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Lab 4 V3.0
1.0
Introduction
The objective of this lab is to examine the operation of a typical stepping motor.
Stepping motors are widely used wherever precise control of the position of an object is required.
One of the main uses of these devices is in controlling the position of the heads used to read and
write data in floppy disk drives. They are also used extensively in robots. The precise control
stepping motors provide is achieved at a cost: they cannot match the torque or speed of more
conventional motors of the same size and weight. (The internal structure and electrical drive
arrangements of stepping motors vary, so you should not assume that every stepping motor you
encounter in the future will operate exactly like the one used in this experiment).
2.0
The stepping motor used in this lab consists of a permanently magnetized rotor which
turns inside a stator, as shown in Fig. 1. A disassembled motor may be available for inspection
in the lab. The rotor is built in two sections, one magnetized as a north pole and the other as a
south pole. The sections are separated by a small air gap and attached to a non-magnetic shaft.
Both sections have 45 evenly spaced teeth cut into their surfaces. Although the teeth look like
those of an ordinary gear wheel, they do not serve a mechanical function. The teeth for the north
pole section are offset by one half of a tooth from the south pole section, as shown in Fig. 2. This
offset is essential for the operation of the motor.
Figure 2: North and south pole rotor sections have offset teeth.
The stator contains eight soft" iron pole pieces, as shown in Fig. 3. Evenly spaced
teeth are also cut into the surfaces of the pole pieces, but these teeth have a slightly smaller pitch
than those on the rotor (the pitch of the stator teeth is 48 per revolution). This lack of matching
between the stator and rotor teeth is also essential for motor operation. The pole pieces are
wound with copper wire coils. The pole pieces produce effectively no magnetic field unless the
coils are energized. The poles are divided into two groups attached to separate electrical circuits.
One group is attached to the phase 1 (1) drive circuitry, the other to phase 2 (2). Within the
phase 1 group there are two windings sharing a common center tap. These windings will be
labeled 1a and 1b. Both the 1a and 1b windings wrap around every pole in the phase 1 group
(a so-called bifilar winding). However, the coils are wound in opposite directions so that, for
example, when 1a or a2 is energized the surfaces of the pole pieces labeled N in Fig. 3 become
magnetic north poles, while the pole pieces labeled S become magnetic south poles. When
winding 1b is energized the polarity of the pole surface reverses. Only one of the 1a and 1b
windings is energized at any given time, an arrangement referred to as unipolar drive. The phase
2 coils 2a and 2b are configured in a similar fashion. The electrical connection of the coils is
summarized in Fig. 4.
Next suppose winding 2b is energized, so that pole piece Y becomes a south pole. There
is now an attractive force between pole piece Y and the north teeth of the rotor, causing the rotor
to rotate slightly in the clockwise direction until a new equilibrium position is reached where the
attractive forces to pole pieces X and Y are balanced. If the 1a drive is next shut off, the rotor
rotates until its north teeth align with the teeth of pole piece Y, since the force from pole piece X
is now small. The waveforms required for a complete cycle are shown in Fig. 6. At the end of
the cycle, the rotor has moved by one tooth (360o/45 = 8o). On each step the rotor moves 8/4o =
2o.
In the above description the coils were either fully excited or not powered. By varying
the current applied to the individual coils between zero and the maximum value, it is possible to
move the rotor to intermediate positions. For example, one might apply 25% of the maximum
current to winding 1a and 75% to 2b. Typically the required drive voltages are generated by
digital control circuitry. With suitably fine control over the voltages applied to different
windings, extremely precise orientation of the rotor position is possible. For example, if the
voltage applied to the coils can be specified as one of 28 = 256 equally spaced levels
(corresponding to 8 bit D to A conversion), the 2o angular resolution obtained in full step mode
can be improved to 2o/256 = 0.008o. This precise control is bought at the price of rotation rate,
since there is a limit to the speed at which the control electronics can output new phase values.
(Typically each phase requires a current supply of more than 1 A, and it is not trivial to switch
such large currents quickly).
4. Measurements
4.1 Full Step Mode
a) Select single step operation on the PC set the clutch current to minimum so that the shaft can
turn freely. Choose clockwise rotation and reset the controller. LEDs will light indicating
which windings are energized. Using a DMM, measure and record the voltages across the
1a, 1b, 2a and 2b winding. The connections of the positive (DMM+) and common (DMM) terminals required can be read from Fig. 4, and are summarized in the table below.
Table 1.
WINDING
DMM-
DMM+
1a
RED
BLACK
1b
RED/WHITE
BLACK
2a
BLUE
BLACK
2b
BLUE/WHITE
BLACK
Also measure and record the current I1 flowing in the 1 coils using the Wavetek DMM.
Set the speed in the stepper motor controller to an appropriate value that gives enough time to
make the measurements. Repeat the above measurements of drive voltage and current for
each step the motor takes. Make a table like that shown in Table 2. to record your data.
b) Sketch the winding drive voltages 1a, 1b, 2a and 2b as a function of step index, producing a
graph resembling Fig. 6.
c) Determine the number of steps required for a complete 360o revolution of the shaft.
d) Set the controller for counterclockwise operation and push reset. Repeat the above
measurements. Prepare a table similar to Table 1 summarizing your results. Sketch the drive
voltages as a function of step index, and compare with the corresponding graph in part (b)
above.
e) Return the controller to clockwise operation and press reset. Next apply maximum current to
the clutch, making it lock up. Adjust the top knob on the spring balance until the shaft slips,
indicating that the holding torque has been exceeded. Record the holding torque and the
angular deflection of the shaft at just before slipping occurs, then return the clutch current to
minimum. The lever arm is 10 cm.
Table 2.
STEP
1
2
3
4
1a (V)
1b (V)
2a (V)
2b (V)
I1 (A)
Given that the rotor moves one tooth in a complete cycle of 8 steps, what is the angular
resolution for this mode?
b) Stop the motor, lock the clutch by setting the clutch current to maximum, start the motor, and
measure the holding torque.
c) Reset the motor, step the motor 8 times using the PC, lock the clutch, and measure the
holding torque. How does this result compare with that seen in b?
Table 3.
STEP
1
2
3
4
5
6
7
8
1a (V)
1b (V)
2a (V)
2b (V)
I1 (A)