INTRODUCTION TO

ELECTRICAL MACHINES
A Systems Approach

Mohsen Marefat
EE_466_566 Module 2: Lecture 4
 Topic PPT Assessment
1 28-Aug Introduction and Electrification Landscape Lecture 0, E- Transportation
2 11-Sep DC Motors Lecture 1
3 18-Sep BLDC and Systems Considerations Lecture 1F
4 25-Sep Module 1 - Summary, Problem Set 1 Lecture 2 Problem Set #1 Due
5 2-Oct Module 1 - Assessment In Class Test - Open Book
6 9-Oct Hoilday!
7 16-Oct Stepper Systems Lecture 3
8 23-Oct Power Considerations Lecture 4
9 30-Oct Module 2 - Summary, Problem Set 2 Problem Set #2 Due
10 6-Nov Module 2 - Assessment In Class Test - Open Book
11 13-Nov Induction Motors Lecture 5
12 20-Nov Synchronous Motors Lecture 6
13 27-Nov Module 3 - Advanced Motors, Problem set 3 EV Considerations Problem Set #3 Due
14 4-Dec Module 3 - Summary and Review Online via Zoom
15 13-Dec Module 3 - Assessment In Class Test - Open Book
• The scientists:
• Georg Ohm ( 1789 – 1854 )
• Michael Faraday ( 1791 – 1867 )
• Emil Lenz ( 1804 – 1865 )
• James Maxwell ( 1831- 1879 )
• Hendrik Lorentz ( 1853 – 1928 ) F= q (E + v x B )
• Edwin Hall ( 1855 – 1938 )

• The Engineers:
• Thomas Edison ( 1847 – 1931 )
• Nicolai Tesla ( 1856 – 1943 )

• The Corporations:
• General Electric
• Superior Electric (Stepper Motors: 1952 to 1970’s)
• Sigma Instruments (Cyclonome Motor: 1952 to Hybrid Stepper 1984)
Naval: engine order telegraph
• Open-loop Off/ON
• Uni or Bi-Directional Speed Control
• Load variations: Including Stall Conditions
• Acceleration requirements: Tacc > 10x Tss
• Incremental Motion Control

APPLICATION REQUIREMENTS
Torque-Speed Characteristics
A. Motor Types (PM, VR, Hybrid)
B. Winding Types (Uni, Bi Polar)
C. Drive Methods (Wave, Full,
Half, Micro) Stepping

STEPPER MOTORS
Phases, Coils, and
Poles, Oh my!
https://www.youtube.com/watch?v=eyqwLiowZiU
https://www.allaboutcircuits.com/textbook/alternating-current/chpt-13/stepper-motors/
Detent!
A. Motor Types (PM, VR, Hybrid)
B. Winding Types (Uni, Bi Polar)
C. Drive Methods (Wave, Full,
Half, Micro) Stepping
 8-Wire Motor

• 4-phase unipolar - All the common wires are connected together -

just like a 5-wire motor.
• 2-phase series bipolar - The phases are connected in series - just like
a 6-wire motor.
• 2-phase parallel bipolar - The phases are connected in parallel. This
results in half the resistance and inductance - but requires twice the
current to drive. The advantage of this wiring is higher torq ue and top
speed.

6-Wire Motor
This motor only joins the common wires of 2 paired phases. These two wires
can be joined to create a 5-wire unipolar motor.

5-Wire Motor
This style is common in smaller unipolar motors. All of the common coil
wires are tied together internally and brought out as a 5th wire. This motor
can only be driven as a unipolar motor.

Advanced full bridge chopper drivers

A. Motor Types (PM, VR, Hybrid)
B. Winding Types (Uni, Bi Polar)
C. Drive Methods (Wave, Full,
Half, Micro) Stepping
One Full Electrical Cycle
“cycle of excitation”
 A4970: Dual Full-Bridge PWM Motor Driver by Allegro Microsystems
Wave drive: 1000 0100 0010 0001;
Full step drive: 1100 0110 0011 1001;
Half step drive: 1000 1100 0100 0110 0010 0011 0001 1001
Unipolar step sequences

AA’ BB’ CC’ AA’ BB’ CC’

1 0 0 1 1 0
0 1 0 0 1 1
AA’ BB’ CC’
0 0 1 1 0 1
1 0 0
1 0 0 1 1 0
1 1 0
Wave Drive Full Step
0 1 0
0 1 1
0 0 1
1 0 1
1 0 0
Half Step
https://www.makerguides.com/a4988-stepper-motor-driver-arduino-tutorial/
https://www.makerguides.com/28byj-48-stepper-motor-arduino-tutorial/
A. Motor Parameters
B. System Considerations
C. Applications
ENERGIZING A COIL
L/R VS. CHOPPER DRIVES
Electrical: Phase Current

Mechanical: Shaft Position

Holding Torque
Detent Torque
Pull-in Torque
Pull-out Torque
Rated Torque?
 Specific stepper motor parameters
1. Size– NEMA (National Electrical Manufacturer Association)
2. Step angle – represents angular displacement of the rotor for one control impulse;
3. Maximum no load start frequency – represents the maximum control impulse frequency at which the unloaded
motor can start, stop or reverse without losing steps;
4. Pull-in torque – represents maximum torque load at the shaft, at which the motor can start without losing steps;
5. Maximum no load frequency – represents the maximum impulse frequency that the motor can follow without
losing synchronization;
6. Pull-out torque – maximum torque that can be maintained by the motor at a certain speed, without losing steps;
7. Angular speed – is calculated as a product between the stepping angle and the control frequency;
8. Detent torque – represents the value of the holding torque presented by at the motor shaft when it is not
electrically energized.
A. Limit start frequency – represents the maximum impulse frequency at which the motor can start without losing
steps, when a given moment of inertia and torque load are presented at the shaft;
B. Maximum frequency – maximum frequency of impulses at which a motor keeps its timing for given torque load
and inertia;
 Size Step Angle
Model PDF
[mm] [deg]

