Stepper motor control lab manual

1. 1
STEPPER MOTOR CONTROL TRAINER
IT-5170

2. 2
TABLE OF CONTENTS
 Features....................................................................................................................2
 Techinical Specifications .........................................................................................4
 Theory......................................................................................................................5
 Experiment 1............................................................................................................9
 Experiment 2..........................................................................................................11
 Experiment 3..........................................................................................................13
 Experiment 4..........................................................................................................15
 List of Accessories.................................................................................................17

3. 3
FEATURES
 A Self contained trainer
 Built in DC Power supply
 Compact size

4. 4
TECHINICAL SPECIFICATIONS
Generator : waveform : TTL
Amplitude : 5V p-p
Motor : Stepper
Controller Section
Drivers : Uni-polar, Bi-polar
Switches : Manual Operation
Power : 220V-AC 50Hz
Fig. 1

5. 5
THEORY
Motion Control, in electronic terms, means to accurately control the movement of an
object based on speed, distance, load, inertia of a combination of all these factors.
There are numerous types of motion control systems, including; Stepper Motor,
Linear Step Motor, DC Brush, Brushless, Servo, Brushless Servo and more.
In Theory, a Stepper motor is a marvel in simplicity. It has no brushes, or contacts.
Basically it’s a synchronous motor with the magnetic field electronically switched to
rotate the armature magnet around.
A stepper motor is an electromechanical device which converts electrical pulses into
discrete mechanical movements. The shaft or spindle of a stepper motor rotates in
discrete step increments when electrical command pulses are applied to it in the
proper sequence. The motors rotation has several direct relationships to these applied
input pulses. The sequence of the applied pulses is directly related to the direction of
motor shafts rotation. The speed of the motor shafts rotation is directly related to the
frequency of the input pulses and the length of rotation is directly related to the
number of input pulses applied.
Types of Stepper Motors
There are basically three types of stepping motors; variable reluctance, permanent
magnet and hybrid. They differ in terms of construction based on the use of
permanent magnets and/or iron rotors with laminated steel stators.
Variable Reluctance
The variable reluctance motor does not use a permanent magnet. As a result, the
motor rotor can move without constraint or “detent” torque. This type of construction
is good in non industrial applications that do not require a high degree of motor
torque, such as the positioning of a micro slide.
A B
Stator Pole
A1
C
Winding
Rotor
The variable reluctance motor in the above illustration has four “stator pole sets” (A,
B, C,), set 15 degrees apart. Current applied to pole A through the motor winding
causes a magnetic attraction that aligns the rotor (tooth) to pole A. energizing stator
Pole B causes the rotor to rotate 15 degrees in alignment with pole B. this process will
continue with pole C and back to A in a clockwise direction. Reversing the procedure
(C to A) would result in a counterclockwise rotation.

6. 6
Permanent Magnet
The permanent magnet motor, as the name implies has, a permanent magnet rotor. It
is a relatively low speed, low torque device with large step angles of either 45 or 90
degrees. Its simple construction and low cost make it an ideal choice for non
industrial applications, such as a line printer print wheel positioned.
A
1
D1 B
D B1
C1
C
Unlike the other stepping motors, the PM motor rotor has no teeth and is designed to
be magnetized at a right angle to its axis. The above illustration shows a simple, 90
degree PM motor with four phases (A-D). Applying current to each phase in sequence
will cause the rotor to rotate by adjusting to the changing magnetic fields. Although it
operates at fairly low speed the PM motor has a relatively high torque characteristic.
Hybrid
Hybrid motors combine the best characteristics of the variable reluctance and
permanent magnet motors. They are constructed with multi-toothed stator poles and a
permanent magnet rotor. Standard hybrid motors have 200 rotor teeth and rotate at 1.8
step angles. Other hybrid motors are available in 0.9 and 3.6 step angle
configurations. Because they exhibit high static and dynamic torque and run at very
high step rates, hybrid motors are used in a wide variety of industrial applications.
Stator Winding
otor (PM)
C
Bipolar Motor
Bipolar motors have logically a single winding per phase. The current is a winding
needs to be reversed in order to reverse a magnetic pole, so the driving circuit must be
more complicated, typically with an H-bridge arrangement. There are two leads per
phase, none are common.
A Stator
B
S
N N D
1
R
S S
C
1
N N
B1
D S
A
1
A

