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PLC-controlled stepper motor drive for NC positioning system

Article · June 2014

DOI: 10.14419/ijet.v3i3.2796

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 International Journal of Engineering & Technology, 3 (3) (2014) 298-307
©Science Publishing Corporation
www.sciencepubco.com/index.php/IJET
doi: 10.14419/ijet.v3i3.2796
Research Paper

PLC-controlled stepper motor drive for NC positioning system

Hussein Sarhan

Faculty of Engineering Technology, Amman, Jordan

E-mail: [email protected]

Copyright © 2014 Hussein Sarhan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

In this paper, an electric drive system for precision control of numerically-controlled positioning system is designed,
assembled and experimentally tested. The proposed drive system is based on PLC-controlled stepper motor. The PLC is
used as an indexer to perform full stepping, half stepping and microstepping modes of operation of stepper motor. The
drive system has been implemented in two-axes NC positioning system. The linear displacement for each machine axis
has been evaluated and compared for the three stepping modes of stepper motor. Experimental and calculation results
show that the response per pulse (resolution) for full stepping mode is 8.35000m , for half stepping mode is
4.17500m and for microstepping mode is 1.04375m , which means that the microstepping mode is the best one for
precision control of NC positioning system.

Keywords: Electric Drive, NC Positioning System, PLC, Stepper Motor, Stepping Mode.

1. Introduction
The stepper motor is an electromechanical actuator which converts the input pulse train into a precisely defined
increment in the shaft position. Each pulse moves the shaft through a fixed angle, called step angle. Stepper motors
have emerged as cost-effective alternatives for DC servomotors in high-speed, motion control applications, where the
high torque is not required, with the improvements in permanent magnets and the incorporation of solid-state circuitry
and logic devices in their drive systems. These motors are commonly used in measurement and control applications,
such as positioning systems for NC machines, ink jet printers, volumetric pumps, computer peripherals, automotive
devices, and small business machines [1], [2].
A stepper motor system, as shown in figure 1, consists of the following three basic components, often combined with
user interface [3-5]:

Fig. 1: Block Diagram of Stepper Motor System.

1) Indexer or controller used to generate pulse trains and perform other sophisticated command functions.
2) Driver (or amplifier) who converts the indexer command signals into the power necessary to energize the motor
windings.
3) Stepper motor, which converts the pulses into mechanical motion.
According to their construction, stepper motors are classified into three types: variable reluctance, permanent magnet
and hybrid. The variable reluctance stepper motor does not use a permanent magnet. As a result, the motor rotor can
move without constraint or "detent" torque. The permanent magnet stepper motor has a permanent magnet rotor. It is
International Journal of Engineering & Technology 299

relatively low speed, low torque device with large step angles of either 45 or 90 degrees. Hybrid stepper motors
combine the best characteristics of variable reluctance and permanent magnet motors.
According to the stator windings, stepper motors are classified into unipolar motors, as shown in figure 2, and bipolar
motors, as shown in figure 3.

Fig. 2: 4-Lead Unipolar Motor.

Fig. 3: 6-Lead (A) and 8-Lead (B) Bipolar Motor.

Depending on stepping mode (value of step angle), stepper motors drives are classified as:
1) Half stepping, where the drive alternates between two phases ON and a single phase ON. This increases the
angular resolution.
2) Full stepping, where two phases are always ON, so the motor will provide its maximum rated torque.
3) Micro stepping, which is typically used in applications, requiring accurate positioning and fine resolution over a
wide range of speeds [6-8].
In this paper, a control circuit of stepper motor based on PLC is designed, assembled and experimentally tested for two-
axes, open-loop NC- positioning system. The control circuit enables the stepper motor to operate at any stepping mode.
The machine axes can be controlled for three different levels of linear motion (velocity): slow, medium and fast.

2. Description of the proposed NC positioning system

The functional diagram of the proposed NC-positioning system is shown in figure 4 (for x-axis). The system is used for
précised motion of the work table in x-y plane. The main components of the system are:
1) Two stepper motors for x and y-machine axes. The technical specifications of the selected motors are given in
table 1.
2) Lead screw, with pitch p  1.67mm / rev
3) Work table
4) Frame of 62cm x 30 cm dimension.
5) Control circuit, which is shown in figure 5.

Fig. 4: Functional Diagram of Open-Loop NC Positioning System.

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Table 1: Technical Specifications of Motors

Item Motor 1 Motor 2
Name Nippon pulse motor Vexta stepping motor
Model PF55-48015 C62244-9212K
Resistance 100  7.4 
Step angle 7.5o 1.8o
Shaft diameter 4 mm 6 mm
Type Hybrid HB Hybrid HB

The control circuit consists of user interface, indexer and driver. The function of user interface is to determine the
operation mode, select the machine axis, select the velocity of table and avoid the table to exceed the range of motion
axis. The PLC is used as indexer. The 470 resistors in the PLC outputs are used for protection purpose. The dual-H
bridge L298 (figure 6) is used to drive the stepper motors coils according to the required sequence of stepping.
The PLC is managed to achieve the following stepping modes:
1) Full stepping mode, according to the sequence shown in table 2.

