International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.

3 (2016) 33

The Modelling, Simulation and Hardware Implementation for

FPGA-based Stepping Motor Motion Drives
*
Chiu-Keng Lai, Wei-Nan Chien, Shou-Liang Tsai and Yaw-Ting Tsao

In this paper, we focus the development of a

hybrid stepping motor drive system on current
Abstract regulator design, drive system modelling,
performance simulation, functional analysis and
hardware implementation. We first build a stepping
In this study, we establish the model and motor current regulation model for simulation by
implement the hardware controller for the stepping Matlab/Simulink and ModelSim system. The
motor drive system using FPGA. Through the full developed system is subjected to the following
bridge power circuits for a hybrid stepping motor, we limitations: (1) The trapezoidal velocity profile is for
create two Verilog HDL-based systems by peak motion control. (2) The maximum velocity is limited
current and average current methods to simulate and by the desired position displacement. (3) The current
realize hardware the current regulators. The hardware regulating strategies are, respectively, the peak
systems are first simulated with ModelSim and current method and the average current one.
Quartus II, and the resulting Verilog HDL codes are Regarding the hardware implementation, in order to
implemented on Altera FPGA as current regulators to leave out the usage of hall current sensors and ADC
adjust the duty cycle to regulate the stepping motor converters, a one-bit comparator is used to detect the
current. Human machine interface and motion control winding current, and its output is fed back to the
are considered to the experiment simultaneously. The controller. Further, to get the average current without
performances for the two proposed hardware the ADC, we develop a hardware system by FPGA to
controllers are compared. obtain the average current. Combining several blocks,
Keywords: FPGA, Stepping Motor, Peak Current the two proposed FPGA-based digital controllers are
Regulation, Average Current Regulation, then synthesized to simulate the current control on
Matlab/Simulink, Modelsim. Quartus II and ModelSim. Both the regulation
methods are simulated by different speeds and their
results are compared.
1. Introduction Based on the created hardware systems by
Matlab/Simulink, and through some modifications to
Field Programmable Gate Arrays (FPGAs) fit the Altera Cyclone III C10 FPGA, the hardware
allow designers to integrate their hardware functions regulators are finally realized on Altera Cyclone III
in a chip. The researches of FPGA applied to the FPGA, and are applied to hybrid stepping motor
controller design have been reported, and such papers drives to practically realize the current regulation
could be found in [1-4]. Chan, Moallem and Wang according to the desired velocity profile. At last, the
designed their PID controller by FPGA, and applied simulations and experimental results are verified and
it to realize a temperature controller [1]. Tezuka, compared to each other.
Ichikawa and Noda designed and implemented their The paper is organized in the following manner.
motor tracking controller on FPGA using The hardware drive systems for a hybrid stepping
two-degree-of-freedom control strategy [2]. Siwakoti motor are first shown in Section 2. Next, Section 3
and Town used Matlab/Simulink to simulate and describes the algorithms of current regulation about
develop their motor drive and PWM control module the methods of peak current and average current by a
[3]. Finally, Gao and Kennel implemented a hybrid signal flow chart. And Section 4 shows the simulated
sensorless control for SMPMSM using FPGA [4]. results for both the proposed structures with Quartus
Regarding the stepping motor drive design II and ModelSim. Then the experimental setup and
realized by FPGA, several reports are seen in [5-9]. results of the two proposed methods are illustrated
In [5], the authors used Cyclone II FPGA and two and compared in Section 5. And finally, the
digital-to-analog converters (DACs) to implement the conclusions are given in Section 6.
micro-stepping control, where velocity and position
profiles are generated by FPGA. In [6], the authors
adopted analog to digital converter (ADC) to obtain
*Corresponding Author: Chiu-Keng Lai
(E-mail: [email protected])
1
National Chin-Yi University of Technology No.57, Sec. 2,
Zhongshan Rd., Taiping Dist., Taichung 41170, Taiwan
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 34