7. 7
A+
Acom
A-
B+ B-
Bcom
Unipolar Motor
A Unipolar stepper motor has logically two windings per phase, one for each direction
of current. Since in this arrangement a magnetic pole can be reversed without
switching the direction of current, the commutation circuit can be made very simple
(e.g. a single transistor) for each winding. Typically, given a phase, one end of each
winding is made common: giving three leads per phase and six leads for a typical two
phase motor. Often, these two phase commons are internally joined, so the motor has
only five leads.
4 6
Coil 4
1
Coil 1
Center
Shaft Coil 3
3
Coil 2
5 2
Half Step
Half step simply means that the motor is rotating at 400 steps per revolution. In this
mode, one winding is energized and then two windings are energized alternately,
causing the rotor to rotate at half the distance, or 0.9:’s. (the same effect can be
achieved by operating in full step mode with a 400 step per revolution motor). Half
stepping is a more practical solution however, in industrial applications. Although it
provides slightly less torque, half step mode reduces the amount “jumpiness” inherent
in running in a full step mode.
Microstep
Micro stepping is a relatively new stepper motor technology that controls the current
in the motor winding to a degree that further subdivides the number of positions
between poles. AMS micro step drives are capable of rotating at 1/256 of a step (per
step), or over 50,000 steps per revolution.
S N

8. 8
Driver Voltage
The higher the output voltage from the driver, the higher the level of torque vs. speed.
Generally, the driver output voltage should be rated higher than the motor voltage
rating.
Motor Stiffness
By design, stepping motors tend to run stiff. Reducing the current flow to the motor
by a small percentage will smooth the rotation. Likewise, increasing the motor current
will increase the stiffness but will also provide more torque. Trade-offs between
speed, torque and resolution are a main consideration in designing a step motor
system.
Motor Heat
Step motors are designed to run hot (50-90oC). However, too much current may cause
excessive heating and damage to the motor insulation and windings. AMS step motor
products reduce the risk of overheating by providing a programmable Run/Hold
current feature.
Driver Technology Overview
The stepper motor driver receives low-level signals from the indexer or control
system and converts them into electrical (step) pulses to run the motor. One step pulse
is required for every step of the motor shaft. In full step mode, with a standard 200
step motor, 200 step Pulses are required to complete one revolution. Likewise, in
micro-stepping mode the driver may be required to generate 50,000 or more step
pulses per revolution.

9. 9
EXPERIMENT 1
Objective:
Stepper motor in unipolar mode and Full step Operation.
Requirements
1. Stepper Motor Control Trainer IT-5170
2. 2mm Patch cords
Experimental Setup:
Refer to the following diagram to configure setup for the present experiment
Fig. 1.1
Procedure:
Switch off main Power supply
1. Carry out the following connections according to Fig. 1.1
2. Connect Clock output TP1 to the clock input TP2 of Motion Control block
3. Connect Logic Switches output S3 to CW/CWW input TP3.
4. Connect Logic Switches output S2 to Half/Full input TP4.
5. Connect Logic Switches output S1 to Enable input TP5.

