Sultan Qaboos University جامعة السلطان قابوس
College of Engineering كلية الهندسة
Department of Electrical and Computer Engineering
Electric Machines
ECCE4358-Spring22
Project:
Done by
Yaseen Salim Al Rawahi 122721
Ahmed Hamood Al Sawafi 122814
Osama Khalifa Al Hammadi 127286
Loay Yousuf Al Abdali 127674
Instructor
Dr. Razzaqul Ahshan
1 CONTENTS
2 Background................................................................................................3
3 Introduction ...............................................................................................4
4 Construction of Stepper Motor..................................................................5
5 Working Principal of Stepper Motor.........................................................6
6 Types of Stepper Motors ...........................................................................8
6.1 Permanent Magnet Stepper Motor .....................................................9
6.2 Variable Reluctance Stepper Motor ..................................................10
6.2.1 Single-Stack VR Stepper Motor ..................................................10
6.2.2 Multi-Stack VR Stepper Motor ...................................................11
6.3 Hybrid Synchronous Stepper Motor ................................................12
6.4 Comparison.......................................................................................14
7 Stepper Motor Applications ....................................................................15
8 Advantages and disadvantages of Using Stepper Motor ..........................17
8.1 Advantages ........................................................................................17
8.2 Disadvantages ....................................................................................17
9 Conclusion ...............................................................................................18
10 References ...............................................................................................18
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2 BACKGROUND
The stepper motor foundation dates back to the 19th century. But it was first
patented in 1919 . Frank W. Woods the engineer who was credited this
[1]
invention to him mostly. His motor is relied on 5 stator coils which have the
ability to generate a discrete step movement when they are charged in different
combinations. The stepper motor passed through various development stages.
Such as in 1930s for warship purposes. Then, in 1960s, a stepper motor with
large angle permanent magnet replaced the basic type and resembled the
common recent types of stepper motors. The resonance issues of the stepper
motors were solved by developing the controllers starting from 1970s up to
1990s. Moreover, the cost of these motors and their controllers got reduced in
2000s due to the major developments as it was so expensive in the past [2].
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3 INTRODUCTION
The device in which produces mechanical energy from the electrical energy is
called as “Electric Motor” [3]. The electric motors can be sorted as shown in
the figure below:
Figure 1: Classification of the electric motors [4]
The AC motor can produce mechanical power from the alternating current. It
is also classified to: synchronous, asynchronous (induction), and linear motor.
The synchronization of the motor speed with the supply current frequency exists
in the synchronous motor. However, the motor cannot run in a speed equal to
the synchronous speed in the induction motor. In the linear motor, the linear
force is considered as an output instead of the rotational force [1]. Moving to the
stepper motor, when this motor is driven by “sequentially switched DC power
supply” [5] rather than a continuous supplying voltage [6], it will convert the digital
pulses to a mechanical shaft rotation. Thus, its motion will be in discrete steps
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of angular movements with uniform magnitude [5]. Each movement requires a
certain number of pulses. From what is mentioned above, since it revolves with
one increment at each pulse, it is given the common name “stepper, stepping,
or step motor” [6]. Basically, it is a synchronous brushless electric motor [5].
4 CONSTRUCTION OF STEPPER MOTOR
The stepper motor has almost similar construction to the DC motor. The rotor
(the moving part) is positioned in the middle and encircled by several stators (the
stationary part), and a magnetic coil wounds each stator, so they are classified as
A, B and C [7] [8]. The stator should be located in a very close position to the rotor
. Both stator and rotor poles are teethed [9], and the number of poles in the
[7]
rotor is less than those in the stator (e.g., if the rotor has 4 poles, then the stator
will have 6 poles). If the coils are energized, the shaft connected to the rotor will
have the ability for rotation [8]. This set of rotor and stator are combined in a core
which is made from a group of laminated steel lined up together [8].
Figure 2: The core of stepper motor [8]
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The following figure points out the position of “Bearing House”, “Motor Case”,
“Stator Coils”, “Rotor Poles”, “Magnetic Shafts”, and “Shaft Bearing”:
Figure 3: Demonstration of the stepper motor components [9]
5 WORKING PRINCIPAL OF STEPPER MOTOR
Like all electric motors, stepper motors have a stationary part which is the stator,
and a moving part which is the rotor. The stator consists of teeth on which coils
are wired, while the rotor is either a permanent magnet or a variable reluctance
iron core. Figure 4 shows a section of the motor where the rotor is a variable-
reluctance iron core.
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Figure 4: Cross-Section of a Stepper Motor
The working principle of the stepper motor is that by energizing one or more of
the stator phases, a current flow in the coils generates a magnetic field causing
the rotor to align with this field.
The rotor can be rotated by a specific amount, by supplying different phases in
sequence, to reach the desired final position. Figure 2.2 shows a representation
of the working principle. At the starting, coil A is energized, and the rotor is
aligned with the magnetic field coil A produces. When coil B is energized, the
rotor rotates clockwise by 60° to align with the new magnetic field. Similarly,
when coil C is energized. In the figure, the colors of the stator teeth indicate the
direction of the magnetic field generated by the stator winding.
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6 TYPES OF STEPPER MOTORS
Stepper motors are classified into three main types: permanent magnet stepper
motors (PM), variable reluctance stepper motors (VR), and hybrid synchronous
stepper motors. The permanent magnet stepper motors are further categorized
into two basic categories that are the single-stack variable reluctance stepper
motors and the multi-stack variable reluctance stepper motors. The following
tree diagram shown in figure 5 summarized the classification of the stepper
motors.
single-stack
variable
reluctance
Variable
Reluctance
multi-stack
variable
reluctance
Permanent
Stepper Motors
Magnet
Hybrid
Synchronous
Figure 5: Stepper Motor Classification
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6.1 PERMANENT MAGNET STEPPER MOTOR
The rotor of the PM stepper motor is a permanent magnet poles of high
retentivity steel and of disk shape that has no teeth. The number of rotor poles
varies from motor to motor. Moreover, the stator has some number of teeth and
usually has two or more windings (phases) with each winding wound around a
soft metallic core. Figure 6 shows a three-phase PM stepper motor whose phases
are A, B and C. Each tooth will form a north or south pole once it is energized
and therefore attracting with the opposite pole of the rotor.