2. The Hardware Circuits of a The circuit of power converter for a hybrid

stepping motor drive system is shown in Fig. 2. The
Stepping Motor Drive System DC bus voltage is 48 V, and current command is set
as 1 A. The stepping motors are operated in a
The circuits used to the modelling and full-step mode, and winding current detection is
hardware implementation for stepping motors include executed by resistors R A and RB . The voltages
FPGA, gate driver, power converter and current on resistors are proportional to the winding currents,
sensor. The FPGA-based control board designed for and are compared with the desired current level by
the hardware controller is shown in Fig. 1, which is two analog comparators. The output signals of
mainly realized on Altera Cyclone III C10 FPGA.
comparators, V A and VB , are then fed back to the
Besides, an 8051 compatible micro-controller IP is
embedded in the FPGA to do the following things: (1) current regulators established by FPGA to make the
to help the realization of pulse width modulation current reach the desired level.
(PWM); (2) to realize the digital differential
analyzer (DDA) and acceleration and deceleration
control under a trapezoidal velocity profile, (3) and to 3. The Algorithms of Current
be as the interface for the communication between Regulation
current regulator of the study and human machine
interface (HMI) on PC. Besides, due to the purposes
of hardware modelling, hardware and software The two current regulating algorithms of peak
co-simulation and practical hardware implementation, current and average current are applied to the current
the blocks of PWM and current control are further control of stepping motor drive design. The current
considered and discussed in the next section. regulating sequence is done by three modules:
dead-time module, delay-time module and PWM
module. Dead-time module is used to set the
switching dead time to be 1 s , while delay-time
and PWM modules are designed to make the winding
current reach to the desired level rapidly, and keep on
it consistently until the next excitation phase is
alerted. The current control is implemented on 20
kHz sampling frequency. The inputs of current
comparator are, respectively, from the command of
winding current and the detected voltage on RA
and RB . The two proposed hardware control
algorithms are implemented on FPGA and leave out
the necessary ADC converter. The procedures are
shown in the following.

3.1 The Peak Current Regulation

The peak current regulating procedure runs
with a time period of 50 μs , or 20 kHz sampling
Figure 1: The FPGA-based control board. frequency. For a new stepping command arrival, the
MOSFET switch is first turned on, and the
corresponding phase current increases. In the moment,
VCC a 4 MHz sampling clock monitors the output of the
Q1 Q3 Q5 Q7
current comparator to decide the conditions of
switches. The strategies are: if the level of winding
current ( I fb ) is lower than the desired current
A B command, I cmd , i.e., the comparator outputs
Q2 Q4 Q6 Q8
VA  0 . The MOSFET switch keeps turning on.
VA VB Once the level of winding current is greater than the
+ FB_A + FB_B
-
RA = 0.5Ω
-
RB = 0.5Ω command, i.e. I fb  I cmd or VA =1, the
Command Command
GND MOSFET switch is then turned off, and the motor
current decreases. The switches keep off until the
next PWM cycle alerts. The flow chart of peak
Figure 2: The power converter for a hybrid
current regulation is shown in Fig. 3.
stepping motor driver.
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 35

Start 3.2 The Average Current Regulation

In this strategy, the delay-time and PWM
modules are used, and the average current regulation
procedure runs on a period of 50s as the same
Switch ON peak current strategy. The concept is based on the
average of winding currents during the sampling
period to get the average current without using ADC,
so it is the most important design. The flow chart of
Yes average current regulation is shown in Fig. 4, and the
(Ifb > Icmd ) ?
details are as follows.
No

Switch Hold Switch OFF

No
Next Step ?

Yes

Figure 3: The flow chart of peak current

regulation.

Start
n=0
Duty(n) = 50%
Duty = 100%

No Yes
Yes No I > Iref ?
All Ifb = 0 ?

