EE6703 UNIT 2 – STEPPER MOTORS

Constructional features – Principle of operation – Variable reluctance motor – Hybrid

motor – Single and multi stack configurations – Torque equations – Modes of excitation –
Characteristics – Drive circuits – Microprocessor control of stepper motors – Closed loop
control - Concept of lead angle – Applications

2.1 INTRODUCTION

It is an electrodynamics and electromagnetic equipment.

These motors are also referred to as step motors or stepping motors.

On account of its unusual construction, operation and characteristics it is difficult to define a

stepper motor.

A stepper motor is brushless dc motor whose rotor rotates in discrete angular displacements
when its stator windings are energized in a programmed manner. Rotation occurs because of magnetic
interaction between rotor poles and poles of the sequentially energized winding. The rotor has no
electrical windings, but has salient and magnetic/or magnetized poles.

The stepper motor is a digital actuator whose input is in the form of digital signals and whose
output is in the form of discrete angular rotation. The angular rotation is dependent on the number of
input pulses the motor is suitable for controlling the position by controlling the number of input
pulses. Thus they are identically suited for open position and speed control.

Applications:

 Printers

 Graph plotters

 Tape driver

 Disk Drives

 Machine Tools

 X-Y Recorders

 Robotics space Vehicle

IC Fabrication and Electric Watches

2.2 CLASSIFICATION OF STEPPER MOTORS

As construction is concerned stepper motors may be divided into two major groups.

1. Without Permanent Magnet

(a) Single Stack
(b) Multi Stack

2. With Permanent Magnet

(a) Claw Pole Motor
(b) Hybrid Motors

1
EE6703 UNIT 2 – STEPPER MOTORS

2.3 SINGLE STACK VARIABLE RELUCTANCE STEPPER MOTOR

2.3.1 Construction:

The VR stepper motor characterized by the fact there is no permanent magnet either on the rotor or
the stator. The construction of a 3-phase VR stepper motor with 6 poles on the stator and 4-pole on
the rotor as shown.

Fig 2.1 Single Stack Variable Reluctance Stepper Motor

The Stator is made up of silicon steel stampings with inward projected even or odd number
of poles or teeth. Each and every stator poles carries a field coil an exciting coil. In case of even
number of poles the exciting coils of opposite poles are connected in series. The two coils are
connected such that their MMF gets added .the combination of two coils is known as phase
winding.

The rotor is also made up of silicon steel stampings with outward projected poles and it does
not have any electrical windings. The number of rotor poles should be different from that of stators
in order to have self-starting capability and bi direction. The width of rotor teeth should be same as
stator teeth. Solid silicon steel rotors are extensively employed. Both the stator and rotor materials
must have lowering a high magnetic flux to pass through them even if a low magneto motive force
is applied.

2.3.2 Electrical Connection

Electrical connection of VR stepper as shown fig. Coil A and A‘ are connected in series to
form a phase winding. This phase winding is connected to a DC source with the help of
semiconductor switch S1.Similary B and B‘ and C and C‘ are connected to the same source through
semiconductor switches S2 and S3 respectively. The motor has 3 –phases a, b and c.

 a phase consist of A and A‘ Coils

 b phase consist of B and B‘ Coils

c phase consist of C and C‘ Coils

2
EE6703 UNIT 2 – STEPPER MOTORS

2.3.3 Principle of Operation

It works on the principle of variable reluctance. The principle of operation of VR stepper

motor explained by referring fig.

(a).Mode 1 : One phase ON or full step operation

In this mode of operation of stepper motor only one phase is energized at any time. If
current is applied to the coils of phase ‗a‘ (or) phase ‗a‘ is excited, the reluctance torque causes the
rotor to run until aligns with the axis of phase a. The axis of rotor poles 1 and 3 are in alignment
with the axis of stator poles ‗A‘ and ‗A‘‘. Then angle θ = 0° the magnetic reluctance is minimized
and this state provides a rest or equilibrium position to the rotor and rotor cannot move until phase
‗a‘ is energized.

Next phase b is energized by turning on the semiconductor switch S2 and phase ‗a‘ is de –
energized by turning off S1.Then the rotor poles 1 and 3 and 2 and 4 experience torques in opposite
direction. When the rotor and stator teeth are out of alignment in the excited phase the magnetic
reluctance is large. The torque experienced by 1 and 3 are in clockwise direction and that of 2 and 4
is in counter clockwise direction. The latter is more than the former. As a result the rotor makes an
angular displacement of 30° in counterclockwise direction so that B and B‘ and 2 and 4 in
alignment. The phases are excited in sequence a, b and c the rotor turns with a step of 30° in counter
clockwise direction. The direction of rotation can be reversed by reversing the switching sequence
in which are energized and is independent of the direction of currents through the phase winding.