Figure 6: Three-Phase PM Stepper Motor
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The resolution or the step angle of this type of motor depends on the number
of the phases (2𝑁∅) or the number of stator teeth (𝑁𝑡 ) as well as the number of
rotor poles (𝑁𝑝 ). The step angle is given by the following equation.
360 360
𝜃𝑠 = =
2𝑁∅ 𝑁𝑝 𝑁𝑡 𝑁𝑝
6.2 VARIABLE RELUCTANCE STEPPER MOTOR
6.2.1 Single-Stack VR Stepper Motor
The rotor of the single-stack VR stepper motor is a toothed nonmonetized bar
made of soft-iron. Furthermore, the stator is a laminated toothed iron that has
several windings (phases) with each phase has number of salient poles and in
some cases each pole has number of teeth to get higher resolution (lower step
angle). Figure 7 shows the stator and rotor of the single-stack VR stepper motor.
Figure 7: Single-Stack VR Stepper Motor
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The step angle of this type of stepper motor depends on the number of rotor
poles (𝑁𝑟 ) as well as the number of stator pole (𝑁𝑠 ). The step angle formula is
given below.
(𝑁𝑠 − 𝑁𝑟 )360
𝜃𝑠 =
𝑁𝑠 𝑁𝑟
𝑁𝑠
The value is the number of stator phases (𝑚𝑠 ), so the formula can be
𝑁𝑠 −𝑁𝑟
written as following.
360
𝜃𝑠 =
𝑚𝑠 𝑁𝑟
6.2.2 Multi-Stack VR Stepper Motor
The multi-stack VR stepper motor is divided along its axial length into
magnetically isolated sections called stacks each stack is excited by a separate
winding or phase. This isolation reduces the leakage flux to achieve better
performance. The greater number of stacks increases the holding torque, but in
other hand increasing the number of stacks will increase the motor length and
weight. Both stator and rotor are constructed from laminated electrical steel.
Increasing the magnetic field rapidly will not cause excessive eddy current losses
because of laminations. A part of the phase winding is wound around each pole
to produce radial magnetic field in the pole while the adjacent poles are wound
in the opposite sense, so that the radial magnetic fields in adjacent poles are in
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opposite direction. Figure 8 shows a real three-stack stepper motor and its block
diagram.
Figure 8: Multi-Stack VR Stepper Motor
6.3 HYBRID SYNCHRONOUS STEPPER MOTOR
The hybrid stepper motor has a doubly salient (two stacks), but the magnetic
circuit is excited by the combination of the windings that are placed on the stator
poles and by the permanent magnet that is mounted on the rotor. Furthermore,
both stator and rotor end-caps are toothed. Figure 9 shows the stepper motor
construction while figure 10 shows the real hybrid stepper motor.
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Figure 9: Hybrid Stepper Motor
Figure 10: Hybrid Stepper Motor in Market
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6.4 COMPARISON
A brief comparison among the stepper motor types is tabulated in table 6.1
below.
Characteristics VR PM Hybrid
Rotor Nonmonetized Magnetized rotor Two stacks of
toothed soft-iron rotor teeth
rotors forming the two
poles of a
permanent
magnet
Rotor Inertia Low Moderate High
Design Moderate Simple Complex
Complexity
Cost Moderate Cheapest Most Expensive
Step Size Typical 15 Typical 15 typical 1.8
degrees degrees degrees (Best)
Winding and Unifilar Unifilar and Unifilar and
drive bifilar bifilar. Unipolar
Bipolar
and bipolar
Unipolar and
bipolar.
Speeds Moderate/High Low High
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7 STEPPER MOTOR APPLICATIONS
Stepper motors can be used in many applications that require accurate position,
speed control and low torque.
▪ 3D printing equipment
Stepper motors can be used in many applications that require accurate position,
speed control and low torque.
Figure 11: Stepper motors in 3D printers
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▪ Medical machinery
Stepper motors are used inside medical scanners, fluid pumps, respirators and
blood analysis machinery. An example of medical equipment that use stepper
motors is the motorized handheld pipettes shown in figure 12 below.
Figure 12: Motorized Handheld Pipettes
▪ Small robotics
▪ CNC machines
▪ Welding equipment
▪ Textile machines
▪ Printing presses
▪ Gaming machines
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8 ADVANTAGES AND DISADVANTAGES OF USING STEPPER
MOTOR
8.1 ADVANTAGES
▪ Flexibility
Stepper motors can be used in many applications.
▪ Greater Torque
The torque of a stepper motor compared to that of the same dimension of a
servomotor, at low speeds is greater than that of the servomotor
▪ Low cost
This because of the Open-loop position control system and it do not have
feedback path.
▪ Long lifetime
Because the stepper motor is brushless.
8.2 DISADVANTAGES
▪ Requires a drive circuit
▪ Stepper motors have limited speeds and low torques
▪ Low efficiency
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9 CONCLUSION
Stepper motor is an important and widely used motors in the industry and in
other applications. It moves as steps and have open-loop position and speed
control system. It can be made in different ways, so there many types of stepper
motor depending on the motor stator and rotor material and shape. Since
stepper motor operates with pulses, so it needs a driver circuit to do so.
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