12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

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Stepper Motor: Know The Working Principle, Types, & Applications

Last Updated on Sep 20, 2024

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A stepper motor, also known as step motor or stepping motor, is a brushless DC electric motor that
converts digital pulses into mechanical shaft rotation incrementally (around 1.8 degrees for a typical
stepper) rather than continuously rotating as DC motors do.

The stepper motor works on the principle of electromagnetic induction, where a rotating magnetic field
is used to turn the motor's shaft incrementally.

It is one of the most commonly used motion control components in industrial systems due to its
simplicity of operation, accuracy and smooth movement.

In this article, we will dive deep into the working principle, construction of stepper motor, different
types, advantages and applications of stepper motors to gain a comprehensive understanding of this
versatile device.

What Is Stepper Motor

A stepper motor is essentially a synchronous motor that divides a full rotation into a number of equal
steps (around 200 steps). It is an electromechanical device which converts digital pulses into mechanical
shaft rotation.

Some key aspects of a stepper motor include:

It has a rotor with permanent magnets and a stator that contains winding. The winding is divided
into phases (often two or more).
Each step is caused by the energizing of the motor's stator winding in a particular sequence. The
rotor aligns itself to the nearest stator pole.
Step angle is defined as the angular rotation produced per pulse applied to the motor. A typical
step angle is 1.8 degrees.
Speed and distance covered by the motor are directly proportional to the rate at which pulses are
applied.
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12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

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Working Principle Of Stepper Motor

Stepper motor working principle:

The basic working principle of a stepper motor can be explained as follows:

It consists of a stator (stationary outer cylinder) and a rotor (inner cylinder attached to the shaft).
The stator contains electromagnets which are organized into groups known as "phases". The most
common types have two or four phases.
The rotor contains permanent magnets or pole pieces. It is attached to the motor shaft which
extends outside for connection to a device.
When one phase is energized, it rotates the rotor slightly in one direction. As soon as the first
phase is energized, the second one is powered to continue the motion.
Repeating the process of energizing the phases in sequence causes the rotor to rotate in steps.
By controlling the sequence of energizing the electromagnets, the direction of rotation can be
controlled.
Varying the number of steps per pulse gives finer position resolution. Higher number of steps per
pulse means smaller angular rotation per step.

Stepper motor diagram:

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12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

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Fig- Construction Diagram of Stepper Motor

A stepper motor converts digital pulses into mechanical rotation incrementally by energizing its
electromagnetic stator coils in a sequence. This makes it suitable for open-loop precision motion
control applications.
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Step Angle in Stepper Motor

Step angle is defined as the angular rotation produced by the stepper motor per pulse given as input. A
standard step angle varies between 1.8° to 0.9°. Smaller the step angle, better the positional accuracy
and higher the number of steps per revolution.

Common step angles of 1.8° gives a resolution of 200 steps/revolution while 0.9° gives 400
steps/revolution. Microstepping techniques can produce step angles less than 1° for high precision
applications.

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Types of Stepper Motor

There are mainly three types of stepper motors based on the rotor arrangements. They are as follows:

Stepper motor types:

Fig- Block Diagram Of Types Of Stepper Motor

Variable Reluctance Stepper Motor

In variable reluctance (VR) stepper motors, the rotor contains soft iron teeth while the stator contains
electromagnets only. It works on the principle of minimum magnetic reluctance. When one
electromagnet is powered, the rotor teeth align to reduce reluctance. When the next electromagnet is
powered and the first one turned off, the rotor rotates slightly to align again, thus producing step
motion. VR stepper motors are less efficient but simpler in construction compared to permanent
magnet types.

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12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

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Fig- Stator of Stepper Motor

Construction: VR stepper motors consist of a rotor with teeth and stator windings. The rotor
aligns itself with the stator poles when energized, causing rotation.

Advantages:

Simple construction leads to low manufacturing costs.

High torque output compared to size.
Suitable for applications requiring moderate precision.

Permanent magnet rotor

Permanent magnet (PM) stepper motors use strong permanent magnets in the rotor. The stator
contains electromagnets only. The rotor aligns itself to the nearest stator pole depending on which
electromagnet is powered. It generates higher torque compared to variable reluctance type. PM
steppers are more efficient and produce precise stepping but the rotor magnets increase its cost.

