REFERENCE MANUAL

STEPPER MOTOR A stepper motor is a low speeed ,

high torque motor which characterises itself with a number of unusual features such
as mentioned below:

1) It moves in 200 discret steps in one revolution.

2) It is a bi-directional motor, can rotate in either direction.
3) It is a self-starting motor, no external means are required for starting it.
4)

Its affective inertia is very low. It starts, stops and reverses practically instantaneously.

5) Its starting, running and stalling currents are of the same order. There is no heavy
inrush current at start. Its motor can be stalled forcibly without any fear of damage
to windings.

6)

Its low basic shaft speed eliminate the complex gear trains in many applications
When driven through a translator a stepper motor acts as a Transducer having a
high gain. It generate large torques with micro watts of input control power.
Its torque output is manyfold on comparison with the conventional motor of the
same size and weight.

A stepping motor can also be used in integrator by feeding a continuously variable

signal to an anlogue to digital convertor giving a pulse frequency proportional to
the amplitude of the input signal. A stepping motor when supplied with these pulses
will move the load attached to its shafts through a distance proportional to the time
integral of the signal.

-STATOR

WINDIN
GS .
p ARMAMENT
MAGNCT

/ / s

7ZZZZZZ
FIG. 21 PERMANENT MAGNET MOTOR

r
ROTOR DISC

Some of the common applications of stepper motor are 1)

Remote control of Dimmerstats, potentiometers, camera focusing process

timing etc,

2)

Numerically controlled machine tools and robots.

3)

Punched tape drives.

4)

As variable speed drives.

5)

Paper feed drive in recorder.

6)

Drives for electronic sweep generators.

7)

Curve tracers.
TYPES OF STEPPER MOTOR CONSTRUCTION
Three basic type of stepper motor are there in use . They are permanent magnet,
variable reluctance and hybrid .Each type may vary widely in constructional details
but all have a cylindrical stator with salient poles or teeth each of which carries a
coil to which the pulses are sucessively applied.
1) PERMANENT MAGNET MOTOR

As name suggests this type of motor has a permanent megnet rotor. Rotor has two
identical discs withs a permanent megnet between them. It has teeth, the number of
which decides the degree of angular movement of the shaft per switching pulse.
Stator has two phase winding ; the coils of which produce mmf fields displaced by 90
electrical in space from each other.
When supplied with two phase A.C. supply; a rotating magnetic field is produced
which make the permanent magnet rotor to rotate. In D.G. operation, pulses are
applied to each of stator winding, sucessively creating a series of magnetic fields.
The rotor with this magnetic field experiences torque. By changing the excitation
sequence, the motor can be made to rotate in the clockwise or anticlockwise
direction. Hence It Is a blrectional motor.

BEDARE ELECTRONICS

PLC APPLICATION TRAINER

Permanent magnet Stepper motor can have either single winding (coil) per phase

or two windings per phase (bifilar wound motor). Formar is a 3-lead motor requiring two power supplies, while the
later is a 5 lead motor requiring only single power supply . In bifilar wound motor , to reverse the magnetie polarity ,
instead of reversing current in winding , current of same polarity is switched to an indentical winding wound in
opposite direction.
Because of rotor reaction and relatively large step angles, there is little tendency to overshoot. So damping is rarely
used in this type of motors. These type of motors have therefore lower stepping rates.

2) VARIABLE RELUCTANCE MOTOR :

In this type of motors, It is made up of soft iron with negligible residual magnetism and has
number of poles teeth differing from that for the stator. When a pulse is . applied to coils on
stator, the rotor tries to seek a position of minimum reluctance and moves by a step of angle
which depends on stator and rotor pole numbers.
Torque is produced by electromagnetic flux as it establishes paths of least reluctance
through what amounts to a variable air gap between a multipole,multi phase stator and a
toothed, nonretentive rotor.
HYBRID MOTOR >
These combines the above two types of motors. It has a rotor comprising or axially
magnetized permanent magnet with two cup shape end pieces with axial teeth . The
number of rotor and stator teeth governs the stepping angle.

Depending on the characteristics, these motors can be compared as below. 4-LEAD

TYPE : The 4 Leads Stepper Motors are useful when the isolation between the two
windings is required .4 Leads Stepper Motor can be easily converted into 3 leads type
by shorting terminals 2 and 4 . These require single ended power supply and double
pole double through switchings.

BEDARE ELECTRONICS
TRAINER

PLC

APPLICATION

REFERENCE MANUAL

5-LEADS. (BIFILAR TYPE): This type of stepper Motor is useful where application of push-pull circuitory and centre tap power supply is not possible and also
more where more torque output is required at higher stepping rates. In bifilar
motor each stator coil is wound in opposite directions and these are stepped by
switching from one half of the winding to the other half.