Duty = 0%
Duty = 100% Duty(n+1) Duty(n+1)
= Duty(n)+1% = Duty(n)-1%
PWM Out
PWM Out
Duty(n+1) No Duty(n+1) No
>80 % ? < 20 % ?
Stop
No Yes Yes
I = Iref ?
Yes Duty(n+1) Duty(n+1)
= 80 % = 20 %

n=n+1

PWM Out

Next Step? No

Yes

Figure 4: The flow chart of average current regulation.

 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 36

First, the current detector checks whether the smaller than the desired. Otherwise, the average
current feedback signal ( I fb ) exists or not. If no current is greater than the desired. With this
algorithm, the ADC for current detection is
feedback signal is detected, the PWM module then unnecessary.
sets the duty cycle to 0 %, i.e., turns off the PWM
modules. Otherwise, if the current feedback signal
exists, the PWM duty cycle is then set to be 100 %. 4. The System Modelling and
In this during, it is called the delay time, and the
winding current increases rapidly. After the Simulation
comparator outputs VA  1 , i.e., I fb  I cmd , the
PWM module then resets the PWM duty cycle to 50 The overall block diagram for simulations
%, and adjusts the duty cycle according to the shown in Fig. 5 includes all the components
average of winding current. In the developed system, corresponding to the real hardware system. In Fig. 5,
the upper and lower bounds of PWM duty cycle are the block (1) includes the generation of speed
set to be 80 % and 20 %, respectively. The adjusting command and DDA algorithm, and block (2) is the
procedures of PWM duty cycle for average current current regulator; block (3) is the driver and motors,
regulation are: (1) If the winding current is greater and block (4) is the current comparators. Motion
control is dominated by a trapezoidal velocity profile
than the current command ( I fb  I cmd ), the as shown in Fig. 6. Two-axis synchronous motion
PWM module decreases the PWM duty cycle 1 % per control is realized by DDA and included in block (1)
sampling period (0.25 s ), and the minimum duty [10]. The maximum operation speed is set as 180 rpm
cycle is 20 %. (2) If the average current is smaller which is according to the real condition for a
than the current command, then PWM module commercial caving machine [10].
increases the PWM duty cycle 1 %, and the The stepping motor model is created by Sim
maximum duty cycle is 80 %. Power System module in Matlab as shown in Fig. 7.
In this strategy, the average of winding currents Furthermore, the current control module is shown in
is calculated by a counter which accumulates the Fig. 8, which is developed to generate the
amount of clock pulses for the current level being corresponding Verilog HDL file for realizing the
higher or lower than the command, and the frequency actual hardware controller by FPGA. In this module,
of clock pulse is 4 MHz. When the output of two 0.5  resistors are set to detect the current as
comparator is VA  0 , the counter increases,
in the real system.
otherwise, the counter decreases. If the accumulated
value is negative, the average of winding currents is
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 37

(1)

(4)
(2)

(3)

Figure 5: The simulation system.

To verify the accuracy of the created modelling (rpm)

system, simulations and practical experiments are
done. The simulations are carried out based on the Acceleration Run Deceleration
Matlab/Simulink and Modelsim system as shown in
Fig. 5, and the stepping motor is set on the full-step
mode. The speed commands and DDA system are 180
operated under period of 6.5 ms, and maximum 4 135
steps per sampling time are generated as shown in 90
Fig. 6; the corresponding speeds are approximated as 45
45 rpm, 90 rpm, 135 rpm and 180 rpm. The simulated k
0
results for the proposed two current regulation 1 2 3 4 (n-4)
(n-2) n
methods are demonstrated in the following. (n-3) (n-1)

Figure 6: The trapezoidal velocity profile for

speed command.
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 38

Figure 7: The hybrid stepping motor module and full-step driver module.

Figure 8: The current control module.

