Example: If the resolution being used is 10, steps per revolution with ounce inch motor, then each microstep will generate a torque change of 3. Increasing the resolution to 50, steps per revolution will cause each microstep to produce a torque change of 0. If the resolution is 10, steps per revolution, with the friction of the load as 3 oz-in, it is expected to get an immediate response to your command to move. Increasing the resolution to 50, steps per revolution would take 5 microsteps to be commanded before the torque can build to a level in which it can move the load.
This is often called "Empty Stepping," and can be overcome if step resolutions and stepper motor sizes are selected properly. A stepper driver and controller is controlled by a DC power supply with associated circuits and software architecture for controlling the switching sequence sent to the stepper motor which causes the shaft to rotate. The circuitry involved not only sends the proper pulse sequence to the motor but also controls speed, direction and the resolution steps per revolution of the stepper motor.
The speed and direction of rotation of a stepper motor is determined by the appropriate configurations of digital control devices. Selecting the most compatible stepper driver and controller and stepper motor can save the user money and be a less cumbersome motion control solution. Anaheim Automation categorizes the major types of digital control devices as follows:. With each pulse converted into digital information, the motor is able to undergo an exact incremental rotation without the need for feedback mechanisms i.
With an open-loop system, the problems of feedback loop phase shift and resultant instability, common with servo drives, are eliminated. Before a designer selects a suitable stepper motor and driver and controller combination for an application, there are certain variables which need to be considered.
A machine or process designer must examine several parameters such as load characteristics, performance requirements and mechanical design including coupling techniques for an optimal solution. Failure to do so may result in poor system performance or be more costly than necessary.
For optimum stepper driver and controller motion control, the following factors should be taken into consideration:. Distance to be traversed b. Maximum time allowed for a traverse c. Desired detent static accuracy d. Desired dynamic accuracy overshoot e. Time allowed for dynamic accuracy to return to static accuracy specification settling time f.
Required step resolution combination of step size, gearing, and mechanical design g. System friction: All mechanical systems exhibit some type of frictional force. When sizing the motor, remember the motor must provide enough torque to overcome any system friction. A small amount of friction is desired since it can reduce settling time and improve performance h.
System inertia: An object's inertia is a measure of its resistance to changes in velocity. The larger the inertial load, the longer it takes a stepper motor to accelerate or decelerate the load. The speed at which the motor rotates is independent of inertia.
For rotary motion, inertia is proportional to the mass of the object being moved times the square of its distance from the axis of rotation i. When selecting a stepper driver and motor, the capacity of the motor must exceed the overall requirements of the load. The torque any motor can provide varies with its speed.
Torque-to-Inertia Ratio: This value is defined as a motor's rated torque divided by the rotor's inertia. This ration measurement determines how quickly a motor can accelerate and decelerate its own mass.
Motors with similar torque ratings can have different torque-to-inertia ratios as a result of varying construction k. Torque margin: Whenever possible, a stepper driver and controller which can provide more torque than is necessary should be specified.
This torque margin allows for mechanical wear, lubricant hardening, and other unexpected friction. Resonance effects can cause the motor's torque to be slightly lower at some speeds. Calculation: Measurement of inertia, friction and workloads reflected to motor. In an open-loop stepper motor drive system, the motor does not "know" if excessive inertia or friction has made the motor lose or gain one or more steps, thus affecting the position accuracy.
Load inertia should be restricted to no more than four times motor rotor inertia for high performance relatively fast systems.
A low performance system can deliver step accuracy with very high inertia loads, sometimes up to ten times rotor inertia. System friction may enhance performance with high inertia loads Experimentation: Tailoring Experimentation for motor sizing is critical due to dynamic changes in system friction and inertia, load anomalies which are difficult to calculate.
Stepper motor resonance effects can also change when the motor is couple to its load. Some criteria include options of 0. With our friendly customer service and professional application assistance, Anaheim Automation often surpasses customer expectations for fulfilling specific stepper driver and motor requirements, as well as other motion control needs. Anaheim Automation's cost-effective stepper motor, driver and controller product lines are a wise choice for both OEM and user accounts.
Anaheim Automation's customers for the stepper motor, driver and controller product lines are diverse: industrial companies operating or designing automated machinery or processes that involve food, cosmetics or medical packaging, labeling or tamper-evident requirements, cut-to-length applications, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, inspection and security devices, pump flow control, metal fabrication CNC machinery , and equipment upgrades.
A stepper motor, driver and controller are most often found in motion systems requiring position control. Anaheim Automation also offers a stepper driver and controller product line that integrates a matched stepper motor into one simple unit. This design concept makes selection easy, thus reducing errors and wiring time. With friendly customer service and professional application assistance, Anaheim Automation often surpasses the customer's expectations for fulfilling specific stepper motor, driver and controller requirements, as well as other motion control needs.
NOTE: Technical assistance regarding the stepper driver and controller product line is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for a stepper driver and controller, or any other product, offered from Anaheim Automation's staff, its' representatives or distributors, are only to assist the customer.