Permanent
Magnet
1)Maximum pulse
rate per second
2)Stepping angle

400
40-120

3)Maximum torque N-m . 0.3 -20

4)lnertia Kg-m210

1-20

Hybrid

Variable
Reluctance

1000

20,000

1.8-30

0.9 -15

30 -40

0.15-8

2-200 -

3 -4000

TERMINOLOGY USED IN STEPPER MOTORS :1)

STEP ANGLE The motor shaft rotateis its specific angular increment each time the
winding polarity is changed . This specific degree of rotation on increment is called
the step angle . It is specified in degrees . Now a days motors with step angle as
small as 0.9 are available .

2)

STEPS PER REVOLUTION : This term describes the total number of steps required
for the output shaft to rotate through 360 or one complete revolution . Steps per
revolution are calculated by dividing 360 by step angle.

3)

STEPS PER SECOND :-The number of angular moments (steps) accomplished by

the motor in one second of time . It corresponds to pulse rate.

REFERENCE MANUAL

04)3TEP ACCURANCY : It is defined as a positionai accurancy tolerance . This

figure is generally expressed in percent and indicate the total error Introduced by
the stepping motor in a single step movement . The error is non cumulative l.e. , it
does not increase as additional steps are taken.

05)HOLDING TORQUE : With the motor shaft at standtUt or zero r.p.m.

condition , the amount of torque from an external source , required to break
away the shaft from its holding position . This is measured with rated voltage
and current applied to the motor and is the basic characteristic of stepping
motor.
Q6)RESIDUAL TORQUE: The torque present at standstill under power -off condition is a result of the
permanent magnetic flux acting on the stator poles. Residual torque is present under power off
condition only with a motor of permanent magnet rotor design.

7)

TORQUE TO INERTIA RATIO :Thts ratio is determined try dividing the rased holding torque of the
motor by its inertia. The better the torque to inertia ratio, the better the response. When dealing with
step response problems, it is important to know the torque to inertia ratio of the motor.

8)

STP RESPONSE >When given a command to move a step, the mater will respond within a specific
time period . This time for a single stepper step response is a fuction of the torque to inertia ratio of
the motor and the characteristics of electronics drive system. Ratings are given for ncload ccrrtitions with time generally expressed in miViseconds.

Q9)RESONANCE .-Stepper motors cart be simulated as a spring mass

system, and 33

3:UC

n have certain natural * frequency chractenstics

.When motor's natural frequency orresGoance* is reached, an

increase in toe audible \evei of toe
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PLC APPLICATION

motors operation can be detected . In case of severe resonant condition

ffi may loose steps and or oscillate about a point. The frequency at which
this resonance occurs varies, depending on the motor and the load.
10) DRIVES > This is a broad term used to describe the circuitary which controls
the stepping motors and usually consist of a power supply, sequencing logic
and power output switching components.
11) RAMPING The process of controlling pulse frequency to acceleate the rotor
from zero speed to maximum speed as well as to deaccelerate the rotor from
maximum speed to zero speed . Ramping increases the capability of driving
motor and load to higher speed levels, particularly with large intertial loads.
12) START / STOP ERROR :-An additional curve found on some speed torque
curves which indicates the maximum step rate to which the particular motor can
start and stop without loosing steps or falling out of synchronism. This condition
assumes no acceleration /deceleration time. These are usually the result of
actual testing with negligible external load inertia.
13) SLEW RATE An area of high speed operation where the motor can run
unidirectionaly in synchronism. However, it cannot instantaneously start, stop or
reverse. A stepper motor is brought up to slewing rate using acceleration and is
then decelerated to stop under conditions where no step loss can be tolerated .
Now a days motors with slewing speeds of from 10,000 steps/sec to 20,000
steps/sec are available . The secret lies in the electronics control.
14) DAMPING :-The reduction or elimination of step overshoot is defined as damping It
is used in applications where settling down time is important. Damping methods
used include mechanical, electronic and viscous (fluid).

TRANSLATOR.

'.-Stepper

Motor

translator

Is

versatile

electronic

control,capable of producing the proper pulse trains for driving the stepper
motor . It is designed for controlling 5-lead type i.e. bifilar motor only . The
complete circuit diagram Is shown in figure . It basically consists of a CMOS
dual D-type Flip-Flop CD 4013.
The Q and Q outputs of 1st D-flip-flop are directly connected to windings Aland A2
of stepper motor through power Amplifiers . Whereas other two inputs to B1 &
B2 are controlled by 2nd D-FLIP-FLOP and a CMOS DEMULT\RLEXER CD 4053 The
functionn of DEMULTIPLEXER is to change the direction of stepper motor .
This is done by either grounding pin 10 and 11 or connecting them to +Vcc .The truth table
for logic signals for forward and reverse direction is given along with timing diagram.

CLOCK GENERATOR Thie clock pulses are generated by using 555 Timer \C.
The clock frequency can be selected in two modes, High or Low . This is done by selecting
different values of capacitors . Fine adjustments of the ciock frequency can be done by
varying the potentiometer provided on the front pannei.
POWER AMPLIFIERS Since the output of the translator cannot drive the stepper Motors
windings directly hence the use of power Ampiifiers. \t consists of a driver stages SL100 and
power transistors 2N3055 . The Stepper Motor windings are connected in series with the power
transistor. Four such stages of power Amplifiers are used .