Fig 2.3 step motions as switching sequence process in a three phase VR motor

The truth table for mode I operation in counter and clockwise directions are given in the
table

3
EE6703 UNIT 2 – STEPPER MOTORS

Table 2.1: Counter Clockwise Rotation (CCW)

S1 S2 S3 θ
* - - 0
- * - 30
- - * 60
* - - 90
- * - 120
- - * 150
* - - 180
- * - 210
- - * 240
* - - 270
- * - 300
- - * 330
* - - 360

(b).Mode II: Two Phase on Mode

In this mode two stator phases are excited simultaneously. When phases a and b are
energized together, the rotor experiences torque from both phases and comes to rest in a point mid-
way between the two adjacent full step position. If the phases b and c are excited, the rotor
occupies a position such that angle between AA‘ axis of stator and 1-3 axis of rotor is equal to
45°.To reverse the direction of rotation switching sequence is changed a and b,a and c etc. The
main advantage of this type of operation is that torque developed by the stepper motor is more
than that due to single phase ON mode of operation.

The truth table for mode II operation in counter clockwise and clockwise directions is given
in a tableTable

2.3: Counter Clockwise Rotation (CCW) Mode III: Half step Mode

S1 S2 S3 θ°

* * - 15° AB
- * * 45° BC
- * - 75° CA
* * - 105° AB
- * * 135° BC
- * - 165° CA
* * - 195° AB
- * * 225° BC
- * - 255° CA
* * - 285° AB

4
EE6703 UNIT 2 – STEPPER MOTORS

Table 2.4: Clockwise Rotation (CW) (C)

S1 S2 S3 θ
AC - * - 15°
CB - * * 45°
BA * * - 75°
AC - * - 105°
CB - * * 135°
BA * * - 165°
AC - * - 195°
CB - * * 225°
BA * * - 255°
AC 285°

5
EE6703 UNIT 2 – STEPPER MOTORS

In this type of mode of operation on phase is ON for some duration and two phases are
ON during some other duration. The step angle can be reduced from 30° to 15° by exciting phase
sequence a, a+b, b,b+c, c etc. The technique of shifting excitation from one phase to another from
a to b with an intermediate step of a+b is known as half step and is used to realize smaller steps
continuous half stepping produces smoother shaft rotation.
The truth table for mode III operation in counter and clockwise directions are given in the
table
Table 2.5: Counter ClockwiseRotation (CCW) Table 2.6: Clockwise Rotation (CW)

S1 S2 S3 θ
S1 S2 S3 θ
* - - 0° A°
* - - 0° A°
* - * 15° AB°
* * - 15° AB°
- - * 30° B°
- * - 30° B°
- * * 45° BC°
- * * 45° BC°
- - * 60° C°
- - * 60° C°
- * - 75° CA°
* - * 75° CA°
* * - 90° A°
* - - 90° A°
* - - 105° AB°
* * - 105° AB°
* - * 120° B°
- * - 120° B°
- - - 135° BC°
- * * 135° BC°
- * * 150° C°
- * - 150° C°
- * - 165° CA°
* - * 165° CA°

2.4 MICRO STEPPING CONTROL OF STEPPING MOTOR

Stepping motor is a digital actuator which moves in steps of θs in response to input pulses. such
incremental motion results in the following limitations of the stepper motor

Limited resolution

As θs is the smallest angle through which the stepper motor can move, this has an effect on
position accuracy of incremental servo system employing stepper motors because the stepper
motor cannot position the load to an accuracy finer than θs.

Mid frequency Resonance

A phenomenon in which the motor torque suddenly drops to a low value at certain pulse
frequencies as in fig

Fig 2.4 Mid frequency Resonance

A new principal known as micro stepping control has been developed with a view of

6
EE6703 UNIT 2 – STEPPER MOTORS

overcoming the above limitation .It enables the stepping motor to move through a tiny micro
step of size ∆ θs << θs full step angle is response to input pulses.