In all cases, determination of fitness of the stepper driver and controller in a specific system application is solely the customers' responsibility. While every effort is made to offer solid advice regarding the stepper driver and controller in a specific application, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice. Anaheim Automation is in no event responsible or liable for indirect or consequential damages resulting from the use or application of the stepper driver and controller.
Stepper drivers and controllers have become an essential component to applications in many different industries. The following is a list of industries making use of stepper drivers and controllers:. The following environmental and safety considerations must be observed during all phases of operation, service and repair of a stepper driver and controller system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the stepper motor, driver and controller.
Please note that even a well-built stepper driver and controller products operated and installed improperly, can be hazardous. Precaution must be observed by the user with respect to the load and operating environment.
The customer is ultimately responsible for the proper selection, installation, and operation of the stepper motor, driver and controller system. Do not operate the stepper driver and controller in the presence of flammable gases, dust, oil, vapor or moisture.
For outdoor use, the stepper motor, driver and controller must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Due consideration should be given to the avoidance of liquids and vapors of any kind.
Contact the factory should your application require specific IP ratings. It is wise to install the stepper motor, driver and controller in an environment which is free from condensation, electrical noise, vibration and shock.
No work should be performed while power is applied to the stepper driver. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the stepper motor, driver and controller after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the stepper driver.
Plan the installation of the stepper motor, driver and controller in a system design that is free from debris, such as metal debris from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry.
Introduction Proper installation will achieve the best results from the production capability of the stepper driver and controller system. This can only be accomplished if several important steps are implemented and some precautions are taken. Note: Local codes may suggest different requirements, but those given in this section must be satisfied as much as possible. Safety First! Human safety and equipment safety must be the first considerations when performing the installation procedures for the stepper driver and controller system.
CAUTION - Only qualified personnel should be allowed to open and work on the stepper driver and controller, motor, and other components inside electrical enclosures. Equipment and machinery should never be run unless the electrical enclosure door is closed and locked. The electronics inside the main electrical enclosure are sensitive to metal chips and filings. During the installation and use of the stepper driver and controller system, great care must be given to make sure metal chips or filings cannot fall onto or into any of the electrical devices.
Electrical Installation Safety is the number one concern when performing the electrical connection of the stepper driver and controller system, as well as all motion control products and electrical equipment. Therefore, check every step at least once after it has been taken. During the installation of the stepper driver and controller system, it is important to minimize the possibility of electrical noise entering critical sensitive circuits.
This is best accomplished by following the electrical installation procedures precisely. Considerable attention has been given to noise immunity in the basic design and manufacture of the stepper motor and stepper driver and controller.
However, it is essential that great care and attention be given during the installation of the stepper driver and controller in your machine or in your facility. Plan Ahead Before attempting any electrical installations, gather any drawings, instructions or procedural documents you have on the stepper motor, stepper driver and controller, as well as other components in your system.
Reading and studying product the stepper motor and the stepper driver and controller documentation before starting the project, will alert you to any special situations, such as the need for specific tools. Also, you will know where to begin and where to go from there. Always keep the specific stepper motor, stepper driver and controller documentation with you while completing the installation, as you should regularly refer to them. Documentation among motor and stepper motor driver and controller manufacturers will vary greatly, as their designs, layouts and connections will not be the same.
Carefully match the part numbers of the stepper motor, and stepper driver and controller to the documentation before attempting the installation. Make certain that the stepper motor and the stepper driver and controller are compatible.
Even seasoned professionals need guidance and advice while performing complicated electrical installations. This ensures the safest results for everyone. General Electrical Safety Checklist When it comes to electronics in the factory or workplace, make sure both the facility and the employees in it are safe at all times.
Here is an electrical safety checklist, courtesy of the National Electric Safety Foundation: Cords and Cables: Make sure cords and cables are in good conditions. Check cords, cables and other wiring for frays and cracks. Make sure that all wiring and cabling is placed out of reach and out of traffic areas. Cords and cables should never be nailed or stapled to the wall, baseboard or to another object.
Do not place cords under carpets or rugs. Extreme care should be taken if the installer decides to use their own cabling system. Electrical Plugs and Terminals: Make sure that all plugs fit the outlets. Make certain that the terminals of the stepper motor driver and controller are correctly matched and fit snug. Never remove the ground pin the third prong to make a three-prong fit a two-conductor outlet, because it could lead to an electrical shock.
Avoid overloading outlets with too many electronic components. Never force a plug into an outlet if it doesn't fit, nor should you ever modify terminal blocks or cables for the stepper driver and controller.
Look for cracks or damage in wiring, terminals, plugs and connectors. Use a surge protector bearing the seal of a nationally recognized certification agency. Lightning: During an electrical storm, make sure you use surge protectors on electronic devices. The following information is intended as a general guideline for the installation and mounting of the stepper motor, driver and controller system.
Use extreme caution when handling, testing, and adjusting during installation, set-up, and operation. It is very important that the wiring of the stepper motor, driver and controller be taken into consideration upon installation and mounting. Subpanels installed inside the enclosure for mounting stepper motor, driver and controller system components, must be a flat, rigid surface that will be free from shock, vibration, moisture, oil, vapors, or dust.