Fig. 5: Circuit Diagram of the Control System.

Fig. 6: Circuit Diagram of H-Bridge 298.

Table 2: Sequence for Full Stepping Mode

Winding A Winding B Step number
+ 0 1
0 + 2
- 0 3
0 - 4
International Journal of Engineering & Technology 301

The legend "0" means coil OFF, "+" means current flows in one direction, and "-" means current flows in the opposite
direction.
Figure 7 illustrates the voltage waveform for full stepping mode.

Fig. 7: Voltage Waveform for Full Stepping Mode.

To realize the previous sequence, the outputs of PLC (H-bridge inputs) are defined as in table 3.

Table 3: Definition of PLC Outputs

Step number State
1 A+: IN1=1, ENA=1, IN2=0
2 B+: IN3=1, ENB=1, IN4=0
3 A-: IN1=0, ENA=1, IN2=1
4 B-: IN3=0, ENB=1, IN4=1

The block diagram for full stepping mode is shown in figure 8.

Fig. 8: Block Diagram for Full Mode Connection.

The above results are arranged in table 4. The decimal numbers are obtained from binary numbers, and they represent
the PLC outputs from Q0.0 to Q0.7.

Table 4: Full Stepping Mode Sequence

Step number ENA IN1 EN2 INB IN3 IN4 Decimal
1 1 1 0 0 0 0 48
2 0 0 0 1 1 0 6
3 1 0 1 0 0 0 40
4 0 0 0 1 0 1 5

2) Half stepping mode, according to table 5.

302 International Journal of Engineering & Technology

Table 5: Half Stepping Mode Sequence.

Step number 1 2 3 4 5 6 7 8 (0)
1 1 1 1
Rotor position 1 1 2 2 3 3 4/0
2 2 2 2
Current in winding A + 0 - - - 0 + +
Current in winding B + + + 0 - - - 0

Figure 9 illustrates the voltage waveform for full stepping mode.

Fig. 9: Voltage Waveform for Half Stepping Mode.

To realize the previous sequence, the outputs of PLC (H-bridge inputs) are defined as in table 6.

Table 6: Definition of PLC Outputs for Half Stepping Mode

Step number State
1 IN1=1, IN3=1, ENA=1, ENB=1, IN2=0, IN4=0
2 IN3=1, ENB=1, IN4=0
3 IN1=0, ENA=1, IN2=1, IN3=1, ENB=1, IN4=0
4 IN1=0, ENA=1, ENB=1
5 IN1=0, ENA=1, IN2=1, IN3=0, ENB=1, IN4=1
6 IN3=0, ENB=1, IN4=1
7 IN1=1, INA=1, IN2=0, IN3=0, ENB=1, IN4=1
8 IN1=1, ENA=1, IN2=0

The above results are arranged in table 7. The decimal numbers are obtained from binary numbers, and they represent
the PLC outputs from Q0.0 to Q0.7.
3) Micro stepping mode, which can be achieved by one of the following methods: the first one is to make the current
in winding A follow the sin  function, and the current in winding B follow the cos  function and the second
method, the current in one winding is kept constant over half of the complete step and current in other winding is
varied as a function of sin  to maximize the motor torque. The first method can be realized by varying PWM
duty cycle to control the current through the coils. The resultant current in any coil at any angle  should remain
constant and equal to peak value.
Table 8 was designed to decide the values of the PWM through the duty cycle for sin  and cos  functions.

Table 7: Half Stepping Mode Sequence

- - ENA IN1 IN2 ENB IN3 IN4
Step Decimal
8 7 6 5 4 3 2 1
1 0 0 1 1 0 1 1 0 54
2 0 0 0 0 0 1 1 0 6
3 0 0 1 0 1 1 1 0 46
4 0 0 1 0 1 0 0 0 40
5 0 0 1 0 1 1 0 1 45
6 0 0 0 0 0 1 0 1 5
7 0 0 1 1 0 1 0 1 53
8 0 0 1 1 0 0 0 0 48
International Journal of Engineering & Technology 303

Table 8: Micro stepping Sequence According to the First Method

The microstepping chart for the first method is shown in figure 10.

Fig. 10: Micro stepping Chart for the First Method.

304 International Journal of Engineering & Technology

In the second method of microstepping, the current in one winding is kept constant over a half of the complete step
(900), and the current in the other winding varies as a function of sin  to maximize the motor torque.
Figure 11 illustrates the circuit for microstepping mode. PWM1 and PWM2 show the current percentage in each
winding. CD1 and CD2 show the current direction in each winding, which determines the motor direction (FWD or
REV).

