In this guide, we will explore how to achieve forward and reverse control of a stepper motor using a PLC (Programmable Logic Controller) and HMI (Human-Machine Interface). Below are the setup and programming steps required for precise control.
Whether in life or in industrial life, the use of motors is inseparable. In order to meet the needs of different industries, more and more types have gradually appeared on the market. But many users do not know how to choose when purchasing. In fact, to choose the right product, we must first compare different products. Let's take a look at the difference between a DC geared motor and a stepper motor.
Economy linear stepper motor is a stepper motor with lead screw, this stepper motor can be used in many high-precision requirements including precision calibration, precision fluid measurement, and precise positional movement, it can directly move linearly, which can make the machine miniaturized. The step size of the linear stepper motor is determined by the step angle of the motor and the pitch of the internally threaded nut and the lead screw. In order to ensure high working efficiency, there must be a certain degree of freedom between the rotor and the lead screw, which requires a certain gap between the two, which is about 0.03 to 0.08 mm backlash.
A stepper motor is a motor that converts electrical pulse signals into corresponding angular displacement or linear displacement. Each time a pulse signal is an input, the rotor rotates an angle or moves forward one step, the angular displacement or linear displacement it outputs is proportional to the number of input pulses, and the rotational speed is proportional to the pulse frequency. Therefore, the ATO stepper motor is also called a pulse motor.
A stepper motor, also known as step motor or stepping motor, is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor's position can be commanded to move and hold at one of these steps without any position sensor for feedback (an open-loop controller), as long as the motor is correctly sized to the application in respect to torque and speed.
Stepper motor is an open-loop control motor that divides a full rotation into a number of equal steps. The motor's position can be controlled to move and hold at one of these equal steps. Stepper motors come in many different sizes and styles, and they are widely used in a variety of automated control systems.
A Stepper motor is an open-loop control element stepper motor that converts electrical pulse signals into angular displacement or linear displacement. By controlling the sequence, frequency and number of electrical pulses applied to the motor coils, it can realize the steering, speed and rotation angle control.
Hybrid stepper motor is a stepper motor designed by combining the advantages of permanent magnet and reactive. It is divided into 2 phase, 3 phase and 5 phase. The two phase stepping angle is generally 1.8 degrees, the three phase stepping angle is generally 1.2 degrees, and the five phase stepping angle is generally 0.72 degrees.
Stepper motor is one of many motors. Although it is the same as other motors in terms of functional types, it is different from other types of motors in terms of working principle and structural design. The operation form, functional performance, applicable aspects and performance of different stepping motors are different from other types of motors.
The servo motor can make the speed and position control accuracy become very accurate, and can convert the voltage signal into torque and speed to drive the control object. The speed of the servo motor rotor is controlled by the input signal and can react quickly. In automatic control systems, servo motors can be used as actuators. Servo motor has the characteristics of small electromechanical time constant and high linearity, and it can convert the received electrical signal into angular displacement or angular velocity output on the motor shaft. It can be divided into two categories: DC and AC servo motors. Its main feature is that there is no autorotation when the signal voltage is zero, and the speed decreases at a uniform speed with the increase of torque.
When the same stepper motor works with different drive schemes, the torque-frequency characteristics are also very different.
When the stepper motor is working, the pulse signal will be added to each phase winding in turn in a certain order (the ring distributor in the stepper motor driver controls the way the winding is energized and de-energized).
Unlike other motors, the nominal rated voltage and rated current of a stepper motor are only reference values. Because the stepper motor is powered by pulse, the power supply voltage is its highest voltage, not the average voltage. Therefore, the stepper motor can work beyond its rated value range. However, when choosing, it should not deviate too far from the rated value.
The stepper motor does not accumulate errors: The accuracy of the general stepper motor is 3%-5% of the actual step angle, and it cannot be accumulated.