Remember that the stepper motor, driver and controller will produce heat during operation; therefore, heat dissipation should be considered in designing the system layout. Size the enclosure so as not to exceed the maximum ambient temperature rating.
It is recommended that the stepper driver and controller be mounted in position as to provide adequate airflow. The stepper motor, driver and controller should be mounted in a stable fashion, secured tightly. NOTE: In order to comply with UL and CE requirements, the stepper motor, driver and controller system must be grounded in a grounded conducive enclosure offering protection as defined in standard EN IEC to IP55 such that they are not accessible to the operator or unskilled person. As with any moving part in a system, the stepper motor should be kept out of the reach of the operator.
To improve the bond between the power rail and the subpanel, construct your subpanel out of zinc-plated paint-free steel. Additionally, it is strongly recommended that the stepper driver and controller be protected against electrical noise interferences. Noise from signal wires can cause mechanical vibration and malfunctions.
Anaheim Automation's stepper driver and controller product line is offered in a range of voltages, current and steps per revolution. Customers are impressed with Anaheim Automation's designs, in that they provide outstanding motor performance.
Offered in High-Performance Bilevel Half-Step , Microstep and Line-Powered designs, Anaheim Automation has the most fitting stepper driver and controller for your automation requirements. Taking a system design budget into consideration, Anaheim Automation manufactures its stepper driver and controller products in several packaging styles, making them the most cost-effective choice in the industry! These units contain a stepper driver or multiple stepper drivers, with a matched power supply, and are packaged on an open-frame chassis or in an enclosure.
Available in one, two, three or four-axis configurations, with bilevel or micro-stepper driver s in current ranges of 0. Also included in this product offering is a 10Amp Line-Powered stepper driver. This unit contains a stepper driver with a matched power supply, and is packaged in an enclosure. Available in one, two, three or four-axis configurations, with a bilevel or microstep stepper driver in current ranges of 0.
Also including in this product offering is a 10Amp Line-Powered stepper driver. A stepper driver can be manufactured by Anaheim Automation for a variety of applications requiring a DC input. This stepper driver product line is offered as single-axis units in open-frame and enclosed modular sheet metal packaging styles. If the application requires a compact stepper driver for a small stepper motor in the This series of stepper driver use microstep drive technology.
All but the MBC stepper driver is assembled in a small sheet metal package. The low-cost MBC stepper driver model is a printed circuit board style. If an application requires a stepper driver in the 2. A stepper driver in this series is modular, meaning they are assembled in small sheet metal enclosures.
Featured in this series is the popular divide-by microstep, Amp stepper driver model MBC Anaheim Automation offers a stepper driver that is economical and is designed to cover a wide range of stepper motors. When an application requires a stepper driver in the 7. The MBC stepper driver is a fixed divide-by micro-stepper driver with an output capacity of 1. The MBC stepper driver uses selectable divisors of up to which allows for a very wide range of microstepping options.
The older "legacy" high-performance bilevel stepper driver, model BLHP, is a board-level product more commonly used in electrical panels or other similar enclosures. A stepper driver manufactured by Anaheim Automation is also available for applications requiring an AC input.
These stepper driver models require a transformer purchased separately , and are available in printed circuit board and modular stepper driver styles.
To summarize, stepper motors are good when you need an inexpensive, easy-to-control solution and when efficiency and high torque at high speeds are not necessary. To learn more about how to pick the right type of motor for your project, and the differences between stepper, brushed, and brushless motors click here. Due to their properties, stepper motors are used in many applications where a simple position control and the ability to hold a position are needed, including:.
Did you find this interesting? Get valuable resources straight to your inbox - sent out once per month! Some example topi When the solenoid is not activated, the hinge locks Home Stepper Motor Basics. Session popupval Session textval Session Titefor popup. Remember me. Forgot password? Log in. Don't have an account? Sign up. Password Strength: No Password.
Create Basic Account. Already have an account? Forgot Password. Please enter your email address below to receive a password reset link. Go back Go back. Log in to continue. Get early access to new products, datasheets, and free samples. Share this article. Get valuable resources straight to your inbox - sent out once per month Subscribe. Stepper Motor Basics A stepper motor is an electric motor whose main feature is that its shaft rotates by performing steps, that is, by moving by a fixed amount of degrees.
Stepper Motor Working Principles As all with electric motors, stepper motors have a stationary part the stator and a moving part the rotor.
For the stepper motor, this microcontroller should have a minimum of four output pins. In addition, it includes ADC , timers, serial port based on the application of the driver. The selection of the drivers can be done based on the motor ratings like voltages and current. It is suitable for driving the stepper motor. This driver includes a Darlington pair that can handle the max current up to mA and the max voltage up to 50VDC. The stepper motor driver circuit is shown below. The operating voltage range of the stepper motor ranges from 5volts to 12volts.
The current supply drawn from this will be in the range of mA to mA. The design of the power supply can be done based on the motor specifications. The power supply should be regulated to avoid the fluctuations within torque and speed. Drivers are mainly working in two modes like the pulse input mode as well as integrated controller mode. Based on the required operating system, one can select the desired combination.
The control of a stepper motor can be done with the help of a pulse generator offered through the consumer.
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