Stepper motors typically feature a permanent magnet as their rotor, while the stator winding generates a vector magnetic field when current flows through it. This magnetic field prompts the rotor to rotate, aligning its magnetic field with that of the stator. With each adjustment of the stator's magnetic field, the rotor follows suit, rotating along with it. Every time an electrical pulse is received, the Motor progresses further, with the angular displacement being directly proportional to the number of pulses and the rotational speed corresponding to the pulse frequency. By altering the energization sequence of the windings, the motor can change direction. Thus, controlling the number of pulses, their frequency, and the energization sequence allows precise management of the stepper motor's rotation.
Most common motors contain iron cores and winding coils. These windings possess resistance, leading to energy loss during operation. This loss increases with the square of the resistance and current, known as copper loss. If the current isn't a standard DC or sine wave, harmonic losses may occur. Additionally, the core experiences hysteresis, and eddy currents generate losses in alternating magnetic fields, influenced by material, current, frequency, and voltage—this is termed iron loss. Both copper and iron losses manifest as heat, impacting motor efficiency. Stepper motors usually prioritize positioning accuracy and torque output, often operating with high currents and significant harmonic content. As a result, they tend to overheat, especially under varying rotational speeds, making them less efficient compared to AC motors.
1. Stepper motors are best suited for low-speed applications—below 1000 rpm, such as 6666 PPS at 0.9 degrees, ideally between 1000-3000 PPS (0.9 degrees), which can be enhanced with a gearbox for optimal performance. This setup ensures high efficiency and minimal noise.
2. When running at high speeds or handling large inertial loads, avoid starting at full operational speed. Instead, gradually increase the frequency to prevent losing steps, reducing noise, and improving positioning accuracy upon stopping.
3. For high precision requirements, consider mechanical deceleration, increasing motor speed, or using a driver with a high subdivision count. Alternatively, opt for a 5-phase motor, though these systems are pricier, with fewer manufacturers, and often deemed outdated by experts.
4. Avoid operating the motor in its vibration-prone zones; resolve this by adjusting voltage, current, or incorporating damping mechanisms.
5. Motors functioning below 600 PPS (0.9 degrees) should use small current, high inductance, and low voltage drivers.
6. Whole-step mode should be avoided due to excessive vibration.
7. Historically, motors with a nominal 12V voltage require 12V; other motors' voltages aren’t necessarily driving voltages. Drivers dictate the driving voltage; for example, 57BYG motors use DC 24V-36V, 86BYG use DC 50V, and 110BYG use higher than DC 80V. Although 12V can be used, other power sources are possible but consider temperature rise.
8. Motors handling large moments of inertia should use larger frame sizes.
9. Always follow the motor selection principle post-motor choice.
By understanding these nuances, users can maximize the potential of stepper motors, optimizing performance across various applications while addressing common challenges like overheating and vibration.
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