Stepper motors typically feature a permanent magnet as their rotor, and when current passes through the stator windings, they generate a vector magnetic field. This magnetic field prompts the rotor to rotate, aligning the rotor’s magnetic field pairs with that of the stator. As the stator's magnetic field rotates, the rotor follows suit, turning in synchronization. With each electrical pulse input, the Motor advances further, with angular displacement being directly proportional to the number of pulses received, while rotational speed corresponds to the frequency of these pulses. By altering the energization sequence of the stator windings, the motor can reverse direction. Thus, controlling the number of pulses, their frequency, and the energization sequence allows for precise control over the stepper motor's rotation.
Motors commonly include iron cores and winding coils internally. These windings possess resistance, leading to energy loss during operation. This loss is proportional to the square of both the resistance and the current, referred to as copper loss. If the current isn't a standard DC or sinusoidal waveform, harmonic losses occur. The core exhibits hysteresis, and eddy currents within an alternating magnetic field cause additional losses, influenced by material, current, frequency, and voltage. Known as iron loss, this too results in heat generation, affecting motor efficiency. Stepper motors usually prioritize positioning accuracy and torque output, which often leads to lower efficiency, higher currents, and elevated harmonic content. Since the frequency of alternating current varies with rotational speed, stepper motors tend to overheat, a condition that is even more pronounced in AC motors.
Stepper motors are best suited for low-speed applications—up to 1000 revolutions per minute (equivalent to 6666 pulses per second at a 0.9-degree step angle). Ideally, operating speeds range from 1000 to 3000 pulses per second (at 0.9 degrees), which can be achieved with the help of a gearbox to enhance performance, efficiency, and minimize noise.
When operating at high speeds or under heavy inertial loads, stepper motors should avoid starting at full operational speed. Instead, gradually increasing the frequency helps prevent losing steps, reduces noise, and improves positional accuracy upon stopping. For high precision tasks, consider mechanical deceleration, increasing motor speed, or using a driver with a high subdivision count. Alternatively, a five-phase motor could be employed, though this option is costlier, less common, and somewhat outdated.
Avoid operating the motor in its vibration-prone zones. If unavoidable, address this by adjusting voltage, current, or incorporating dampening mechanisms. Motors operating below 600 pulses per second (0.9-degree step) should utilize low current, high inductance, and low voltage settings.
It's advisable to avoid running stepper motors in full-step mode due to increased vibration risks. Historically, motors with a nominal voltage of 12V often operate on 12V, but this doesn’t apply universally. Drivers determine optimal driving voltages; for instance, 57BYG motors work well with 24V-36V DC, 86BYG with 50V DC, and 110BYG with 80V DC. While 12V can still be used, other drivers may require different voltages, so consider thermal considerations.
For loads with significant inertia, select larger motor frames to accommodate the required torque. After choosing a motor, ensure proper selection principles are followed.
The motor’s load capacity should match its design, especially when dealing with large moments of inertia. Selecting the correct motor involves considering these factors comprehensively to ensure optimal performance and longevity.
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