“Interfacing the stepper motor with FPGA
controller”
Chetan Umbarkar * Anshuman Singh ** Shubham
Kushwaha*** Saloni Parab ****
*
Fr. Conceicao Rodrigues Institute of Technology, Navi-Mumbai, INDIA
E-mail: ccumbarkar@gmail.com
Abstract— The use of Field Programmable Gate
Arrays(FPGAs) for enforcing different types of Pulse
Width Modulation(PWM) controllers has increased
steadily in the last many times. They come dominant
tools for enforcing different types of PWM due to the
flexibility they give compared to other Digital Signal
Processors(DSPs). Different types of PWM have
been enforced for single and three-phase circuits
similar as Digital PWM(DPWM), Sinusoidal
PWM(SPWM), Space Vector(SVPWM), carrier phase
shifted SPWM(CPS- SPWM), Third harmonious
Injection Sinusoidal Pulse Width Modulation
(THISPWM) using different FPGA boards. This paper
presents a methodical review of the enforced PWM
regulators grounded on FPGA. It describes in detail
their types, infrastructures, and intended operation they
used for. It also addresses the main benefactions,
advantages, and disadvantages of different exploration
papers in this area. Current limitations and unborn
development have been drawn grounded on pressing the
enforced and unimplemented PWM grounded on
FPGA.
Keywords: Stepper motor, PWM.
I. INTRODUCTION
FPGA stands for "Field-Programmable Gate Array." It is
a type of integrated circuit (IC) that is designed to be
configured or programmed by a user or designer after
manufacturing. FPGAs are unique in that they can be
reprogrammed to perform a wide range of digital
functions, making them highly versatile in a variety of
applications.
To give this programmability, an FPGA has
Configurable (Programmable)Logic Blocks which have
configurable interconnects between these blocks. When
compared to a similar caliber ASIC with Standard Cells.
In current society, the stepper motor is found widely
from family appliances to commercial and industrial
applications.
A field-programmable gate array (FPGA) is an integrated
circuit developed to be built by a client or a developer,
hence the term field-programmable. The FPGA
configuration is generally named using a hardware 9
description language(HDL). FPGAs contain a bunch of
–1 –
programmable rational pieces and pecking order of
reconfigurable permitting pieces to be tied together.
Rationale squares can be designed to perform complex
combinational capacity or act as straightforward rational
passages like AND and XOR.
The VHSIC Hardware Description Language (VHDL)
could be a hardware description language (HDL) that can
display the behavior and structure of advanced frameworks
at different levels of reflection, extending from the
framework level down to that of rationale doors, for plan
section, documentation, and confirmation purposes.
2. APPLICATIONS OF STEPPER MOTOR
Stepper motors are versatile electromechanical devices
widely used in various applications due to their precise
control of position and speed. Here are some common
applications of stepper motors:
1. CNC Machines (Computer Numerical Control):
Stepper motors are extensively used in CNC machines
for controlling the movement of the cutting tools. Their
ability to move in precise increments makes them
suitable for applications where accuracy is crucial.
2. 3D Printers: Stepper motors are essential components
in 3D printers to control the movement of the print
head along the X, Y, and Z axes. They enable precise
positioning and control, contributing to the accuracy of
the printed objects.
3. Robotics: Stepper motors are commonly used in
robotics for precise control of the robot's joints and
limbs. They are favored for their ability to move in
discrete steps, allowing for accurate positioning.
4. Automotive Systems: Stepper motors find applications
in automotive systems, such as fuel injection systems,
HVAC (Heating, Ventilation, and Air Conditioning)
actuators, and automotive instrument clusters. They are
used for controlling various mechanical components
with precision.
5. Printers and Scanners: Stepper motors are used in
printers and scanners to control the movement of print
heads, paper feed mechanisms, and scanning
components. Their ability to move in precise steps
ensures accurate printing and scanning.
 6. Medical Devices: Stepper motors are employed in
various medical devices, such as infusion pumps,
lab automation equipment, and diagnostic
instruments. Their precise control is essential in
applications where accuracy and reliability are
critical.
7. Camera Systems: Stepper motors are used in
camera systems for precise control of focus, zoom,
and aperture mechanisms. They contribute to the
accuracy and stability of the camera's performance.
