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should first know the dynamic torque output of quickly as possible. When using a linear profile
the motor-and-driver and then adapt the velocity the motor torque is considered equal to T1 over
In this paper, a simple but reliable model is advantage of the motor's capability of delivering
used for calculating the dynamic torque output. much more torque at low speed. In
III DYNAMIC TORQUE CALCULATION Figure III-1 illustrates the model we decided
As stated previously, to optimise the speed to use.
profile it is imperative to know the dynamic
R', L
torque of the motor-and-driver unit. There are two
ways of doing so. The first one is to measure it.
This requires the motor, the driver and some
R, L
special equipment. A second method consists
of calculating the torque.
Many papers have been publ ished on how
to calculate the dynamic torque of stepper
Fig. III-1 :
motors, but they often neglect the motor's iron Modelisation of iron losses
losses. At low speed this is correct, but at high
step rates iron losses are no longer negligible. III-1-2 Principle of Measurement
In this Chapter we present a model of iron Two kinds of measurements were made:
losses adapted to the Disc Magnet Motor, and - measure without a rotor
then apply it to the dynamic torque calculation. - measure with the rotor in place
Please note that this model has been It is important to understand the way these
simplified after many practical measurements. measurements were made, because after
These simplifications would not hold with other comparing both methods and their results we
motor technologies. were able to simplify our theoretical model.
An alternating magnetic flux crossing an being close to that of air, it is possible to have
iron structure generates iron losses. There are the rotor locked or to take it out altogether. The
two kinds of iron losses: those due to procedure uses a voltage generator. By
hysteresis and losses due to eddy currents. measuring the voltage, the current and the
To simulate these losses we suppose that phase shift we can figure out the R' value at
the stator magnetic circuit is perfect and that we different frequencies (see fig. III-2).
=n.ω.Φ (L/R').(dΦ/dt)
ϕ ψ
Fig. III-2 : RΙ
Measurements without a rotor Re(Z). Ι
current
we have the following equations: magnet
U = RΙ+n(dφ / dt) E
0 = R'Ι'+n(dφ / dt)
Te
nΙ+nΙ' = φ / A
By using modulus :
By measuring the EMF versus speed we
2 find the losses due to R' generated by the
(LωΙ)
R' = L ⋅ ω / −1
2 2 magnetic flux from the magnet. With a perfect
(U cos ϕ − RΙ ) + (U sin ϕ)
magnetic circuit EMF would rise linearily with
By projecting on the real axis : speed. The value of R' is given by the equation:
2 2
2 2 R' = L ⋅ ω ⋅ E / (K ⋅ ω / N) − E
(L ω) ⋅ (1 ± 1 − 4 ⋅ ( ∆R / Lω) )
R' =
( 2 ⋅ ∆R) By measuring the torque required to drive
the stepper we determine the power loss in the
By using the power dissipated :
magnetic circuit due to flux crossing the winding
R' =
((Ucos ϕ −RΙ) 2 2
+ (Usin ϕ) ) and flux crossing only the edges of the teeth.
25.00
20.00
Resistance in ohms
15.00
R (Z)
Polynomial (R (Z))
0.00
Flux crossing the motor winding 0 500 1000 1500 2000 2500 3000
0.009
0.007
0.006
0.005 L (Z)
0.004 Linear (L (Z))
0.003
0.001
1600
PF1 = Te ⋅ α − PF 2 1400
1200
Note: 1000
R' in ohms
Meth. pui
800 Polynomial (Meth. pui )
400
200
the leakage flux of the magnet crossing only the Fig. III-8 :
From the measure of Re(Z) and
Jm(Z)
tooth edges.
we can calculate R'
PH632-508.002.
30
due to flux created by the winding only.
EFM in volts
25 EMF (V)
Polynomial (EMF (V))
20
0
seen by the magnet and by the coils seem to
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Electrical frequency
be pretty small. Therefore we can separate the
25
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
the motor resistance versus frequency and also
Electrical frequency (Hz)
f
R( Z) = R ⋅ ( λ − 1) ⋅ + 1
25
20 2500
Power in Watts
5
f : electrical frequency
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
λ : value defined for each motor size
(see Fig. III-12).