2.5. MULTISTACK VARIABLE RELUCTANCE STEPPER MOTOR

These are used to obtain smaller step sizes, typically in the range of 2° to 15°. Although three
stacks are common a multistack motor may employ as many as seven stacks. This type is also
known as the cascade type. A cutaway view of a three stack motor is shown in fig. 2.6.

Fig. 2.6: Construction of multi-stack VR motor.

A multistack (or m-stack) variable reluctance stepper motor can be considered to be made up of
‘m‘ identical single stack variable reluctance motors with their rotors mounted on a single shaft.
The stators and rotors have the same number of poles (or teeth) and therefore same pole (tooth)
pitch. For a m0stack motor, the stator poles (or teeth) in all m stacks are aligned, but the rotor
poles (teeth) are displaced by 1/m of the pole pitch angle from one another. All the stator pole
windings in a given stack are exited simultaneously and, therefore the stator winding of each stack
forms one phase. Thus the motor has the same number of phases as number of stacks.

Fig. 2.7: Cross-section of a 3-stack, VR stepper motor parallel to the shaft.

Figure 2.7 shows the cross section of a three stack (3-phase) motor parallel to the shaft. In each
stack, stator and rotors have 12 poles (teeth). For a 12 pole rotor, pole pitch is 30° and therefore,
the rotor poles (teeth) are displaced from each other by 1/3rd of the pole pitch or 10°. The stator
teeth in each stack are aligned. When the phase winding A is excited rotor teeth of stack A are
aligned with the stator teeth as shown in fig. 2.8.

When phase A is de-energized and phase B is excited the rotor teeth of stack B are aligned with
stator teeth. The new alignment is made by the rotor movement of 10° in the anticlockwise

7
EE6703 UNIT 2 – STEPPER MOTORS

direction. Thus the motor moves one step (equal to ½ pole pitch) due to change of excitation from
stack A to stack B

Next phase B is de-energized and phase C is excited. The rotor moves by another step 1/3rd of
pole pitch in the anticlockwise direction. Another change of excitation from stack C to stack A
will once more align the stator and rotor teeth in stack A. however during this process (A → B →
C → A) the rotor has moved one rotor tooth pitch.

Fig. 2.8: Position of stator & rotor teeth of 3 stack VR motor

Let Nr be the number of rotor teeth and ‗m‘ the number of stacks or phases, then

Tooth pitch Tp= 360/Nr ……………… (2.1)

Step Angle α= 360°/mNr ………………. (2.2)

8
EE6703 UNIT 2 – STEPPER MOTORS

2.6. Hybrid stepper motor

Principle of operation

Most widely used hybrid motor is the two phase type as shown in fig2.11. This model
has four poles and operates on one phase on excitation.
.

Fig2.9cross-section of a two phase hybrid motor

The coil in pole 1 and that in pole 3 are connected in series consisting of phase A, and pole 2 and
4 are for phase B. Fig 2.12 shows the proce3ss of rotor journey as the winding currents are
switched in one phase ON excitation

Fig2.10 one-phase on operation of a two-phase hybrid motor.

The poles of phase A are excited the teeth of pole 1 attract some of the rotors north poles,
while the teeth of pole 3 align with rotor‘s south poles. Current is then switched to phase B, The
rotor will travel a quarter tooth pitch so that tooth alignment takes place in 2 and 4.

Next current is switched back to phase A but in opposite polarity to before, the rotor will
make another quarter tooth journey. The tooth alignment occurs in opposite magnetic polarity to
state 1. When current is switched to phase B in opposite polarity (4) Occurs as a result of quarter
tooth pitch journey.

The structures of two phase motor considered in fig.2.11 will not produce force in a
symmetrical manner with respect to the axis. The motor having 8 poles in the stator shown in
fig2.13 considered as the structure in which torque is generated at a symmetrical position on the
surface.

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Fig2.11 Two-phase hybrid motor with 8 stator poles.

2.9. THEORY OF TORQUE PREDICTION

According to Faradays laws of electromagnetic induction

10

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

11

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

12

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

13

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

14

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

15

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

16

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

17

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

18

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

19

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

20

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

21

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

22

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

2.11. CHARACTERISTICS OF STEPPER MOTOR

Stepper motor characteristics are divided into two groups


 Static characteristics

Dynamic characteristics


2.11.1. Static characteristics

It is divided into two characteristics.

(i)Torque Angle curve

(ii)Torque current curve

(i)Torque-Angle curve

Torque angle curve of a step motor is shown in fig.2.19. it is seen that the Torque
increases almost sinusoid ally, with angle Θ from equilibrium.