Construction: PM stepper motors feature a rotor with permanent magnets and stator windings. The
interaction between the magnetic fields generates rotational motion.

Advantages:

Higher efficiency and torque compared to VR motors.

Precise positioning and control.
Lower power consumption.

Hybrid Stepper Motor(combination of VR and PM type)

Hybrid stepper motors combine features of both PM and VR motors to achieve high performance in
small form factor.
The rotor contains both soft-iron teeth and permanent magnet segments. This utilizes the advantages
of high torque due to magnets as well as wide polar arc due to salient rotor poles. Hybrid steppers are
most commonly used due to their efficiency, precision and reasonable cost.

Construction: Hybrid stepper motors integrate elements from both VR and PM designs, featuring a
rotor with permanent magnets and toothed stator poles.
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Reduced step size for smoother motion.
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12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

Wide range of applications, from CNC machines to 3D printers.

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Advantages of Stepper Motor

Some key advantages of using stepper motors include:

Precise positioning over full or part rotation with high resolution.

Excellent speed and position control in open loop systems without feedback devices.
Ability to start, stop and operate at constant angular velocity with high degree of precision.
Hold their position efficiently without power due to highly detented nature.
Easy control using pulses which makes programming simpler.
Less maintenance required as there are no brushes.
Suitable for applications like CNC machines where position must be accurately controlled.

Disadvantages of Stepper Motor

Some disadvantages include:

produce less torque compared to brushed DC motors of similar size.

Vibration and resonance are likely if not designed properly.
Require driver circuit to function properly which increases cost.
Feedback devices may be required for applications requiring high level of precision.
Speed variations at higher output speeds due to limitations in response time.

Applications of Stepper Motor

Some common applications of stepper motors include(Stepper motor applications)

CNC machines like routers, lathes, mills, 3D printers.

Peripheral equipment like printers, scanners, plotters, tape drives and CD/DVD drives.
Industrial robotics, material handling, wafer handling equipment.
Medical equipment like blood analyzers, imaging equipment.
Automated production machinery like labeling machines.
Scientific instruments like spectroscopy equipment.
Desktop CNC machines, laser cutters, laser engravers.
CCTV camera systems - for focus/zoom lens control.
Radio-controlled vehicles,quadcopters, cranes for positioning.

Difference between Stepper Motor and Servo Motor

While stepper motors and servo motors share some similarities, they exhibit distinct differences in
terms of performance and control:

Stepper Motor Servo Motor

Open loop control as position is calculated Closed loop control using feedback for higher
by step counts. accuracy.
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12/24/24, 1:40 AM Stepper Motor: Know The Working Principle, Types, & Applications

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Holds position without any power. Requires continuous power for holding position
using feedback.

Less accurate at high speeds due to delay More accurate at all speeds using feedback
between pulses. control.

Makes a full rotation in discrete steps. Can rotate continuously in any position.

Less complex driver required. Require more complex drivers including an

amplifier.

Applications include printers, scanners, CNC Applications include robotics, industrial

machines. automation, 3D printers.

Conclusion
Stepper motors are versatile actuators that excel at applications requiring precise positioning control.
Their ability to divide a rotation into increments, hold position without feedback and ease of operation
makes them well suited for open-loop motion control.

With the advancements in motor design and driver technologies, their performance is ever improving
while costs are declining. Stepper motors will certainly continue dominating precision motion
applications like 3D printing, robots, CNC machines etc.

With their unique working principles, diverse types, and wide-ranging applications, stepper motors
continue to drive innovation across various industries. Understanding the intricacies of stepper motors
is essential for engineers and enthusiasts alike, as they navigate the complexities of modern
automation and robotics.

This article summarises all the information related to Stepper Motor, which helps in propelling your
preparation for various AE/JE and ESE examinations. You can visit the Testbook app to keep yourself
updated with all the exam-oriented information related to the upcoming examination, like SSC JE,
GATE, ESE, RRB JE, and state AE/JE Exams.

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Faq Related To Stepper Motor

What is step angle in stepper motor?

What is the difference between variable reluctance and permanent magnet stepper motor?

Which is more efficient - stepper motor or servo motor?

What type of motion is produced by a stepper motor - continuous or discrete?

What is a stepper motor driver?

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