8. Textile Machinery: In textile manufacturing,
stepper motors are used in machines for controlling
the movement of yarn feeders, fabric cutters, and
other components. Their ability to provide precise
control aids in maintaining quality in the
production process.
9. Consumer Electronics: Stepper motors can be
found in various consumer electronics, such as disk
drives, camera lenses, and home automation
systems. They are used for precise control of
moving parts in these devices.
10. Satellite Systems: Stepper motors are employed in
satellite systems for accurate positioning of
antennas, solar panels, and other movable
components. Their reliability and precision make
them suitable for space applications.
11. Industrial Automation: Stepper motors play a
significant role in industrial automation for tasks
such as conveyor belt control, pick-and-place
operations, and other manufacturing processes that
require precise movement and positioning.
Overall, stepper motors are widely used in
applications where precise control of position,
speed, and torque is essential. Their reliability, ease
of control, and ability to move in discrete steps
make them suitable for a diverse range of
industries.
3. STEPPER MOTOR
Stepper motors are chosen for various applications due to
their specific characteristics and advantages that make them
well-suited for certain tasks. Here are some reasons why
stepper motors are commonly used:
1. Precise Position Control: Stepper motors move in
discrete steps, allowing for precise control of position
and rotation. This characteristic is beneficial in
applications where accuracy and repeatability are
critical, such as in CNC machines, 3D printers, and
robotics.
2. Open-Loop Operation: Stepper motors can operate in
an open-loop control system, meaning they can
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function without the need for external feedback devices.
This simplicity makes them easier to implement and more
cost-effective in certain applications.
3. Simple Control Interface: Stepper motors are relatively
easy to control using simple pulse and direction signals.
This makes them suitable for applications where a
straightforward control interface is desired, especially in
scenarios where complex feedback systems may not be
necessary.
4. Low-Speed Torque: Stepper motors provide high torque at
low speeds, making them suitable for applications where
low-speed precision and control are essential. This is
advantageous in tasks such as positioning and holding
loads.
5. No Feedback Required for Basic Tasks: For applications
that do not require continuous feedback and correction,
stepper motors offer a cost-effective solution. Open-loop
stepper control can be sufficient for scenarios where
precise positioning is more critical than closed-loop
feedback.
6. Reliability: Stepper motors have a relatively simple
construction with fewer parts compared to some other
types of motors. This simplicity often translates to
increased reliability and robustness in certain applications.
7. Compact Design: Stepper motors can be designed with a
compact form factor, making them suitable for
applications where space is limited. This characteristic is
valuable in various industries, including automotive,
aerospace, and consumer electronics.
8. Low Maintenance: Stepper motors typically have a simple
design with fewer wear parts, leading to lower
maintenance requirements compared to some other motor
types. This can contribute to increased system reliability
and reduced downtime.
9. Low-Cost Solutions: Stepper motors are often more cost-
effective than alternative motor types for certain
applications. This cost advantage, combined with their
suitability for specific tasks, makes them a preferred
choice in budget-conscious projects.
Despite these advantages, it's essential to note that stepper
motors also have limitations, such as potential heat generation
during operation, a tendency to lose steps under high loads, and
a lower efficiency compared to some other motor types.
Therefore, the selection of a stepper motor should be based on
a thorough understanding of the application requirements and
trade-offs involved.
A. Open Loop Operation of stepper motor ❑ An ideal stepper motor has a sinusoidal torque
One of the most significant advantages of a stepper vs displacement characteristic as shown in
motor is its ability to be accurately controlled in an open figure 2
loop system. Open loop control means no feedback
information about position is needed. This type of
control eliminates the need for expensive sensing and
feedback devices such as optical encoders. Here position
is known simply by keeping track of the input step
pulses.

