Astrosyn

Guide to Stepper Motor Selection

Astrosyn International Technology Ltd,

The Old Courthouse, New Rd Ave,
Chatham, Kent, ME4 6BE, England
Tel +44 (0) 1634 815175
Fax +44(0) 1634 826552
www.astrosyn.com
 Astrosyn GUIDE TO STEPPER MOTOR SELECTION

Introduction
Choosing the right stepper motor for a particular
application can be confusing for anyone without
significant experience in the field. Simon Hunt of
Astrosyn International Technology outlines some stepper
motor fundamentals and offers advice on their selection
for industrial applications. requirement of the
system, complexity of the
Stepper motors have a number of features that make them controller, and the
the motor of choice for a wide range of applications, physical characteristics of
particularly in measurement and control. They are low cost, the motor.
highly reliable, produce high torque at low speeds and
benefit from a simple, rugged construction. Choosing the right
stepper motor depends
They also have the advantage of operating in open loop upon the application. The
mode. As long as the motor runs within its specified torque, motor’s specification will
the position of the shaft is known at all times without the include the following
need for a feedback loop. parameters:-

Stepper motors are available in three main types:  the number of full
steps per
Permanent magnet motors. revolution
These are widely used in non-industrial applications, such as  whether to
computer peripherals, and are operate in full
low-cost, low-torque and low- step, half step or
speed devices. Their design microstep mode
means that their step angles are  the rotational
relatively large, but their inertia of the rotor
simplicity lends itself to high- and shaft
volume production at low cost.  holding torque -
the maximum
Variable reluctance motors. restoring torque
These do not contain permanent magnets, giving them a developed by the
good torque to inertia ratio. They are frequently used in rotor when one or
small sizes for applications such as micro-positioning tables. more phases of
However, they require a different driving arrangement from the motor are
the other two types and are seldom used in industrial energised
applications.  detent torque –
the torque
Hybrid motors. As their name suggests, these combine the required to rotate
operating principles of the previous two types, which the motor’s shaft
enables them to provide higher torques. Experience at when the
Astrosyn and elsewhere shows that these are by far the most windings are not
widely used stepper motors in industrial applications and for energised
that reason we will consider only this type here.  pull-out torque –
the maximum
Making the right choice torque that can be
Several factors affect the choice of stepper motors for applied to a
particular applications, such as the type of motor, the torque stepper motor

Astrosyn International Technology Ltd

The Old Courthouse, New Rd Ave, Chatham, Kent, ME4 6BE, England
Tel +44 (0) 1634 815175 Fax +44 (0) 1634 826552 www.astrosyn.com
 GUIDE TO STEPPER MOTOR SELECTION Astrosyn

running at constant speed without causing a loss of flux density. This means
synchronism that stepper motors
 expected ambient temperature range should not be dismantled,
since this flux will be
A standard 1.8° stepper motor has 200 steps per revolution. largely destroyed if the
Full-step mode in single phase is rotor is removed. Unlike
when the motor is operated with with DC servo motors, it is
only one phase energised at a not generally possible to
time. This requires the least power demagnetise stepper
from the driver power supply, and motors by applying excess
can be used where the motor is current.
operated at a fixed speed. Dual
phase provides increased torque, However, too high a
but uses more power. current can damage the
Half-step operation involves alternating single and dual motor in other ways:
phase operation and provides twice the resolution, which excess heating may melt
results in increased smoothness at low speeds. the insulation or the
Microstep operation divides each full step into much smaller winding transformers, and
angles by using sine and cosine functions to drive the may soften the bonding
windings. Astrosyn supplies motors with resolutions of up to material holding the rotor
12 800 microsteps per revolution, and this mode is used laminations. If the
when smoother motion or increased resolution is required. laminations are displaced,
the effects can be the
To design stepper motors with higher torque output, same as if the rotor was
manufacturers need to increase the strength of both the demagnetised.
permanent magnet in the rotor and the field produced by
the stator. Rare earth magnets offer increased magnetic field Note that continuous
strength, and further torque increases can be achieved operation at high speeds
through mechanical changes. can lead to overheating of
the rotor, but high speeds
A stronger rotor magnet can be can be used successfully
obtained by increasing its for positioning
diameter, producing a larger cross- applications.
sectional area, but this decreases
the acceleration of the motor Because the shaft of a
because the torque-to-inertia ratio hybrid stepper motor
becomes worse. passes through the centre
However, torque output can be increased without degrading of the permanent magnet,
acceleration by adding further magnet sections or “stacks” to it must be made of non
the same shaft. A second stack will enable twice the torque magnetic material to
to be produced with double the inertia, so the torque-to- avoid a magnetic short
inertia ratio remains the same. Hence stepper motors are circuit. Stepper motor
often available in single, double and three stack versions in shafts are therefore made
each frame size. of stainless steel, and this
should be borne in mind
Practical tips when handling the motor.
As a rule of thumb, the torque-to-inertia ratio reduces by a
factor of two with each increase in frame size. An unloaded Small diameter motors are
34-size motor can accelerate twice as fast as a 42-size motor, particularly vulnerable if
regardless of the number of stacks. they are dropped on their
shaft end, as this is likely
In the manufacture of stepper motors, the rotor is to bend the shaft.
magnetised after assembly to produce the highest possible

Astrosyn International Technology Ltd

The Old Courthouse, New Rd Ave, Chatham, Kent, ME4 6BE, England
Tel +44 (0) 1634 815175 Fax +44 (0) 1634 826552 www.astrosyn.com