Fig. 11: Block Diagram For Microstepping Mode.

The microstepping sequence is shown in table 9 and the microstepping chart is shown in figure 12.
The first column in table 9 shows the number of steps or pulses, the second column shows the electrical angle for each
pulse, the third one shows the current percentage in winding A, and the fourth one shows the current in winding B.
The PLC acts as indexer, which gives the desired pulses according to the stepping mode and table velocity. The logic
block controls the current direction, which depends on the motor speed direction. The motor driver (dual H-bridge)
enables the current in the same winding to flow in different directions. PLC here acts like an indexer, which give pulses
decide the direction and the working mode (Full or Half or Microstepping mode) and the velocity, and make controlling
for other things.
Table 9: Micro stepping Sequence (Second Method)
International Journal of Engineering & Technology 305

Fig. 12: Micro stepping Chart (Second Method).

The control panel is shown in figure 13. It contains ON/ OFF push button to turn ON or OFF the system, stepping mode
selector, two push buttons to change the speed, and four push buttons to select the direction.

Fig. 13: Control Panel.

The PLC has been programmed to perform the desired tasks according to the different stepping modes.

3. Main results
The proposed system was assembled, programmed and tested to control NC positioning system according to three
stepping modes. The results are given in tables (10-12).

Table 10: Results for Full Stepping Mode

Indicator Slow speed Medium speed High speed
Step time, ms 50.75 25.75 11.5
Rotational speed, rpm 5.91 11.65 26.1
Linear velocity, mm/min 9.87 19.46 43.59
Resolution, m 8.3500 8.3500 8.3500
Accuracy, m 4.8000 4.8000 4.8000

Table 11: Results for Half Stepping Mode

Indicator Slow speed Medium speed High speed
Step time, ms 25.37 12.87 5.75
Rotational speed, rpm 5.91 11.65 26.1
Linear velocity, mm/min 9.87 19.46 43.59
Resolution, m 4.1750 4.1750 4.1750
Accuracy, m 2.5000 2.5000 2.5000
 306 International Journal of Engineering & Technology

Table 12: Results for Micro stepping Mode

Indicator Slow speed Medium speed High speed
Step time, ms 6.34 3.22 1.44
Rotational speed, rpm 5.91 11.65 26.1
Linear velocity, mm/min 9.87 19.46 43.59
Resolution, m 1.0437 1.0437 1.0437
Accuracy, m 0.6500 0.6500 0.6500

4. Conclusion
In this paper, a PLC-based control scheme is proposed to provide any stepping mode of stepper motor to control the
motion of two-axes NC positioning system with high accuracy. Experimental and calculation results confirm the
validity of the proposed system. The main advantage of the proposed system is its simplicity, high accuracy and it does
not need conventional programming codes.

References
[1] Aranjo. B., Soori P. K. and Talukder P., “Stepper Motor Drives for Robotic Applications”, Proceedings of power engineering and
optimization conference (PEDCO), Melaka, Malaysia, (2012), pp. 361-366
[2] Barhoumi E.M, Ben Salah B, “New Positioning Control of Stepper Motor Using BP Neural Networks”, Journal of emerging trends in
computing and information sciences, Vol. 2, No. 6, (2011), pp. 300-306
[3] Sharan R. V., Onwubolu G. C., “Simulation the Arm Movements of a Stepper Motor Controlled Pick-and-Place Robot Using the Stepper
Motor Model”, International journal of advanced sciences and technology, Vol. 60, (2013), pp. 59-66
[4] Sagarika Pal, Niladri S. Tripathy, “Remote Position Control System of Stepper Motor Using DTMF Technology”, International journal of
control and automation, Vol. 4, No. 2, (2011), pp. 35-42
[5] Maher Dababneh, Walid Emar and Issam Ttrad, “Chopper Control of a Bipolar Stepper Motor”, International journal of engineering (IJE),
Vol. 7, No. 2, (2013), pp. 61-73
[6] D Carrica, M. A. Funes and S. A. Gonzalea, “Novel Stepper Motor Controller Based on FPGA Hardware Implementation”, IEEE/ ASME
Trans. Mechatronics, Vol. 8, No. 1, (2003), pp. 120-124
[7] Kausik Chakraborty et al, “Design and Development Stepper Motor Position Control System Using Atmel 85c51 Microcontroller”,
International journal of emerging research in management and technology, Vol. 2, No. 12, (2013), pp. 44-48
[8] N. Naresh, T.S. Sirish and Dr. K.S. Sivanandan, “Design and Implementation of Driving Circuits for Stepper Motor Control Using PIC”,
International journal of emerging trends in engineering and development, Vol. 2, No. 2, (2012), pp. 106-112

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