B. Torque Generation of stepper motor

Figure 2. Torque Vs. Rotor Angular Position
The torque produced by a stepper motor depends
on several factors.

• The step rate

• The drive current in the windings
• The drive design or type

In a stepper motor a torque is developed when the

magnetic fluxes of the rotor and stator are displaced from
each other [5].
Figure 3. Angular Position at Different Holding Torques

C. Stepping Modes of stepper motor

The following are the most common drive modes.

❑ Wave Drive (1 phase on)

❑ Full Step Drive (2 phases on)

❑ Half Step Drive (1 & 2 phases on)

❑ Micro stepping (Continuously varying motor

currents)

D. Torque Vs. Angle Characteristics of stepper motor

❑ The torque vs angle characteristics of a stepper
motor are the relationship between the displacement
of the rotor and the torque which applied to the
rotor shaft when the stepper motor is energized at its
rated voltage.
E. Torque Vs Speed characteristic
❑ The torque vs speed characteristics are the key
to selecting the right motor and drive method
for a specific application.

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 Z. Ali , R. V. Kshirsagar • Development of a CPLD-based Novel Open Loop Stepper Motor Controller for High Performance Using VHDL

❑ These characteristics are dependent upon ✓ The advantage of microprocessor is that it is

(change with) the motor, excitation mode and easy for design the control mode of stepper
type of driver or drive method[4] motor by user, including start, stop, and
clockwise or counter- clockwise indeed.

Nevertheless, it cannot make a breakthrough in

variable speed controller of stepper motor for
limited capability of microprocessor[2].

However, microprocessor can only control by

Figure 5. A typical “speed – torque curve”
constant speed.

Although the capability of microprocessor is limited, it

According to various situations of applications, the
choice of stepper motor controller between the
controlling scheme of position or speed must be made in
advance. For performing high precision positioning and
smooth rotation operation, design of stepper motor
controller is a very important issue.
II. NECESSITY OF STEPPER MOTOR CONTROL
has taken some important steps in automation.
To control the stepper motor, the driver can apply an
open loop control algorithm or closed loop algorithm.
Bae and Krishnan (1996) reported that when the open
loop driver is implemented with a DSP in the C
programming language, the coding and debugging is
straightforward [3].

CRUCIAL CONTROL PARAMETERS

As the IC industry boomed over the recent decade, large
amounts of data process more and more fast in digital
system. Because of this, the system on chip (SOC) and
DSP are popular with designers.
Position Time

Kos (2006) presented an algorithm to realize the linear

Stepper motors can be found in
printers, disk drives, X-Y plotters,
and many others which are
required to move controlled objects
to accurate positions within
nominated time. The precision
positioning is a top priority than
others consideration.
For those applications that demand
the controlled objects moved with
designated time to prearranged
positions; such as those used in
autonomous cars, robotic arms with
low moment of inertia, industrial
plants, etc. In such cases, time
should dominate among others.
variable speed controller by adjusting the torque
corresponding current [4].
Le (2006), proposed variable speed controller using
close-loop control. He used an optical encoder coupling
with motor. This encoder can check the angle of motor.
If angle exceed the range between winding and rotor, it
will switch to close-loop, whereas open loop. This
system is implemented on DSP, and velocity profile
stored in memory [5].

III. WORK DONE IN PAST FOR THE CONTROLLER

SIDE OF STEPPER MOTOR
Petrov (1988) proposed a system by a microcomputer
achieved a variable speed controller. On account of
processing speed restrictedly, high resolution could not
be provide. In order to approach the linear acceleration,
the digital-to-analog converter (DAC) is used to increase
resolution [1].
With applications where load torque is stable and
operations are at low speed, an open loop driver is
preferred since it needs a simple control algorithm and an
encoder is not required[12].Here in this work as we are
forcing motor to rotates in two direction clockwise and
counter clock wise mode.The output sequence for driver
circuit is as follows.

Kenjo (1994) advanced a theory that derived the

formulas of linear acceleration [2].

Kang (1994) developed a new method using single

microprocessor to control stepper motor at the same
time.