Electrical frequency (Hz)
Fig. III-11 :
Analysis of power distribution versus Equation of the torque to be subtracted from the
step rate calculated torque :
TF = a ⋅ ωmechanical + b
III-1-3-3Interpretating the Measurements
The coefficients a and b have been identified
The measure of EMF shows that the
for each Portescap motor (see fig. III-12).
magnetic flux crossing the motor winding does
not generate too much losses. The torque Motor a b λ
necessary to rotate the stepper is mainly due to Type
P520/PP520 13,4.10-6 3.10-3 4 the BEMF can be a time function just like the
T is:
The average torque per phase
T /2
2
T=
T ⋅ω
⋅ ∫ i( t) ⋅ E( t)dt
0
with i(t) the actual instantaneous current and
E(t) the BEMF.
-Ιfin.
E(t) in V.
Ic(t) and i(t) A
Iinit.
E(t)
T/2
Ic(t)
0 t0 Time
i(t)
Ifin.
Fig. III-13 :
Shape of the back-EMF (E(t)), the current
reference Ιc(t) and the actual current
i(t) for a
phase advance of tox360/T electrical degrees
Variables :
ω : Motor Speed
ψ : Commutation angle (electrical degrees)
Ιc(t) = f(t)
Example formicrostep mode
Ιc(t) = Ιc.sin(N.ω.t)
E(t) = K.ω.sin(Nω(t-t0))
i(t=0)=0
t=0
yes no
Ι c(t) ≥ i(t)
yes no
Regenerative
U − E( t ) − T d τ −T /τ Mode ?
i( t + T d ) = 1 − e
+ i( t ). e d
R
− E (t )
( ) + i(t ). e− t
− U − E( t ) −t τ −T /τ
i( t + T d ) = 1 − e d + i( t ). e d i (t + t d ) = 1 − e− t d τ d /τ
R R
no yes
t+T d = T/2
t=t+T d
no
i(t+Td)+i (0) ≤ Ι c MAX 1000
i(0)=-i(t+T d)+i (0)
2
Average torque per phase = (2/ T. ω).Mechanical power for t ∈ (0, T/2)
Fig. III-14 :
Dynamic torque algorithm for constant motor speed and commutation angle
(C) Portescap. All right reserved.
Dynamic Torque
0.25
Equations :
0.2
During acceleration
Calculated Value
0.15
Measured Value
Tmotor = TM(1−ω / ωM )
dω
0.1
J = Tmotor
dt
Solving this differential equation results in :
0.05
0
dω
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
J = TM (1 − ω / ωM )
dt
Speed in step/s
TM
Fig. III-15 −t
Jω M
Dynamic torque of the PH632-508-002 with an ω( t) = ωM (1 − e )
L/R driver, U=36V, serial resistance 33 ohms
TM
−t
ωM Jω M
θ( t) = ωM [ t + J (e − 1)]
IV Adequate speed profile TM
In the previous paragraph we calculated the Another method is to proceed in discrete steps.
dynamic torque of the stepper associated with Let ωn be the average speed of step number n.
its driver. Knowing this torque and the The torque is considered constant from ω(n) to
kinematics of the mechanical transmission, like
ω(n+1).
friction and viscous torque, and reflected inertia,
ω(n) is:
Then the motor torque at the speed
we can calculate the velocity profile.
Tmotor (ωn) = TM . (1-ωn / ωM)
i=i+1
ω n < ωAi + 1
Fig. IV-2 yes no
Torque versus speed of a stepper motor
assimilated to parts of straight lines ω (n+1)2 = ω n 2 + P ( ω n - ωA i ) . ( T A i - TAi+1) T A i
( ωAi+i - ω A i) +
J. π
is:
ω − ωA(i) Fig. IV-3
TA(i) (ω) =
ω − ωA(i+1) − ωA(i)
[ ]
⋅ TA(i) − TA(i+1) + TA(i)
Fig. IV-5
Timer Counter
µP
XA = X A + 1
XD = XD + 1
no ω(XA) > ω (XD)
yes
yes no
X D + X A < XT
Fig. IV-6
Calculation of the number of steps
(C) Portescap. All right reserved.