First, to demonstrate the four speed commands shown in Fig. 10 which is from the simulated results
shown in Fig. 6 in steady-state condition, Figs. 9 and of the average current regulation. Since the adjusting
10 are the results to demonstrate their performances. rate for the average current method is  1 % per
In Fig. 9, it shows the four step speeds, 45 rpm, 90 sampling time, the slow adjusting rate causes the
rpm, 135 rpm and 180 rpm in peak current regulation, system with a slow regulation rate in their current
and the system which is modulated in 20 kHz has response as compared with the method of peak
lower ripple current as compared with those results current regulation. Regarding the acceleration and
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 39

deceleration conditions for the two methods, Figs. 11 Phase A

PWM
and 12 illustrate their results with the constraints as Phase A Current Command

shown in Fig. 6. Fig. 11 gives the results for peak Phase A

Current
current regulation in acceleration and deceleration
conditions, and Fig. 12 is the corresponding results of Phase B
average current strategy. PWM

Phase B
Current
Phase A
PWM
Phase A Current Command

Phase A
(a)
Current

Phase B Phase A
PWM PWM
Phase A Current Command
Phase B Current Command

Phase B Phase A
Current Current

Phase B
PWM
(a) Phase B Current Command

Phase B
Current

Phase A
PWM
Phase A Current Command
(b)
Phase A
Current

Phase A
Phase B PWM
PWM Phase A Current Command
Phase B Current Command
Phase A
Phase B Current
Current

Phase B
PWM
Phase B Current Command
(b) Phase A
Current

Phase A
PWM
Phase A Current Command
(c)
Phase A
current
Phase A
Phase B PWM
PWM Phase A Current Command
Phase B Current Command

Phase B Phase A
current Current

Phase B
PWM
Phase B Current Command
(c)
Phase B
Current

Phase A
PWM
Phase A Current Command (d)
Phase A
Current
Figure 10: The simulated steady-state currents
Phase B
PWM respond to the average current
Phase B Current Command
control method for speed commands:
Phase B
Current (a) 45 rpm, (b) 90 rpm, (c) 135 rpm
and (d) 180 rpm.
Phase A
(d) PWM
Phase A Current Command

Phase A
Figure 9: The steady-state current responses for Current

peak current control method for speed

command: (a) 45 rpm, (b) 90 rpm, (c) Phase B
PWM
135 rpm and (d) 180 rpm. Phase B Current Command

Phase B
Current

(a)
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 40

Phase A
Phase A PWM
PWM Phase A Current Command
Phase A Current Command
Phase A Phase A
Current Current

Phase B
PWM Phase B
Phase B Current Command PWM
Phase A Current Command
Phase B Phase B
Current Current

(b) (b)

Figure 11: The simulated responses of peak Figure 12: The simulated response of average
current regulation on: (a) current regulation on: (a)
acceleration, (b) deceleration. acceleration, (b) deceleration.

Comparing the four simulated results, owing to

the slow change rate of duty cycle, the average
current regulation has a bigger current ripple than the
results from the method of peak current regulation.
However, the average current method has a smaller
noise component when compared with the peak
current method. For average current regulation, to
increase the adjusting rate, such as  2%/s or even
bigger, it may lead to the current response similar to
a PI controller with a high proportional gain. If the
adjusting rate is large enough, the responses
controlled by the average current regulation will
approach to the results by the peak current regulation
method.

Phase A
PWM
Phase A Current Command

Phase A
Current

Figure 13: The hardware setup for experiment.

Phase B
PWM
Phase B Current Command

Phase B
Current

(a)

Delay
PWM
Time

Figure 14: The trigger signals from FPGA-based motion controller.

 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 41

Phase A
PWM 10V/DIV

Phase B
PWM

Phase A
PWM

Phase B
PWM

Figure 15: The one-axis trigger signals measured by oscilloscope.