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INES 2010 • 14th International Conference on Intelligent Engineering Systems • May 5–7, 2010 Las Palmas of Gran Canaria, Spain

TABLE II.

OUTPUT SEQUENCE FOR DRIVER CIRCUIT

Start
output Step Step Step Step Step Step Step Step
Initialization of Clock, Reset, and Full_Half_step & CW_CCW as input pins And A, A_n, B, B_n as output
0 1 2 3 4 5 6 7

A 1 0 0 0 0 0 1 1
Architecture begin

A_n 0 0 1 1 1 0 0 0

B 1 1 1 0 0 0 0 0 Clock “event”
A Clock=1 B
B_N 0 0 0 0 1 1 1 0 1

Step 0
For initial condition assumed that motor is in step 0 If
Reset=1
1
which shows A A_n B B_n=1010 ,after every clock 0

State_motor<- Next_State_motor=0
motor is incremented by one for half step mode.

So, State_motor<= next_state_motor+1 0

If
CW_CCW Full_Half= 1
& for,, Full step mode it is incremented by =1
1
two 0
State_motor<=next_ motor+2
State_motor<=next_
motor+1
State_motor<= next_state_motor+2 1
0
If Full
Both is true for clockwise rotation.similarly for counter _Half=1
clockwise rotation for Half step mode it is decremented B
State_motor<=n ext_motor-1 State_motor<=ne xt_motor-2
by 1
State_motor<= next_state_motor-1
A
For full step motor it decremented by 2
State_motor<= next_state_motor-2.

Figure 7. Proposed algorithm Flow chart

These is the case because in Half step mode motor rotates
for all eight step if we take rotation for 45° from step 0 to
step 7 (0 1 2 3 4 5 6 7)
Whereas for full step mode the rotation takes place for
90° in four step only from step 0 to step 6
(0 2 4
The state diagram for eight half step mode is as follows
The design and simulation of the stepper motor controller
can be performed using Active VHDL[14]. Also the
timings of various signals can be verified. Then the
system can be implemented in CPLD.The flow chart for
controlling stepper motor using VHDL is already been
6). explain.If CPLD’s are compared with FPGA[9] then this
design can fit into FPGA with some changes[8][11]

Clock = 1, Reset
=0 Here in this work we are Controlling Stepper motor
using VHDL and its implementation into CPLD. When
0/7 1010
1/0
CPLD is interface with stepper motor then due to
difference in there specification one driver circuit is to be
0/6
1000
0/0 0010
connected between them.various Ic’s are available which
1/7 will work as driver circuit between two depending upon
1001 0010 1000
1/1
specification of motor & designing we can select any one
0110
by connecting some buffers and latches to driver
0/5
0/1 IC’s.The clock generator is also connected so that
1/6
1/2 continous 5v for CPLD is generated.The ULN2801A-
0110 1001
ULN2805A can be better choice for small voltage motor.
0001
0100
0/2

0/4 1/5
0100
1/3
0101 0001
0/3

1/4 0101

Figure 6. State diagram

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Z. Ali , R. V. Kshirsagar • Development of a CPLD-based Novel Open Loop Stepper Motor Controller for High Performance Using VHDL

when coding is done in VHDL and xylinx its shcematic

and RTL(Resistor transfer logic) is generated.The RTL
view is shown below in fig 10.