The table calculated previously has to be two frequencies corresponds to a speed jump of
converted into the number of periods of the 196 steps/s.
external clock. Firstly, the microprocessor If the motor makes 10 microsteps/step, the
resets both timers. Once a motion is required, a speed of 10000 steps/s is generated by loading
pulse is sent to the driver. The timer (pulse the value 10 into the timer. The closest smaller
generator) is loaded with the frequency required frequency we can generate by loading 11 is
next. The microprocessor checks the number of 90909 Hz. The jump between these two
steps already made and compares it to the frequencies equals 909 full steps/s, which is
displacement profile in order to know the next much higher than when working in half step
frequency to be put into the timer once the mode. Figure V-1 illustrates this example.
preceding pulse is sent. The next frequency to
Speed in pulse/s
load will be :
- the following period in the acceleration table
when accelerating
- the previous period in the deceleration table
when braking
- the same period when running at constant time
Example:
If the frequency to be generated is X times the
A motor with 200 steps/rev. has to rotate at
value of fh, then ∆f is X2.fh/N 2 which as a speed
10'000 steps/s. The external clock frequency is
jump is X times larger.
1 MHz. If the motor is working in half step
Very often, the electronics designer is not aware
mode, the value 50 has to be loaded into the
of this phenomenon which can disturb the motor
timer to generate a frequency of 20 khz. The
behaviour at high speed.
closest smaller frequency we can generate is
CONCLUSION:
obtained by loading the value of 51.
This speed is 19607 Hz. The jump between the
(C) Portescap. All right reserved.
Today, stepper motor technologies like the Disc motor performance. Other methods exist, like
Magnet motor ofPortescap allow to use stepper the phase plane, which consists of calculating
motors not only as apositioner but also for fast the motor position and speed step by step.
incremental motion. Such motors can really Unfortunately, such a process requires to know
compete against traditionalBrushless DC perfectly well all the kinematics of the entire
motors without the need of an expensive drive system which is difficult in an industrial
electronics for closing the loop. To fully take environment.
advantage of such a motor, it is important to The paper allows to take full advantage of the
know with reasonable accuracy the dynamic Disc Magnet Motor. The calculation of the
torque of the motor associated to its driver. This dynamic torque as well as the optimum velocity
paper describes an easy way to introduce iron profile have been implemented in a software
losses into the model for determining the called "SOAP", developed by Portescap for use
dynamic torque. With a very simple algorithm, a by its application engineers in order to help
speed profile close to the optimum can be customers to optimise their incremental motion
calculated. It is clear that with such a method applications.
we always need a safety factor of roughly 70%
meaning that we are not using 100% of the
Bibliography:
• C. Oudet
"A New Family ofMultipolar P.M. Stepper Motors"
IMCSD, 1981
• M. Crivu, M. Jufer
"Auto-commutation de Moteurs Pas-à-pas sansCapteur"
6e colloque sur les moteurs pas-à-pas, EPFL, July 4-5, 1990
• M Jufer and R.Osseni
"Brushless DC Motor and Driver
Modeling with Iron Losses Effects"
IMCSD, 1988
• R. Osseni
"Modélisation et Auto-
asservissements deMoteurs Synchrones Autocommutés"
Thèse, EPFL, 1988
• L. Antognini
"Réglage etCommande deMoteurs Pas-à-pas"
Thèse # 547, EPFL, 1984
• P.P. Acarnley
"Stepping Motors"
IEE Control Engineering series 19
• M. Simon-Vermot and Dr.Karmous
"Optimisation of the Utilisation of a Stepper Motor"
Electric Drive Design and Applications, EPFL,oct. 19-20, 1994