PWM
10V/DIV

Current

1A/DIV

(a)

PWM
10V/DIV

Current

1A/DIV

(b)
Figure 16: The experimental results of the gate driver signals and current responses in acceleration and
deceleration. (a) The peak current regulation algorithm; (b) the average current regulation
algorithm.
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 42

5. The Experimental Setup and To verify the validness and correctness, the
conditions of hardware realizations are set the same
Results as the software evaluation process as shown in
Section 4. The PWM signals of power converter are
To actually verify the validness of system captured by a logic analyzer and digital oscilloscope
modelling and hardware controller design, an as shown in Figs. 14 and 15, respectively. It is
XYZ-table which is driven by stepping motors is obvious that the current control process includes the
built as shown in Fig. 13. It includes the human dead-time module, delay-time module and PWM
machine interface (HMI), the power converter, the module.
speed command generator, comparator and current
regulator as the block diagram shown in Fig. 5. HMI First, the effects of acceleration and
programmed by C++ language can directly read the deceleration for both the current control strategies are
G codes and convert them into a series of stepping shown in Fig. 16, where there are the current
commands. The stepping commands on HMI are responses from the hardware realized by a peak
transferred to the stepping motor drive system current regulator. The traces are the PWM signals of
through the UART interface. The stepping motor gate driver and the corresponding phase current,
drives are controlled by FPGA-based system, and the respectively. Besides, Fig. 16(b) shows the results of
hardware Verilog code is created from those a current control by the average current regulator.
modelling as stated in Section 4, and realized by The two figures are very similar to the results as the
Altera Cyclone III C10 FPGA. The power converter simulations by Matlab/Simulink and ModelSim. The
includes the photocouples, gate drivers IR2101 and peak current response is fast enough to regulate the
power MOSFET. The experimental current responses stator current to a quite small ripple as compared with
are captured by a current probe and digital the average current algorithm. However, the peak
oscilloscope to illustrate their performances. current strategy has a bigger high frequency noise
The procedures of experiment are as follows: than average current one.
1) The controller is designed to drive the Afterward, the following demonstrations are
XYZ-table for a commerical caving the four steady-state current responses of 45 rpm, 90
machine. The stepping commands are from rpm, 135 rpm and 180 rpm, respectively, to verify the
the G-code on HMI, and they are performance in different operating speeds. Figs.
transferred to the FPGA-based controller 17(a)~(d) are the results for motors controlled in peak
by UART interface with 19200 bps. current regulation, and Fig. 18(a)~(d) are the
2) The acceleration and deceleration are corresponding results for average current regulation.
according to the desired trapezoidal These responses and trajectories deeply match to the
velocity profile as shown in Fig. 6. The co-simulation results as shown in Section 4. Through
stepping commands and the constraints of those simulation results and hardware realized system,
maximum speed are also decided by the the modelling about the stepping motor drive system
HMI system. incorported with an XYZ-table and the hardware
3) An embedded micro controller 8051 in controller created by Verilog HDL codes are
FPGA receives the serial commands from successfully modelled and hardware realized.
HMI, and converts them into the stepping
commands for 3-axis stepping motor
drives. According to the stepping
commands, the designed three control
modules: dead-time module, delay-time
module and PWM module, are then
sequentially executed to control the
currents on the desired level. The
experimental results about the hardware
regulators are shown in the following.
International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 43

PWM

10V/DIV

1A/DIV
Current

(a)

PWM

10V/DIV

1A/DIV
Current

(b)

PWM

10V/DIV

1A/DIV
Current

(c)
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 44

PWM

10V/DIV

1A/DIV
Current

(d)

Figure 17: The steady-state current responses for peak current control method on speed command: (a) 45
rpm, (b) 90 rpm, (c) 135 rpm and (d) 180 rpm.