Brushless dc motor
The brushless DC motor is composed of a motor body and a brushless motor driver. It is a typical mechatronics product. Because the brushless DC motor runs in a self-control mode, it will not add a start winding to the rotor like a synchronous motor started under heavy load under variable frequency speed regulation, nor will it cause oscillation and loss of step when the load changes suddenly. The permanent magnets of small and medium-capacity brushless DC motors now mostly use high magnetic energy level rare earth neodymium iron boron (Nd-Fe-B) materials.
Stepper motor
A stepper motor is a motor that converts electrical pulse signals into corresponding angular or linear displacements. Every time a pulse signal is input, the rotor rotates an angle or moves forward. The output angular displacement or linear displacement is proportional to the number of input pulses, and the speed is proportional to the pulse frequency. Therefore, the stepper motor can be called the pulse motor.
As a common electrical actuator, stepper motor is widely applied in automatic control field. Stepper motor needs to be equipped with a special drive power the output of which is controlled by external pulse signal and direction signal. Each pulse signal can make stepper motor rotate a fixed angle, which is called step angle. Total angle and speed of rotation respectively depend on the number and frequency of pulse. The direction of rotation depends on direction signal. For a equipment with a known transmission ratio, the movement distance and speed of its parts can be controlled by controlling the number and frequency of pulse without the requirements for the feedback of distance and speed signals; and direction signal can control moving direction. Therefore, open loop control is a simple and economic electronic control technical scheme.
Generally speaking, one of the commonly used methods to achieve precise linear positioning is to make a set of linear positioning system by pairing the motor with the sliding bar. Here we will discuss several different ways to create a linear actuator by using the sliding bar and stepper motor. The stepper motor is the most commonly used selection in the application of motor control because if the operation is correct, it is an economic solution that can achieve accurate positioning without the need of position feedback.
Stepper linear actuator can be divided into three types, external shaft type, non-captive shaft type and captive type.
Stepper motor is to receive the pulse current to achieve speed, position and direction of control. The number of pulses determines the position of the stepper motor, the pulse rate determines the motor speed and pulse direction determines the steering of motor. The control mode of most stepper motor is using PLC to send pulses to the driver and then drive motor to operate. Pulse mode has been around for several decades, and for some applications requiring high frequency, the pulse type can no longer meet the requirements, and it needs to be controlled by the bus type.
Stepper motor is an actuator that transforms the digital pulse signal into angular displacement. Namely, when stepper drive receives a pulse signal, it drives the stepper motor to rotate at a fixed angle (i.e. step angle) in the set direction. Stepper motor is a main executive component in the modern digital control system, and has a very wide range of applications because of the following advantages:
Stepper motor is an open loop control element that transforms the electrical pulse signal into angular displacement or linear displacement. When a pulse signal is added to the motor, and the motor turns a step angle. The existence of this linear relationship, and stepper motor with only periodic error and no accumulated error, makes it widely used in various fields. This article describes the application of stepper motor in electronic clocks, industrial robot and packaging machine.
Stepper motors is used in open-loop control, thus it is simple, low cost and can be widely used. However, the open-loop control of the stepper motor cannot avoid the inherent disadvantages of the stepper motor itself, that is, resonance, oscillation, step loss and difficult to achieve high speed. Correspondingly, the closed-loop control of stepper motor can make up these shortcomings, and have the advantages of open-loop drive and brushless DC servo motor.
Stepper motors are now widely used in the industrial areas, but from time to time some problems with stepper motors occurs as follows. Aimed to these problems, there are some troubleshooting for your reference.
Stepper motor is an open-loop control motor which transforms electric pulse signal into angular displacement or linear displacement. However, there are some errors occuring between the actual angle stepper motor rotates and the theoretical step distance. There are some certain errors from one step to any other step, but the step number of each cycle of the stepper motor is the same. In the case of no step loss, the step error is not accumulated for a long time.
How to prevent step loss with stepper motor as the above mentioned? First of all, we need to know why stepper motor losses step?