Fig. 2.19 Torque Angle

Holding Torque (TH)

It is the maximum load torque which the energized stepper motor can withstand without slipping
from equilibrium position. If the holding torque is exceeded, the motor suddenly slips from the
present equilibrium position and goes to the static equilibrium position.

Detent torque (TD):

It is the maximum load torque which the un-energized stepper motor can withstand slipping.
Detent torque is due to magnetism, and is therefore available only in permanent magnet and
hybrid stepper motor. It is about 5-10 % of holding torque.

Torque current curve

A typical torque curve for a stepper motor is shown in fig.2.19. It is seen the curve is
initially linear but later on its slope progressively decreases as the magnetic circuit of the motor
saturates.

23

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Fig.2.20 Torque-current Curve

Torque constant (Kt)

Torque constant of the stepper is defined as the initial slope of the torque-current (T-I)
curve of the stepper motor. It is also known as torque sensitivity. Its units N-mA, kg-cm/A or
OZ-in/A

2.11.2. Dynamic characteristics

A stepper motor is said to be operated in synchronism when there exist strictly one to one
correspondence between number of pulses applied and the number of steps through which the
motor has actually moved. There are two modes of operation.

Start-Stop mode

Also called as pull in curve or single stepping mode.

Slewing mode

In start –stop mode the stepper motor always operate in synchronism and the motor
can be started and stopped without using synchronism. In slewing mode the motor will be in
synchronism, but it cannot be started or stopped without losing synchronism. To operate the
motor in slewing mode first the motor is to be started in start stop mode and then to slewing
mode. Similarly to stop the motor operating in slewing mode, first the motor is to be brought to
the start stop mode and then stop.

Start Stop mode

Start stop mode of operation of stepper motor is shown in fig.2.21 (a).In this second pulse
is given to the stepper motor only after the rotor attained a steady or rest position due to first
pulse. The region of start-stop mode of operation depends on the operation depends on the torque
developed and the stepping rate or stepping frequency of stepper motor.

24

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Fig. 2.21 Modes of operation




2.12. TORQUE-SPEED CHARACTERISTICS

Torque developed by the stepper motor and stepping rate characteristics for both modes
of operation are shown in fig.2.22.the curve ABC represents the "pull in" characteristics and the
curve ADE represents the "pull-out" characteristics.

Fig. 2.22 Torque-Speed Characteristics

The area OABCO represents the region for start stop mode of operation. At any operating
point in the region the motor can start and stop without losing synchronism. The area ABCEDA
refers to the region for slewing mode of operation. At any operating point without losing
synchronism to attain an operating point in the slewing mode at first the motor is to operate at a
point in the start-stop mode and then stepping rate is increased to operate in slewing mode,
similarly while switching off it is essential to operate the motor from slewing mode to start-stop
mode before it is stopped.

25

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Pull in torque

It is the maximum torque developed by the stepper motor for a given stepping rate in the start-
stop mode of operation without losing synchronism. LM represents the pull in torque (i.e)TPI
corresponding to the stepping rate F (i.e.) OL.

Pull out torque

It is the maximum torque developed by the stepper motor for a given stepping rate in the
slewing mode without losing synchronism. LN represents the pull in torque (i.e.) TPO
corresponding to F (i.e.) OL.

Pull in range

It is the maximum stepping rate at which the stepper motor can operate in start-stop mode
developing a specific torque (without losing synchronism). PIT represents pull in range for a
torque of T (i.e.) OP. This range is also known as response range of stepping rate for the given
torque T.

Pull out range

It is the maximum stepping rate at which the stepper motor can operate in slewing mode
developing a specified torque without losing synchronism. PIPO represents the pull out range for
a torque of T. The range PIPO is known slewing range.

Pull in rate (FPI)

It is the maximum stepping rate at which the stepper motor will start or stop without
losing synchronism against a given load torque T.

Pull out rate (FPO)

It is the maximum stepping rate at which the stepper motor will slew, without missing
steps, against load torque T.

Synchronism

This term means one to one correspondence between the number of pulses applied to the
stepper motor and the number of steps through which the motor has actually moved.

Mid frequency resonance

The phenomenon at which the motor torque drops to a low value at certain input pulse
frequencies.

