DC Motors

DC (Direct Current) Motors are two wire (power & ground), continuous rotation motors. When
you supply power, a DC motor will start spinning until that power is removed. Most DC motors
run at a high RPM (revolutions per minute), examples being computer cooling fans, or radio
controlled car wheels!

The speed of DC motors is controlled using pulse width modulation (PWM), a technique of
rapidly pulsing the power on and off. The percentage of time spent cycling the on/off ratio
determines the speed of the motor, e.g. if the power is cycled at 50% (half on, half off), then the
motor will spin at half the speed of 100% (fully on). Each pulse is so rapid that the motor appears
to be continuously spinning with no stuttering!

Servo Motors

Servo motors are generally an assembly of four things: a DC motor, a gearing set, a control
circuit and a position-sensor (usually a potentiometer).

The position of servo motors can be controlled more precisely than those of standard DC motors,
and they usually have three wires (power, ground & control). Power to servo motors is
constantly applied, with the servo control circuit regulating the draw to drive the motor. Servo
motors are designed for more specific tasks where position needs to be defined accurately such
as controlling the rudder on a boat or moving a robotic arm or robot leg within a certain range.

Servo motors do not rotate freely like a standard DC motor. Instead the angle of rotation is
limited to 180 Degrees (or so) back and forth. Servo motors receive a control signal that
represents an output position and applies power to the DC motor until the shaft turns to the
correct position, determined by the position sensor.

PWM is used for the control signal of servo motors. However, unlike DC motors it’s the duration
of the positive pulse that determines the position, rather than speed, of the servo shaft. A neutral
pulse value dependant on the servo (usually around 1.5ms) keeps the servo shaft in the centre
position. Increasing that pulse value will make the servo turn clockwise, and a shorter pulse will
turn the shaft anticlockwise. The servo control pulse is usually repeated every 20 milliseconds,
essentially telling the servo where to go, even if that means remaining in the same position.

When a servo is commanded to move, it will move to the position and hold that position, even if
external force pushes against it. The servo will resist from moving out of that position, with the
maximum amount of resistive force the servo can exert being the torque rating of that servo.

Stepper Motors

A stepper motor is essentially a servo motor that uses a different method of motorisation. Where
a servo motor uses a continuous rotation DC motor and integrated controller circuit, stepper
motors utilise multiple toothed electromagnets arranged around a central gear to define position.
Stepper motors require an external control circuit or micro controller (e.g. a Raspberry Pi or
Arduino) to individually energise each electromagnet and make the motor shaft turn. When
electromagnet ‘A’ is powered it attracts the gear’s teeth and aligns them, slightly offset from the
next electromagnet ‘B’. When ‘A’ is switch off, and ‘B’ switched on, the gear rotates slightly to
align with ‘B’, and so on around the circle, with each electromagnet around the gear energising
and de-energising in turn to create rotation. Each rotation from one electromagnet to the next is
called a "step", and thus the motor can be turned by precise pre-defined step angles through a full
360 Degree rotation.

Stepper motors are available in two varieties; unipolar or bipolar. Bipolar motors are the
strongest type of stepper motor and usually have four or eight leads. They have two sets of
electromagnetic coils internally, and stepping is achieved by changing the direction of current
within those coils. Unipolar motors, identifiable by having 5,6 or even 8 wires, also have two
coils, but each one has a centre tap. Unipolar motors can step without having to reverse the
direction of current in the coils, making the electronics simpler. However, because the centre tap
is used to energise only half of each coil at a time they typically have less torque than bipolar.

The design of the stepper motor provides a constant holding torque without the need for the
motor to be powered and, provided that the motor is used within its limits, positioning errors
don't occur, since stepper motors have physically pre-defined stations.

Summary

This is a rather condensed overview of a complicated and somewhat disputed field (especially
regarding the pros and cons of stepper vs servo!), but hopefully it should help you make a more
informed choice with your motoring needs!

DC Motors

Fast, continuous rotation motors – Used for anything that needs to spin at a high RPM e.g. car
wheels, fans etc.

Servo Motors

Fast, high torque, accurate rotation within a limited angle – Generally a high performance
alternative to stepper motors, but more complicated setup with PWM tuning. Suited for robotic
arms/legs or rudder control etc.

Stepper Motors

Slow, precise rotation, easy set up & control – Advantage over servo motors in positional
control. Where servos require a feedback mechanism and support circuitry to drive positioning, a
stepper motor has positional control via its nature of rotation by fractional increments. Suited for
3D printers and similar devices where position is fundamental.