TRANSIENT VOLTAGE SUPPERESSION:- During D.C. stepping transient voltages are

generated as the voltage is swithced across the windings . if these voltages are not
removed or limited to a safe value, they can cause fauity operation or damage to Motor and
other circuit components. Hence Shunt diodes an
connected across each windings as shown in circuit digram.

BEDARE ELECTRONICS

PLC APPLICATION TRAIN

Stepper motor requires an electronic controller to energise its windings in the

proper sequence, there by causing It to step. Block diagram of stepper motor
controller Is as under

Stator windings of the PM stepper motor must be excited in a pedicular sequence to cause the motor to move from the exciting step to the next step.
Logic circuit is to be designed OR tn case of Microprocessor based
system , program is to be prepared to provide the proper sequential
output to power driver. Excitation sequence for bifilar wound PM

motor is shown in Table,.

The signal from the 8256 PR of Mtcroprcces&er kit provide proper sequential output.
To increase fie power level of these signal sufficiently, to energies the motor wmdfcig 'power drivers vsmgpomer transistor or
fiyrators are used

PROCEDURE :

Stepper motor with dial & pointerls provided on main unit.

Operating voltage : 12 volt DC
Torque
: 3.5 Kg-cm
Step Angle : 1.8
Motor driver and controller is provided in control unit. .
Variable Clock Generator is provided with potmeter (Speed Adjust) for applying
clock to the controller.
Mode Input sets the direction of motor.( Mode = 1 - FW & Mode = 0 - REV).

A) AUTO OPERATION
1)
2)
3)

Connect clock CLK from Clock Generator to the clock input (CLK) of synchronous up/down counter.
Connect MODE input to synchronous up/down counter.
Keep FW/REV switch for FW position.
Connect output from code converter and driver stage A11 to base of Q1,
B11 to base of Q2 , A21 to base of Q3 , and B21 to base of Q4.

4)

Make powe on to the unit.

5)

Keep Speed Adjust potmeter for minimum clock speed).

6)
7)

Note the output pulse pattern as observed on LED D1 D2 D3 D4.

Change the MODE switch to REV position.
Note the output pulse pattern as observed on LED D1 D2 D3 D4.

8)

Count total number of steps for one complete rotation.

No. of Steps for one rotation = ____________
360
Step Angle = -----------------------------------------No. of Steps for one rotation .

AUTO OPERATION:

Connect output from code converter and driver stage A11 to

base of Q1,
B11 to base of Q2 ,
A21 to base of Q3 ,
and B21 to base of
Q4.
Connect CLK and MODE input to synchronous up/down counter.

ftcmumcc mmm

Connect 8255 from Benlx 8085 Microprocessor kH to stepper mM$f unit

using fiat cable cord provided with system,
(28 pin FRC connector to 8255 port of Microproc**$6f tot and 9 pin Dconnector(male) to 9 pin Oconnector(fermie) on stopper ewtor control unit.)
Connect output from BUFFER At to base of Q1f
B1 to base of 02,
A2 to base of 03, and
B2 to base of 04.

1)

2)

Connect power supply to Microprocessor kit.

Make power ON to both Microprocessor kit and Stepper motor confrof unit
3)

Hard copy of the program is provided on EPROM at location 4300W

Execute the program stored at location 4300H.
GO 4 3 0 0 EXEC

4) Direction of motoris controlfed by FW/REV switch on Stepper motor control unit

*12 VOLT

RE
V

STEPPER MOTOR

asTORFA -OilTWJT ant FOPTH-.NFUT PLC

APPUCATICN TRACER.

82S5
a* PORT

Define

NPur

$ PVT im

BEOARE
ELECTRON

ADDRES
S
1000

OPCODE
3E

82

MNEMONI
C
IVM 82

1002

D3

03

OUT 03

SET 82?5 CONTROL REGISTOR

PORTA-O/P PORT B -I

1004 L1

06

04

MVI 6 04

SET COUNTER

1006

DB

01

IN B

1008
100
A
100
D

E6

01

ANI 01

CHECK FW/REV MOTOR

DIRECTION

CA

13

10

JZ L2

21

50

10

LX I H 1050 LOAD HL POINTER (FW)

1010
1013 L2

C3

16
60

10
10

JMP L3

1016 L3

23

INX H

7E

MOV A , M GET DATA VALUE

21

1017

LXI H 1060 LOAD HL POINTER (REV)

1018

D3

00

101A

11

FF

3F

101D

CD

98

09

1020

05

LXI D 3FFF LOAD DELAY COUNT

CALL
DELAY
DCR B
DECREMENT COUNTER

1021

C2

16

10

JNZ L3

1024

C3

04

10

JMP L1

FORWARD SEQUENCE
1051
5
1062

COMMENT

OUT A

OUT DATA ON PORT A

IF COUNTER NOT ZERO GO TO

L3

REVERSE SEQUENCE
1061
1062

6
A

1053

1063

1054

1064

Enter the above programme in RAM from location 1000H. Execute: 00 1 0 0 0

EXEC