□20×30
08PM-K(20□ 1.8deg.) 1.8 [189.8 KB]
□20×40

□25×23.5
□25×27.5
10PM-K(25□ 1.8deg.) □25×33 1.8 [243.6 KB]
□25×40.5
□25×51.5 □56×42
23KY-K(56□ 0.9deg.) □56×54 0.9 [390.2 KB]
□35×22 □56×76
14PY-Z(35□ 0.9deg.) 0.9 [208.4 KB]
□35×26
□56×42
□35x32 □56×50
14PM-F(35□ 1.8deg.) □35x36 1.8 [200.7 KB] 23KM-K(56□ 1.8deg.) □56×54 1.8 [332.7 KB]
□35x51 □56×66
□56×76
□42×26
□42×30 □56×43
□42×34 □56×51
17PY-Z(42□ 0.9deg.) 0.9 [249.2 KB] 23KM-H(56□ 1.8deg.) 1.8 [316.9 KB]
□42×38 □56×55
□42×42 □56×77
□42×48
○71×39.5
□42×26 ○71×43.5
□42×30 ○71×46.5
□42×34 ○71×51.5
17PM-K(42□ 1.8deg.) □42×38 1.8 [304.8 KB] 29SM-K(71○ 1.8deg.) 1.8 [323.3 KB]
○71×55.5
□42×42
○71×67.5
□42×48
○71×77.5
□42×60
○71×87.5

□42×40
□85×68
□42×42
17PM-F(42□ 1.8deg.) 1.8 [196.8 KB] 34KM-K(85□ 1.8deg.) □85×96 1.8 [209.8 KB]
□42×48
□42×60 □85×124

HTTPS://WWW.EMINEBEA.COM/EN/PRODUCT/ROTARY/STEPPINGMOTOR/HYBRID/STANDARD/
https://www.eminebea.com/en/product/rotary/steppingmotor/hybrid/standard/__icsFiles/afieldfile/2017/09/29/17pm-k_1.pdf
https://www.makerguides.com/wp-content/uploads/2019/04/ULN2003-Stepper-Motor-Driver-PCB.pdf
https://www.orientalmotor.com/motor-sizing/beltActuator-sizing.html
https://www.orientalmotor.com/motor-sizing/index.html

SYSTEM CALCULATOR
A. Motor Parameters
B. System Considerations
C. Applications
• Steady State Performance
• Acceleration
• Duty Cycle
• Limitations

MOTION PROFILES
• Steady State Performance
• Acceleration
• Duty Cycle
• Limitations

MOTION PROFILES
 https://reprap.org/wiki/Stepper_motor
 https://www.geckodrive.com/support/step-motor-basics.html

ADDITIONAL RESOURCES
 Stepper Motors (Stepping Motor):
• The name stepper is used because this motor rotates through a fixed angular step in response to each input current
pulse received by its controller for the position control system.
• Industrial motors are used to convert electric energy into mechanical energy but they cannot be used for precision
positioning of an object or precision control of speed without using closed-loop feedback.
• Stepping motors are ideally suited for situations where either precise positioning or precise speed control or both are
required in automation systems.
• The unique feature of a stepper motor is that its output shaft rotates in a series of discrete angular intervals or steps,
one step being taken each time a command pulse is received.
• These motors develop torques ranging from 1 µN-m (in a tiny wristwatch motor of 3 mm diameter) up to 40 N-m in a
motor of 15 cm diameter suitable for machine tool applications.
• Their power output ranges from about 1 W to a maximum of 2500 W.
• The only moving part in a stepping motor is its rotor which has no windings, commutator, or brushes that make the
motor quite robust and reliable.

ADDITIONAL RESOURCES
• The curve ABC represents the Pull-in torque characteristics, and the curve ADE represents the Pull-out torque characteristics.
• The area OABCO (under pull-in) represents the region for the start-stop mode of operation.
• The area ABCEDA (between pull-in and pull-out curve) refers to the region for slewing mode of operation in which speed is high.
 Pull-in Torque: It is the maximum torque developed by the stepper motor for a given stepping rate in the start-stop mode of operation
without losing synchronism.
 Pull-out Torque: It is the maximum torque developed by the stepper motor for a given stepping rate in the slewing mode without losing
synchronism.
• The higher value of torque is pull-out torque and less torque when the torque is pull-in torque.

 Pull-in Range: It is the maximum stepping rate at which the stepper motor can operate in start-stop mode, developing a specific torque
(without losing synchronism).
 Pull-out Range: It is the maximum stepping rate at which the stepper motor can operate in slewing mode developing a specified torque
without losing synchronism.
 Pull-in rate (FPI): It is the maximum stepping rate at which the stepper motor will start or stop without losing synchronism against a given
load torque T.
 Pull-out rate (FPO): It is the maximum stepping rate at which the stepper motor will slew, without missing steps, against load torque T.
 A stepper motor has a step angle of 3°. If the pulse rate is 2400 pulses per
second for the motor, what is the shaft speed in rpm?
 Step angle, β = 3°
 Pulse rate or stepping frequency f = 2400
 Shaft speed, \(n = \frac{{\beta \times f}}{{360^\circ }}\)
 \(= \frac{{3^\circ \times 2400}}{{360^\circ }}\)
 = 20 rps
 = 20 × 60 rpm
 = 1200 rpm

APPLICATION EXAMPLE