
acceleration, torque due to the load, and torque to overcome friction. Because
maximum torque is required for only a short amount of time, it can fall outside of the
motor’s continuous operating zone, but must fall within the intermittent duty zone.

However, there are two caveats when considering the application’s maximum and its
relationship to the motor’s intermittent operation zone:

1) The duration of maximum torque must fall within the time limit defined by
themotor manufacturer for intermittent operation

2) Both the maximum torque and maximum speed should fall within the
intermittent zone. If either parameter lies outside the motor’s operating
limits,damage to the motor could occur.

The maximum speed of the motor is limited by voltage … or more specifically

by back EMF voltage. Back EMF is generated by the motor’s rotation and
opposes the applied voltage. As speed increases, so does back EMF, and at some
point, the back EMF can reach or exceed the voltage supplied by the drive.

Note that the servo amplifier (aka servo drive) can limit the motor’s maximum
operating parameters, so torque-speed curves are often developed for specific motor-
amplifier combinations. Using a different amplifier than that specified for the
torque-speed curve could change the motor’s continuous and intermittent operation
limits.

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 STEPPER MOTORS VS SERVO MOTORS:

In the manufacturing industry, motors complete the powerful task of converting

electrical energy to mechanical energy. Stepper motors and Servo Motors both have
distinct advantages and serve as common solutions for motion control projects.
Determining the correct motor relies on specifications and application of use.

Stepper Motor vs Servo Motor

Torque & Speed :

Both motors have different speed and torque characteristics, this can be the deciding
factor on which motor is appropriate for the application at hand. At high speeds,
stepper motors typically have poor torque characteristics. Servo motors can generate
speeds anywhere between two and four times the speed of a stepper motor.

Servo motors operate under constant position feedback (closed-loop), as opposed to

the typical open-loop system of a stepper motor. This allows servo motors to operate
at higher speeds and generate higher peak torque. The use of rare-earth magnets in
servos is an additional feature that enables them to create more torque in a small
package.

Stepper Motor and Servo Motor –

Torque vs Speed Graph

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System Control :
Usually, stepper motors operate in the open-loop, constant current mode. Stepper
motor systems operating in a constant current mode (open loop) creates a significant
amount of heat in both the motor and drive, which is a concern for some. Servo
control solves this by only supplying the motor current required to move or hold the
load.

Servo motors operate with a closed-loop system. Closed-loop control systems have
encoders (sensors) to provide feedback. Feedback is data that is passed back from
some point into the control system to another preceding point in the control system.
Servos are controlled by sending an electrical pulse of variable width, known as
pulse width modulation. When the system receives a pulse of some length it will
thenrotate the motor accordingly.

Pole Count :
Stepper motors generally use 50 to 100 poles, whereas servo motors use only 4 to 12
poles. A pole refers to the area of a motor where a North or South Pole is generated
by a permanent magnet or by passing current through coils of a winding. Each pole
offers a natural stepping point for the motor shaft.
The high pole count of steppers allows them to generate holding torque, and
consume less power at zero speed. Steppers don’t require encoders since they can
accurately move between their many poles whereas servos, with fewer poles, require
an encoder to keep track of their position.

Cost Analysis :
Servo motors use rare-earth magnets and also have external features such as an
encoder causing a higher cost. The physical size of a servo motor is larger than a
stepper motor, requiring more raw materials to be manufactured.

Stepper motors are significantly less intricate. Stepper control systems are always
less expensive and are optimal for applications that require low-to-medium
acceleration, high holding torque, and the flexibility of open or closed-loop
operation.

Servo motors are more costly due to the complexity of their internal design. Stepper
motors use less expensive magnets and rarely incorporate gearboxes.

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Which Motor Fits our Application the Best?

Stepper motors are a good candidate for applications that require simple motion and
no feedback. Steppers are available in a large variety of sizes, which helps to
accommodate for size constraints.

Servo motors aid applications where sound and vibration need to be minimal. Servo
motors are better for complex systems that require precise feedback. Certain
applications such as CNC machinery require high accuracy, where a servo motor is
an optimal solution. Servo motors are more efficient than stepper motors, with
efficiencies between 80-90%.

In overall performance, servo motors are best for high speed, high torque
applications while stepper motors are better suited for lower acceleration, high
holding torque applications. ISL Products can help tailor the correct motor for all
applications, small or large.

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Experimental outcome/ output :
The main benefit of servo motors is they provide high levels of
torque at high speed – something stepper motors can't do. They also operate at 80
–90% efficiency. Servo motors can work in AC or DC drive, and do not suffer
from vibration or resonance issues.

Conclusion :
From the all above we seen we came to the conclusion that servo motor
issuitable for hard drive.
In early days, hard disk drives also used steppers, but nowadays hard
drives have replaced the steppers with voice-coil servo motors. In order to
sustain the continuing increase of HDD data storage density, dual-stage
actuator servo systems using a secondary micro-actuator have been developed
to improve the precision of read/write head positioning control by increasing
their servo bandwidth .

Reference :

https://electronics.stackexchange.com/questions/175098/where-exactly-does-the-
ground-line-go-in-an-ac- dc-power-supply

https://en.wikipedia.org/wiki/Power_supply_unit_(computer)#:~:text=A%20power%
20supply%20unit%2
0(PSU,internal%20components%20of%20a%20computer.&text=They%20also%20p
rovide%20a%20si

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 OUTCOME BASED LAB TASKS
RUBRICS FORM (*to be filled by the lab handling faculty only)

Student name:
Register number:
Name of the laboratory:
Name of the lab handling faculty:
Name of the task:
Experiments mapped:
1.
2.
3.

S.No Rubrics Reward points awarded

1
2
3
4
5
Total (150 reward points)

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