PWM

10V/DIV

1A/DIV
Current

(a)
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 45

PWM

10V/DIV

1A/DIV
Current

(b)

PWM

10V/DIV

1A/DIV
Current

(c)

PWM

10V/DIV

1A/DIV
Current

(d)
Figure 18: The steady-state current responses for average current control method on speed command: (a)
45 rpm, (b) 90 rpm, (c) 135 rpm and (d) 180 rpm.
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 46

6. Conclusion [5]. J. X. You and J. H. Kim, “Design of a

Low-Vibration Micro-Stepping Controller for
In the paper, we have proposed two hardware Dom-Camera,” International Conference on
implemented current regulators by peak current and Mechatronics and Automation, pp. 296-301,
average current methods for stepping motor drive 2009.
systems. The designed systems are first modeled by
Matlab/Simulink and Modelsim. The proposed [6]. Y. Mengda and Z. Min, “A Research of A New
systems are first evaluated by simulations with the Technique on Hardware Implementation of
co-design including the Verilog HDL codes and Control Algorithm of High-Subdivision for
Matlab/Simulink system. And the cores of
Stepper Motor,” The 5th IEEE Conference on
hardware regulators are implemented on an Altera
Cyclone III FPGA to verify the performances. Industrial Electronics and Applications, pp.
Co-simulation and hardware realized controllers 115-120, 2010.
show that the proposed modelling systems and their
[7]. J. Xi, G. Liao and W. Yang, “Study of Stepping
hardware design methodologies can be easily used to
help the user evaluate their developing system on the Motor Subdivision Driver,” International
hardware functions and the system’s performances Conference on Intelligent Computation
when FPGA are used to the digital controller design. Technology and Automation, vol. 3, pp.
443-446, 2010.
Acknowledgement [8]. N. Q. Le and J. W. Jeon, “An Open-loop
Stepper Motor Driver Based on FPGA,”
The authors would like to thank the financial International Conference on Control,
support by the project no. NCUT201314 from the Automation and Systems, pp.1322-1326, Oct.
National Chin-Yi University of Technology.
17-20, 2007.
[9]. S.-W. Moon, Y.-J. Kim, Y.-T. Lim and D. H.
References Kim, “Missing Step Detection in a High Speed
Micro Stepping Motor Using Current
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[3]. Y. P. Siwakoti and G. E. Town, “Design of Chiu-Keng Lai received the
B.S. degree in electronic
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engineering from National
Drives Using MATLAB Simulink,” Taiwan University of Science
IEEE/ECCE Asia, pp. 571-577, June, 2013. and Technology, Taipei,
[4]. Z. Ma, J. Gao and R. Kennel, “FPGA Taiwan in 1989, and the M.S.
and Ph.D. degrees in electrical
Implementation of a Hybrid Sensorless Control engineering from National
of SMPMSM in the Whole Speed Range,” Central University, Chung-Li, Taiwan, in 1991 and
IEEE Trans. on Industrial Informatics, vol. 9, 2001, respectively.In 1992, he joined National
Chin-Yi University of Technology, Taichung,
no. 3, pp. 1253-1261, Aug. 2013. Taiwan, where he is an Associate Professor in the
Department of Electrical Engineering. His teaching
and research interests include variable structure
system designs and applications for motor drive
systems, PC-based control system designs with
LabVIEW and Matlab/Simulink, and digital circuit
 International Journal of Computer, Consumer and Control (IJ3C), Vol. 5, No.3 (2016) 47

designs and applications with FPGAs on motor

drive systems and motion controls.

Wei-Nan Chien received the

B.S. and M.S. degrees from
National Chin-Yi University
of Technology, Taichung,
Taiwan in 2011 and 2014
respectively, all in electrical
engineering.

Shou-Liang Tsai received the

B.S. and M.S. degrees from
National Chin-Yi University
of Technology, Taichung,
Taiwan in 2011 and 2013
respectively, all in electrical
engineering. He is now with
the Hiwin Mikrosystem Corp.
in Taichung, Taiwan as an engineer.

Yaw-Ting Taso received the

B.S. and M.S. degrees from
National Chin-Yi University
of Technology, Taichung,
Taiwan in 2012 and 2015
respectively, all in electrical
engineering.