26

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

2.13 DRIVE SYSTEM AND CONTROL CIRCUITRY FOR STEPPER MOTOR

2.13.1 DRIVE SYSTEM

The stepper motor is a digital device that needs binary (digital) signals for its
operation .Depending on the stator construction two or more phases have to be sequentially
switched using a master clock pulse input. The clock frequency determines the stepping rate, and
hence the speed of the motor. The control circuit generating the sequence is called a translator or
logic sequencer.

Fig. 2.23 Block Diagram of the drive system of a stepping motor.

The fig 2.23 shows the block diagram of a typical control circuit for a stepper
motor. It consists of a logic sequencer, power driver and essential protective circuits for current
and voltage limiting. This control circuit enables the stepper motor to be run at a desired speed in
either direction. The power driver is essentially a current amplifier, since the sequence generator
can supply only logic but not any power. The controller structure for VR or hybrid types of
stepper motor

Fig. 2.24 Block diagram of a typical step motor control

2.13.2 LOGIC SEQUENCER

The logic sequencer is a logic circuit which control the excitation of the winding
sequentially, responding to step command pulses. A logic sequencer is usually composed of a
shifter register and logic gates such as NANDs, NORs etc. But one can assemble a logic
sequencer for a particular purpose by a proper combination of JK flip flop, IC chips and logic
gate chips.

Two simple types of sequencer build with only two JK-FFs are shown in fig 2.39
for unidirectional case. Truth tables for logic sequencer also given for both the directions.

27

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

TABLE 2.7 Logic Sequencer

R 1 2 3 4 5 6 ….

Ph A,Q1 0 1 1 0 0 1 1 ….

Ph B,Q2 0 0 1 1 0 0 1 ….

Ph A,Q1 1 0 0 1 1 0 0 ….

Ph B,Q2 1 1 0 0 1 1 0 …

R 1 2 3 4 5 6 ….

Ph A,Q1 0 0 1 1 0 0 1 ….

Ph B,Q2 0 1 1 0 0 1 1 ….

Ph A,Q1 1 1 0 0 1 1 0 ….

Ph B,Q2 1 0 0 1 1 0 0 ….

Fig.2.25 A unidirectional logic sequencer for two phase on operation of a two phase hybrid
motor

The corresponding between the output terminals of the sequencer and the phase windings to be
controlled is as follows.

28

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Q1----- Ph A

Q1----- Ph A

Q2----- Ph B

Q2----- B

If Q1 is on the H level the winding Ph A is excited and if Q1is on L level, Ph A is

not excited.

To reserve the rotational direction, the connection of the sequencer must be

interchanged. The direction switching circuits shown in fig 2.40 may be used for this purpose.
The essential functions being in the combination of three NAND gates or two AND gates and a
NOR gate.

2.13.3. Power Driver Circuit

The number of logic signals discussed above is equal to the number of phases and the
power circuitry is identical for all phases. Fig. 2.26(a) shows the simplest possible circuit of one
phase consisting of a Darlington pair current amplifier and associated protection circuits. The
switching waveform shown in fig. 2.26(c) is the typical R-L response with an exponential rise
followed by decay at the end of the pulses.

In view of the inductive switching operation, certain protective elements are introduced in
the driver circuit. These are the inverter gate 7408, the forward biased diode D1 and the
freewheeling diode D. The inverter IC provides some sort of isolation between the logic circuit
and the power driver.
There are some problems with this simple power circuit. They can be understood by
considering each phase winding as a R-L circuit shown in fig. 2.26(b) subject to repetitive
switching. On application of a positive step voltage, the current rises exponentially as

i(t)=I(1- ) … …(2.29)

Where I=V/R – rated current and

Ԏ=L/R winding time constant.

Fig. 2.26 Power Driver Stage of Stepper Motor Controller

29

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

In practice, the time constant Ԏ limits the rise and fall of current in the winding. At low
stepping rate the current rises to the rated value in each ON interval and falls to zero value in
each OFF interval. However as the switching rate increases, the current is not able to rise to the
steady state, nor fall down to zero value within the on/off time intervals set by the pulse
waveform. This in effect, smoothens the winding current reducing the swing as shown in fig.
2.45. As a result the torque developed by the motor gets reduced considerably and for higher
frequencies, the motor just vibrates or oscillates within one step of the current mechanical
position.

Fig. 2.27 Effect of increasing Stepping Rate on Current Swing

In order to overcome these problems and to make improvement of current build up several
methods of drive circuits have been developed.

