Electric Drives Technical Training for

Pneumatic Sales Engineers

Part 2

Abteilung/Name Projektname 30.03.23 1

 Low Cost Motion

STEPPER SYSTEMS

Abteilung/Name Projektname 30.03.23 2

 Components of a Stepper Motor
Windings Stator Motor Connection

Flange

Motor Axis

Housing

Bearing Rotor Bearing Cable outlet

Abteilung/Name Projektname 30.03.23 3
 The basic principle of stepper drives

Signals:
There are two different square-wave signals PULSE and DIR

• PULSE: Pulse signal

• DIR: Direction ( + or - , cw or ccw)

Abteilung/Name Projektname 30.03.23 4

 W1a
Start Condition
Full Step Mode

+
S N
S

N
-

N
S
W1b

S
N

N
S
S
N

W2a
+
Start FS
-

W2b

Abteilung/Name Projektname 30.03.23 5

 W1a
FS 0

+
N S N
-

S
S
W1b

N
N

S
S
N
N S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 6

 W1a
FS 1

+
N S
N
-

S
N
W1b

N
S
N

S
S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 7

 W1a
FS 2

+
N
S S
-

N
W1b

S
N
N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 8

 W1a
FS 3

+
S
N
N S
-

N
S
W1b

S
N
N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 9

 W1a
FS 4

+
N S N
-

S
W1b

N
S

S
N N
S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 10

 W1a
FS 5

+
N S
N

S
-

S
N
W1b

N
S

S
N N
S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 11

 W1a
FS 6

+
N
S S
-

N
N
W1b

S
S

N
N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 12

 W1a
FS 7

+
N
S
S

N
-

N
S
W1b

S
N

N
S
N S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 13

 W1a
FS 8

+
N S N
-

S
S

N
W1b

S
S
N
N S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 14

 W1a
FS 9

+
N
S

N
-

S
N
W1b

N
S

S
N
S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 15

 W1a
FS 10

+
N
S S
-

N
N
W1b

S
N

N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 16

 W1a
FS 11

+
N
S
S
-

N
S
W1b

S
N

N
S
N S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 17

 W1a
FS 12

+
S N
N
-

S
S

N
W1b

S
S
N S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 18

 W1a
FS 13

+
N S
N
-

S
N
W1b

N
S

S
N
S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 19

 W1a
FS 14

+
N S
S
-

N
N
W1b

S
S
N

N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 20

 W1a
FS 15

+
S N
N

S
-

N
W1b

S
S
N
N S

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 21

 W1a
FS 16

+
S N
N
-

S
W1b

N
S

S
N S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 22

 W1a
FS 17

+
N S
N

S
-

S
N
W1b

N
N

S
S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 23

 W1a
FS 18

+
N S
S
-

N
N
W1b

S
S

N
N
S
S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 24

 W1a
FS 19

+
S N
N

S
-

N
S
W1b

S
N
N

S
S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 25

 W1a
FS 20

+
S N
N
-

S
S

N
W1b

S
S
N S N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 26

 W1a
FS 21

+
N S

N
-

S
W1b

N
S
N
S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 27

 W1a
FS 22

+
N S
S
-

N
W1b

S
S

N
N
S S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 28

 W1a
FS 23

+
S N
S

N
-

N
S
W1b

S
N

N
S
S
N

W2a
+

W2b

Abteilung/Name Projektname 30.03.23 29

 W1a
FS 24=FS 0

+
N S N
-

S
S
W1b

N
N

S
S
N
N S

W2a
+
HS
-

W2b

Abteilung/Name Projektname 30.03.23 30

 Electronic Motor Controllers (Digital Drives)
• The most fundamental way to control a M
motor is through a switch (think of an
electric screwdriver)
Control
• However, to control a motor with Signal(s) Control Firing
Section Pulses Power Stage
precision, an electronic controller (Drive,
Amplifier) must be used.
• Any Digital Drive has three main sections:
• A Power Supply (Rectifier) that Control DC - Bus
Power Power
converts the incoming AC line + Battery
voltage to a DC – Bus Voltage -
Power Supply Module
• A Control Section,
Section that takes input
from the motion controller and
converts it into Firing Pulses
AC
• A Power Stage,
Stage that uses the Firing Power
Pulses to switch the DC - Bus to Line
control the motor rotation precisely