10. 10
6. Connect output pin A TP6 of Motion Control block to pin A TP15 of Unipolar
Power Drive.
7. Connect output pin B TP7 of Motion Control block to pin B TP16 of Unipolar
Power Drive.
8. Connect output pin C TP8 of Motion Control block to pin C TP17 of Unipolar
Power Drive.
9. Connect output pin D TP9 of Motion Control block to pin D TP18 of Unipolar
Power Drive.
10. Connect output pin A+ TP19 of Unipolar Power Driver block to pin A+ TP39 of
Stepper Motor section
11. Connect output pin Acom TP20 of Unipolar Power Drive block to pin Acom
TP40 of Stepper Motor section
12. Connect output pin A- TP21of Unipolar Power Drive block to pin A- TP41 of
Stepper Motor section
13. Connect output pin B+ TP22 of Unipolar Power Drive block to pin B+ TP42 of
Stepper Motor section
14. Connect output pin Bcom TP23 Unipolar Power Drive block to pin Bcom TP43 of
Stepper Motor section
15. Connect output pin B- TP24 of Unipolar Power Drive block to pin B- TP44 of
Stepper Motor section.
16. Put all the logic switches in Low Position.
17. Switch on main Power supply
18. Now put the logic switch S1 to high position.
19. The Stepper motor will start to rotate in CCW direction. To change the direction
Logic Switch S3 is used.
20. Speed of motor could be control through Frequency Adjust knob.

11. 11
EXPERIMENT 2
Objective:
Stepper motor in Unipolar mode full step operation.
Requirements
1. Stepper Motor Control Trainer IT-5170
2. 2mm Patch cords
Experimental Setup:
Refer to the following diagram to configure setup for the present experiment
Fig 2.1
Procedure:
Switch off main Power supply
1. Carry out the following connections according to Fig. 2.1
2. Connect Clock output TP1 to the clock input TP2 of Motion Control block
3. Connect Logic Switches output S3 to CW/CWW input TP3.
4. Connect Logic Switches output S2 to Half/Full input TP4.
5. Connect Logic Switches output S1 to Enable input TP5.
6. Connect output pin A TP6 of Motion Control block to pin A TP15 of Unipolar
Power Drive.

12. 12
7. Connect output pin B TP7 of Motion Control block to pin B TP16 of Unipolar
Power Drive.
8. Connect output pin C TP8 of Motion Control block to pin C TP17 of Unipolar
Power Drive.
9. Connect output pin D TP9 of Motion Control block to pin D TP18 of Unipolar
Power Drive.
10. Connect output pin A+ TP19 of Unipolar Power Driver block to pin A+ TP39 of
Stepper Motor section
11. Connect output pin Acom TP20 of Unipolar Power Drive block to pin Acom
TP40 of Stepper Motor section
12. Connect output pin A- TP21of Unipolar Power Drive block to pin A- TP41 of
Stepper Motor section
13. Connect output pin B+ TP22 of Unipolar Power Drive block to pin B+ TP42 of
Stepper Motor section
14. Connect output pin Bcom TP23 Unipolar Power Drive block to pin Bcom TP43 of
Stepper Motor section
15. Connect output pin B- TP24 of Unipolar Power Drive block to pin B- TP44 of
Stepper Motor section.
16. Put all the logic switches in Low Position.
17. Switch on main Power supply
18. Now put the logic switch S1 and S2 to high position.
19. The Stepper motor will start to rotate in CCW direction. To change the direction
Logic Switch S3 is used.
20. Speed of motor could be control through Frequency Adjust knob.

13. 13
EXPERIMENT 3
Objective:
Stepper motor in Bipolar mode.
Requirements
1. Stepper Motor Control Trainer IT-5170
2. 2mm Patch cords
Experimental Setup:
Refer to the following diagram to configure setup for the present experiment
Fig 3.1
Procedure:
Switch of main Power Supply
1. Carry out the following connections according to Fig. 3.1
2. Connect Clock output TP1 to the clock input TP2 of Motion Control block
3. Connect Logic Switches output S3 to CW/CWW input TP3.
4. Connect Logic Switches output S2 to Half/Full input TP4.
5. Connect Logic Switches output S1 to Enable input TP5.
6. Connect output pin A TP6 of Motion Control block to pin A TP26 of Bipolar
Power Drive.