For example when a transistor is turned on to9 excite a phase, the power supply must overcome
effect of winding inductances has tendency to oppose the current built up. As switching
frequency increases the position that the buildup time takes up within the switching cycle
becomes large and it results in decreased torque and slow response.

2.13.4 Improvement of current buildup/special driver circuit

(a) Resistance drive (L/R drive)

Here the initial slope of the current waveform is made higher by adding external resistance in
each winding and applying a higher voltage proportionally. While this increases the rate of rise
of the current, the maximum value remains unchanged as shown in fig.

Fig. 2.28 L/R drive

30

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

The circuit time constant is now reduced and the motor is able to develop normal torque even at
high frequencies. The disadvantage of this method is

Flow of current through external resistance causes R losses and heating. This denotes wastage
of power as far as the motor is concerned.

In order to reach the same steady state current as before, the voltage required

To be applied is much higher than before. Hence this approach is suitable for small instrument
stepper motor with current ratings around 100 mA, and heating is not a major problem.
(b) Dual voltage driver (or) Bi-level driver

To reduce the power dissipation in the driver and increase the performance of a stepping
motor, a dual-voltage driver is used. The scheme for one phase is shown in fig. 2.29.

When a step command pulse is given to the sequencer, a high level signal will be put out
from one of the output terminal to excite a phase winding. On this signal both 1 and 2 are
turned on, and the higher voltage will be applied to the winding. The diode is now
reverse biased to isolate the lower voltage supply. The current build up quickly due to the higher
voltage . The time constant of the monostable multivibrator is selected so that
transistor 1 is turned off when the winding current exceeds the rated current by a
little. After the higher

Fig. 2.29 Improvement of current buildup by dual voltage drive

Voltage source is cut off the diode is forward biased and the winding current is supplied from
the lower voltage supply. A typical current wave form is shown in fig.

31

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Fig. 2.30 Voltage and current wave form in dual voltage driver

When the dual voltage method is employed for the two phase on drive of a two phase
hybrid motor, the circuit scheme will de such as that shown in fig. Two transistor 1
& 2 and two diodes and are used for switching the higher voltage. In dual voltage
scheme as the stepping rate is increased, the high voltage is turned on for a greater percentage
of time

Fig. 2.31 A dual-voltage driver for the two-phase-on drive of a two phase hybrid motor

This drive is good and energy efficient. However it is more complex as it requires
two regulated power supplies EH& EL end two power transistor switches Tr1 & Tr2 and
complex switching logic. Hence it is not very popular.

(c)Chopper drive

Here a higher voltage 5 to 10 times the related value is applied to the phase winding as
shown in fig. and the current is allowed to raise very fast. As soon as the current reaches about
2 to 5% above the rated current, the voltage is cut off, allowing the current to decrease
exponentially. Again as the current reaches some 2 to 5% below the rated value, the voltage is
applied again. The process is repeated some 5-6 times within the ON period before the phase
is switched off. During this period the current oscillates about the rated value as shown in fig.
A minor modification is to chop the applied dc voltage at a high frequency of around 1khz,
with the desired duty cycle so as to obtain the average on-state current equal to the rated
value.

32

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

Fig. 2.32 Chopper drive

The chopper drive is particularly suitable for high torque stepper motors. It is
ener4gy efficient like the bi-level drive but the control circuit is simpler.

(d) Problems with driver circuits

A winding on a stepping motor is inductive and appears as a combination of inductance

and resistance in series. In addition, as a motor revolves a counter emf is produced in the
winding. The equivalent circuit to a winding is hence, such as that shown for designing a
power driver one must take into account necessary factors and behavior of this kind of circuit.
Firstly the worst case3 conditions of the stepping motor, power transistors, and supply voltage
must be considered. The motor parameters vary due to manufacturing tolerance and operating
conditions. Since stepping motors are designed to deliver the highest power from the smallest
size, the case temperature can be as high as about 100°c and the winding resistance therefore
increases by 20 to 25 per cent.

Suppressor circuits

These circuits are needed to ensure fast decay of current through the winding when it is
turned off. When the transistor in the above fig is turned off a high voltage builds up to Ldi/dt
and this voltage may damage the transistor. There are several methods of suppressing this
spike voltage and protecting the transistor as shown in the following.