Abteilung/Name Projektname 30.03.23 31

 Controlling High Power
• For a Drive to be reliable over the life cycle of a typical machine (at least 10 years), the devices that
switch the high power cannot be prone to failure
• Early Drive designs used SCRs, but these did not have the ability to switch fast enough
• Modern designs use FET (Field Effect Transistor) modules, which have the performance and
reliability necessary.
• These devices are arranged in what is known as an “H-Bridge”
• Here is an H-Bridge
for a stepper drive:
• When the firing pulses for DC - BUS
T1 and T2 are on, Winding 1 T1 T5 T7 T4
(W1) is excited in the direction
W1 W2
“a→b” a b a b
• The control section is responsible
for sequencing the firing pulses, T6 T2 T3 T8
controlling the speed and direction
of the motor _

Abteilung/Name Projektname 30.03.23 32

 The basic principle of modern stepping motor controllers

W1a could be also A1 or A Drive mode bipolar

W1b could be also A2 or A/
W2a could be also B1 or B
W2b could be also B2 or B/
Step
+
W1a
DC - BUS
0

T1 T5 T7 T4
+
W2
0

W1
- W1b a b a b

W2a
T6 T2 T3 T8
+
- _
W2b

Abteilung/Name Projektname 30.03.23 33

 The advanced principle of stepper drives

Full-Step Mode Half-Step Mode

Abteilung/Name Projektname 30.03.23 34
 The advanced principle of stepper drives
Advance of two shifted rectangle to
SIN / COS current / power curve

CMMS-ST
Benefit:
even rotation
on low speeds
up to 10 rpm!

1/16 – Step Mode

Variable Step Mode up to 1/1500!
Abteilung/Name Projektname 30.03.23 35
 PWM – Converting DC to AC Power
• Here’s a problem: DC Bus

• We just got done talking about how motors

need an AC rotating field to operate. Switching

• How do we take a DC voltage and make it

Frequency

seem (to the motor) like it’s getting AC?

DC Bus
• The answer is Pulse Width Modulation (PWM)
• This method of “chopping” the DC Bus
allows the coils in the wire in the motor to
be fooled into thinking it is receiving an DC Bus
AC signal
• An equal pulse width (see top drawing)
looks like a 0 volt signal to the coil
• A narrow pulse looks like a negative signal, DC Bus
and a wide pulse looks like a positive
signal
Resultant Motor Current/Power Curve

Abteilung/Name Projektname 30.03.23 36

 Comparison between micro step and sinusoidal motor control

CMMS-ST

Smooth step resolution

to due constant clock rate !
Abteilung/Name Projektname 30.03.23 37
 Micro Step common method for stepper motor control

Selectable step resolution

• Full step 200 step/rev.
• Half step 400 step/rev.
• ¼ step 800 step/rev
• 1/8 step 1600 step/rev
Full-Step
•…
•1/64 step 12.800 step/rev

Typical pulse train frequency of 200 khz

limits max. velocity to 900 rpm (1/64).

Motor control frequency depends on

motor speed. !!

Micro step 1/16

Abteilung/Name Projektname 30.03.23 38
 CMMS-ST supports sinusoidal motor control

50 khz are far away from any CMMS-ST has a constant

resonance frequency control frequency of 50 kHz - PWM
(sample rate 20 µs)

Very high “step” resolution

at low speed

control frequency 50 kHz/ 20µs (PWM)

Switching
Frequency
Reduced “step” resolution
at higher speed. DC Bus

DC Bus
Smooth motor control
because of sinusoidal
signals.
Resultant Motor Current/Power Curve

Abteilung/Name Projektname 30.03.23 39

 Auto smoothing of CMMS-ST

Sinusoid
Speed Half step 1/8 step 1/64 step CMMS-ST
Step Clock Step Clock Step Clock Step Clock
res. rate res. rate res. rate res. rate,
PWM
10 rpm 2 66 Hz 8 266 Hz 64 2,1 kHz 1500 50 kHz

60 rpm 2 660 Hz 8 1,6 kHz 64 12,8 kHz 250 50 kHz

600 rpm 2 6,6 kHz 8 16 kHz 64 128 kHz 25 50 kHz

1200 rpm 2 12 kHz 8 32 kHz 64 256 kHz 12,5 50 kHz

Auto smoothing: Risk of resonance
Clock rate safely above resonance problems ! problems
Dynamic step resolution  high resolution at low speed
 low resolution at high speed

Abteilung/Name Projektname 30.03.23 40

 Applications Stepper Motor/Drive

• Example: Handling units • Example: belt driven linear axis

• Low to medium speeds • Low to medium speeds

• Low to medium payload • Low to medium payload
• Low accuracy or accuracy is defined by • No measuring system necessary
mechanics