Figure 8. PIN CONNECTION of 2803

The ULN2801A-ULN2805A each contain eight

darlington transistors with common emitters and integral
suppression diodes for inductive loads. Each darlington
features a peak load current rating of 600mA (500mA
continuous) and can withstand at least50V in the off Figure 10. RTL View
state. Outputsmaybe paralleled for higher current
capability. Five versions are available to simplify • This is a schematic representation of the pre-
interfacing to standard logic families : the ULN2801Ais optimized design shown at the Register Transfer
designed for generalpurpose applicationswith a current Level (RTL).
limit resistor ; the ULN2802A has a 10.5kW
inputresistor and zener for 14-25VPMOS; the • This representation is in terms of generic symbols,
ULN2803A has a 2.7kW input resistor for 5V TTL and such as adders, multipliers, counters, AND gates,
CMOS , theULN2804A has a 10.5kW input resistor for - and OR gates.
15V CMOS and the ULN2805A is designed to sink a
minimum of 350mA for standard and Schottky TTL • It is generated after the HDL synthesis phase of the
synthesis process.
where higher output current is required.In our work we
are using ULN2803A.The setup for which is shown The result for rotating stepper motor in clockwise,
below in fig. 9 counter clock wise for full step & for half step is as
5v 12v
follows:
Clock
Generator
1 10 output simulation is shown below:
+5v Reset=0, CW_CCW=1 Full_Half_step=1
C ULN
33 1 2
Reset
10k
8
3 P
+5v 0
12v
35 2 3 A
18

Start B
10k L 17 Stepper
5 Motor
C
+5v 37 316
D
D 15
CW/CCWw

10k
39 4
7
+5

Full/Half
10k

9
9
Figure 11. Output Simulation Result

Figure 9. Functional Block Diagram of

Controller Using Driver

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 INES 2010 • 14th International Conference on Intelligent Engineering Systems • May 5–7, 2010 Las Palmas of Gran Canaria, Spain
Reset=0 ,CW_CCW=0 Full_Half_step=0
Figure 12. Output Simulation Result
Stepper motors are commonly found in consumer,
industrial, medical and scientific applications. The Xilinx
CoolRunner-II CPLD and alteras MAX II CPLD’s is the
perfect device with which to control stepper motors with
the added benefit that the CPLD can be reprogrammed to
accommodate a different motor if the system
specifications change.
IV. CONCLUSION
1. This paper presents an open loop stepper motor
driver using a CPLD. The basics of stepper motor
was described, the CPLD is used to build a high
performance open loop driver without using a
DSP or microcontroller. Furthermore it is
compatible with ASICs and mass production
methods for CPLD’s & FPGA [7]
2. Experimental verification of the proposed
controller is expected to justify the key theoretical
results which will be available in the final version
of paper.
V. REFERENCES
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Controller for Lift Drives”, IEEE Transactions on Applications,
Vol. 24, No. 3, pp. 487 - 498, 1988.
2. T. Kenjo and A. Sugawara, “Stepping Motors And Their
Microprocessor Controls Second Edition”, Oxford University
Press, 1994.
3. Bae and Krishnan (1996) H. K. Bae and R. Krishnan, “A Study
of Current Controllers and Development of a Novel Current
Controller for High Performance SRM Drivers,” IEEE Industry
Applications Conference, vol. 1, pp. 68-75, Oct.1996.
4. D. Kos, A. Kapun, M. Curkovic, and K. Jezernik, “Efficient
Stepper Motor Torque Ripple Minimization Based on FPGA
–7 –
Hardware Implementation”, IEEE Industrial Electronics,
IECON 2006-32nd Annual Conference, pp. 3916 –3921, in
Paris, France, Dec. 2006.
5. N. Q. Le, J. U. Cho, and J, W, Jeon, ”Application of Velocity
Profile Generation and Closed-Loop in Step Motor Control
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–3598, in Bexco, Busan, Korea, Oct. 2006,
6. D. O. Carrica, S. A. González, and M. Benedetti, “A high speed
velocity control algorithm of multiple stepper motors”,
Elsevier, Mechatronics, Vol. 14, Issue 6, pp. 675 – 684, 2004.
7. Xiaoyin Shao and Dong Sun, “Development of an FPGA-Based
Motion Control ASIC for Robotic Manipulators,” IEEE
Proceedings of The Sixth World Congress on Intelligent
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9. Brown and Rose, (1996) Architecture of FPGAs and CPLDs:
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(2003), Novel Stepper Motor Controller Based on FPGA
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Mechatronics, vol. 8, no. 1,pp 120-124.
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& VHDL, 2nd edition , Thomnson Delmar Learning, ISBN 1-
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15. IEEE standard VHDL Language reference manual, IEEE STD
1076-2002.