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7. Connect output pin B TP7 of Motion Control block to pin B TP27 of Bipolar
Power Drive.
8. Connect output pin C TP8 of Motion Control block to pin C TP28 of Bipolar
Power Drive.
9. Connect output pin D TP9 of Motion Control block to pin D TP29 of Bipolar
Power Drive.
10. Connect output pin INH1 TP10 of Motion Control block to pin INH1 TP30 of
Bipolar Power Drive
11. Connect output pin INH2 TP11 of Motion Control block to pin INH2 TP31 of
Bipolar Power Drive
12. Connect output pin SENS1 TP12 of Motion Control block to pin SENS1TP32
of Bipolar Power Drive
13. Connect output pin SENS2 TP13 of Motion Control block to pin SENS2TP33
of Bipolar Power Drive
14. Connect output pin A+ TP34 of Bipolar Power Driver block to pin A+ TP39
of Stepper Motor section
15. Connect output pin A- TP35of Bipolar Power Drive block to pin A- TP41 of
Stepper Motor section
16. Connect output pin B+ TP36 of Bipolar Power Drive block to pin B+ TP42 of
Stepper Motor section
17. Connect output pin B- TP37 of Bipolar Power Drive block to pin B- TP44 of
Stepper Motor section.
18. Put all the logic switches in Low Position.
19. Switch on main Power supply
20. Now put the logic switch S1 and S2 to high position.
21. The Stepper motor will start to rotate in CCW direction. To change the
direction Logic Switch S3 is used.
22. Speed of motor could be control through Frequency Adjust knob.

15. 15
EXPERIMENT 4
Objective:
Stepper motor in Bipolar mode without current sense.
Requirements
1. Stepper Motor Control Trainer IT-5170
2. 2mm Patch cords
Experimental Setup:
Refer to the following diagram to configure setup for the present experiment
Fig 4.1
Procedure:
Switch of main Power Supply
1. Carry out the following connections according to Fig. 4.1
2. Connect Clock output TP1 to the clock input TP2 of Motion Control block
3. Connect Logic Switches output S3 to CW/CWW input TP3.
4. Connect Logic Switches output S2 to Half/Full input TP4.
5. Connect Logic Switches output S1 to Enable input TP5.
6. Connect output pin A TP6 of Motion Control block to pin A TP26 of Bipolar
Power Drive.

16. 16
7. Connect output pin B TP7 of Motion Control block to pin B TP27 of Bipolar
Power Drive.
8. Connect output pin C TP8 of Motion Control block to pin C TP28 of Bipolar
Power Drive.
9. Connect output pin D TP9 of Motion Control block to pin D TP29 of Bipolar
Power Drive.
10. Connect output pin INH1 TP10 of Motion Control block to pin INH1 TP30 of
Bipolar Power Drive
11. Connect output pin INH2 TP11 of Motion Control block to pin INH2 TP31 of
Bipolar Power Drive
12. Connect output pin SENS1 TP12 of Motion Control block to Ground TP14.
13. Connect output pin SENS2 TP13 of Motion Control block Ground TP14.
14. Connect output pin A+ TP34 of Bipolar Power Driver block to pin A+ TP39
of Stepper Motor section
15. Connect output pin A- TP35of Bipolar Power Drive block to pin A- TP41 of
Stepper Motor section
16. Connect output pin B+ TP36 of Bipolar Power Drive block to pin B+ TP42 of
Stepper Motor section
17. Connect output pin B- TP37 of Bipolar Power Drive block to pin B- TP44 of
Stepper Motor section.
18. Put all the logic switches in Low Position.
19. Switch on main Power supply
20. Now put the logic switch S1 and S2 to high position.
21. The Stepper motor will start to rotate in CCW direction. To change the
direction Logic Switch S3 is used.
22. Speed of motor could be control through Frequency Adjust knob.

17. 17
LIST OF ACCESSORIES
1. 2mm Patch cords
2. Main cord
3. Manual