Abteilung/Name Projektname 30.03.23 41

 Festo Stepper Motors EMMS-ST

EMMS-ST

0.5 Nm 0.8 Nm 1.4 Nm 2.5 Nm 5.9 Nm 8.6 Nm

EMMS-ST-42-S EMMS-ST-57-S EMMS-ST-57-M EMMS-ST-87-S EMMS-ST-87-M EMMS-ST-87-L

Abteilung/Name Projektname 30.03.23 42

 Operation mode “open loop” CMMS-ST

Motor current

Current control

Abteilung/Name Projektname 30.03.23 43

 Operation mode “open loop” CMMS-ST

1. Sinusoidal motor control  Reduction of resonances

2. Reduction of motor current at standstill  reduced heading
3. Manual adjustable resonance filters  Workaround at resonance problems
4. Integrated trace function and oscilloscope  Diagnostic help at movement problems

Abteilung/Name Projektname 30.03.23 44

 Operation mode “servo light” CMMS-ST

Motor current

Current control Step angle

Velocity control

Position control

Encoder Feedback
Abteilung/Name Projektname 30.03.23 45
 Servo Control for Stepper Motors

Current control: Only required current will forced to motor.

 Delta of rotation angle increases motor current

Velocity control: The nominal velocity will be adjusted

by setting the motor current value.
If the motor can’t follow, the frequency of
the magnetic field will be reduced
Result: Following error will be increased.

Position control: The pre calculated trajectory, V f(s),

will be cyclically compared with actual position.
An existing following error will be compensated by
increased speed rotation.
As result the position delta will be reduced.

Abteilung/Name Projektname 30.03.23 46

 Product Information CMMS-ST
Stepper Motor Controller
Systematically faster
Electrical drives Motion
at the highest level

CMMS-ST-C8-7

Abteilung/Name Projektname 30.03.23 47

 Properties of CMMS-ST and CMMS-AS
External synchronization
FCT Configuration Software in-/output, encoder signals
I/O Interface
analog control +/-10V

Field bus settings

CANopen integrated
FHPP
Handling and Positioning Profile
Profibus or DeviceNet as
optional slide in card
Field Bus
Position Set Direct Parameter SD-Memory Card
1
2
3
4
n

Abteilung/Name Projektname 30.03.23 48

 Coding of Type Code

CMMS- ST- C8- 7

Motor supply voltage 48 VDC

Motor current 8 A

Motor technology stepper

Motor controller standard

Abteilung/Name Projektname 30.03.23 49

 SD- Memory Card

Optional use for storing of all parameter settings

• Storing device parameters after successful commissioning
• Saving firmware of CMMS-ST

Service friendly:
• No need of second commissioning after replacing defective device
 Transfer of original parameter set to SD-Card.

OEM friendly:
•No compatibility problems when replicating machines.
•Firmware could be unchanged during whole machine lifecycle.

Abteilung/Name Projektname 30.03.23 50

 Features and Benefits
1. Pulse generation included  no external position controller required,
no extra costs, fully functional without
PLC connection.

2. Closed loop Stepper  Safe operation, positioning

faster movements, shorter cycle times
Smooth movements, low noise.

3. Advanced I/O Interface  Easy to use, at many cases no field bus required
flexible functions, new application possible

4. SD-Memory card  service friendly, third party service possible.

5. Sequenced position sets  flexible movements easy to use, without

complex adapted PLC programming.

6. High torque, small sizes

compared to standard Servo  reduction of required space
Abteilung/Name Projektname 30.03.23 51
 Application CMMS-ST – Assembly of axes

Bremen
H.Hamann
(Alrich Siemens)

Automobile industry
Assembly line for
LKW axes

25 Servo Lite axes CMMS-ST

1 Servo Premium CMMP-AS

Abteilung/Name Projektname 30.03.23 52

 Application CMMS-ST – Piston marking system / Automobile
Handling for
•Piston engraving
•Quality check with camera
•Palletising

Abteilung/Name Projektname 30.03.23 53

 Application CMMS-ST – Rotative alignment of cans on a conveyor belt

Function :
Rotate the can until an optical sensor detects the handle.
Then move a defined number of degrees to align the handle.

Abteilung/Name Projektname 30.03.23 54

 Application CMMS-ST – Cash dispensing ATM cash handling

Abteilung/Name Projektname 30.03.23 55

 Electric Drives Technical Training for
Pneumatic Sales Engineers

End of Part 2

Abteilung/Name Projektname 30.03.23 57