(a) Diode suppressor

If a diode is put in parallel with the winding in the polarity as shown in fig. a circulating
current will flow after the transistor is turned off, and the current will decay with time. In this
scheme, no big change in current appears at turn off, and the collector potential is the supply
potential E plus the forward potential of the diode. This method is very simple but a drawback
is that the circulating current lasts for a considerable length of time and it produces a braking
torque.

Fig. 2.33 Diode suppressor

33

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

(b)Diode-Resistor suppressor

A resistor is connected in series with the diode as shown in fig to damp quickly the
circulating current. The voltage VCE applied to the collector at turn-off in this scheme is

VCE=E+IRS+VD

Where E= supply potential

I= Current before turning off

Rs-resistance of suppressor resistor

VD-forward potential of diode

Fig. 2.34 Diode-resistor suppressor

A high resistance RS is required to achieve a quick current decay, but this also results in a
higher collector potential VCE, thus a transistor with a high maximum voltage rating is
necessary.

(a) Zener diode suppressor

In this zener diode are often used to connect in series with the ordinary diode as shown
in fig. Compared with preceding two cases zener diode which provides negative bias causes
the current to decay more quickly after turn off. In addition to this, it is a merit of this method
that the potential applied to the collector is the supply potential plus the zener potential,
independent of the current. This makes the determination of the rating of the maximum
collector potential easy. However zeners are signal diodes, rather than power diodes. Their
power dissipation is limited to 5w. Consequently, this suppressor can be used for very small
instrument stepper motors of typical size 8 to 11.

Comparison of effects of various suppressor schemes of various suppressor schemes

34

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

d)Condenser suppressor

This scheme is often employed for bifilar-wound hybrid motor. An explanation is given
for the given for the circuit shown in fig:

Fig. 2.37 Condenser suppressor

. These
condensers serve two fold purposes.

1. When a transistor is turned off, the condenser connected to it via a diode absorbs the
decaying current from the winding to protect the transistor.

Let us see the situation just after the Tr 1 is turned off in the one phase

are wound in the bifilar fashion, a transient current will circulate in loop. If Tr 3
is turned on when the transient current becomes zero and the charge stored in the condenser
becomes maximum, a positive current can easily flow through phase A winding. By this
resonance mechanism, currents are used efficiently in this scheme. This feature remains in the
two phase on mode too. The condenser suppressor is suited to drives in which stepping rate is
limited in a narrow range.

2 .Another utility of condensers is as an electrical damper, a method of damping rotor

oscillations is to provide a mechanism to convert kinetic energy to joule heating. If a rotor

35

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

having a permanent magnet oscillates, an alternating emf is generated in the winding.

However if a current path is not provided or a high resistance is connected, no current will be
caused by this emf. When the condenser is connected between phases an oscillatory current
will flow in the closed loop and joule heat is generated in the windings, which means that the
condenser works as an electrical damper.

2.14 APPLICATION OF STEPPER MOTOR:

The main application of stepper motor may be divided into the following
groups.

1. Instrumentation applications.

2. Computer peripherals & Office equipment‘s.

3. Numerical control of machine tools and robotics.

4. Applications in semiconductor technology.

5. Space vehicles and satellites.

6. Electro medical and

7. Miscellaneous applications.

1. Instrumentation application:

This involve low torque applications such as

Quartz watches.

Synchronized clocks.

Camera shutter operations.

2. Stepper motor application in computer peripherals:

This involve medium torque, high performance and high volume application such as
Dot matrix and line printers.

Graph plotters.

Floppy disk drives

Digital X-Y plotters.

Magnetic tape drives.

Paper tape drives.

36

Prepared by : U.NAGABALAN., AP/EEE

EE6703 UNIT 2 – STEPPER MOTORS

3. Application is office equipment:

Electronic typewriters.

Copiers

Facsimile machines.

4. Machine tool applications:

This involve high torque application such as

Numerical control system for milling machine

X-Y tables and index table.

Home use and industrial sewing machines.

5. Application in semiconductor technology:

Stepper motors used in high vacuum.

Goniometer-An instrument used to determine crystalline structure.

Electron beam micro fabricator.

6. Stepper motor used in space vehicles and satellites.

7. Robotics.

8. Electro medical applications:

This involve high torque applications such as

X-ray machines.

Radiation therapy units.

Ultra sound scanner.

9. Miscellaneous applications:

Nuclear reactors.

Heavy industry applications.

Automatic focusing mechanism in camera

37

Prepared by : U.NAGABALAN., AP/EEE