Design principles and common faults of waterproof stepper motors

 

1.Definition
The waterproof stepper motor is an electric device with waterproof function, suitable for various scenarios that require waterproof protection. ‌ It has the advantages of high reliability, wide adaptability and easy use. ‌ This motor can work normally in a specific environment, especially in an underwater environment, such as underwater robots and other applications, where waterproof motors are needed to ensure the normal operation and safety of the equipment. ‌

防水 Nema 34 步进电机 1.8 度 6.0A 12Nm(1700oz.in)2 相 P 系列 IP65

2.Design principle
The design principle of the waterproof stepper motor focuses on preventing moisture from invading and causing motor short circuit or failure. ‌ It adjusts the pressure change caused by temperature by forming a pressure regulating chamber, and adopts materials such as polyethylene insulation and nylon household waterproof electromagnetic wire. The cable connection method is based on cable joint technology. The joint insulation is removed from the scraped paint layer, welded firmly, and the raw rubber is wrapped around the layer to ensure waterproofing. ‌ The outer part of the motor is made of anti-corrosion material or anti-corrosion coating. Since the cracks or channels that may exist inside and outside the waterproof motor are blocked by the sealing mechanism, a reliable waterproof effect can be obtained. Even if the motor is watered for a long time, water will not enter the motor and cause a short circuit failure. ‌At the same time, the waterproof stepper motor also has certain explosion-proof performance.

3.Common faults and treatment methods
1.The motor cannot rotate: First, check whether the power supply is working properly, and use a multimeter or voltmeter to measure whether the voltage is stable. ‌If the power supply is normal, the fault may be caused by the driver or the motor itself. At this time, you can try to replace the driver or repair the motor. ‌

2.Unstable rotation or abnormal sound: This may be caused by incorrect configuration or parameter setting of the driver. ‌Check whether the parameters of the driver are correct. ‌If the parameters are correct, it may be that the internal components of the motor are damaged or the magnetic field is unstable. ‌It is necessary to repair or replace the internal components of the motor. ‌

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3.Different or inaccurate rotation speed: Incorrect microstep setting may cause this problem. The correct microstep setting can be achieved by adjusting the parameters of the driver. ‌At the same time, check whether the external load is normal, because the external load may affect the rotation speed of the motor. ‌

4.Excessive heat: Excessive heat after long-term operation may be caused by overload or poor internal heat dissipation of the motor. ‌Check whether the load exceeds the rated operating range of the motor, and consider adding a cooling fan or heat sink to improve the heat dissipation effect. ‌

5.Loose core: During operation, if the core is loose, the motor should be stopped and tightened with tools. If the stator core is damaged, it should be replaced in time. ‌

6.Broken winding wire: The broken winding wire may be caused by abnormal vibration during the use of the motor. The damaged winding wire should be replaced in time. ‌

7.Broken and burnt winding joints: This may be caused by the quality of the motor itself or high-load operation. A motor of better quality should be selected and long-term high-load operation should be avoided. ‌
8.Loose brush slip ring: If the brush slip ring is found to be loose, the motor should be stopped and reinforced. ‌

Application industries of brushless DC motors

1. Basic principles and characteristics of brushless DC motors

Brushless DC motors are high-efficiency, low-noise, high-torque, and low-power motors. The basic principle is to use the principle of electromagnetism to drive the motor by alternating the three-phase AC signals in the permanent magnet and the armature. Since the motor does not need to use brushes and commutators to achieve commutation, the impact of friction and wear on the motor performance can be avoided, thereby improving the reliability and life of the motor.

2. Application industries and related products of brushless DC motors
1. Electric vehicle industry
Brushless DC motors are widely used in transportation tools such as electric bicycles, electric motorcycles, and electric vehicles. Compared with traditional brushed DC motors and AC asynchronous motors, it has the characteristics of high efficiency, low noise, low vibration, low electromagnetic interference, and no commutation operation is required, so it is known as a “special motor for electric vehicles.”
2. Robot industry
Brushless DC motors are widely used in various types of robots, such as household robots, industrial robots, etc. The precision control and high-speed movement of robots require motors with high speed, high precision, and low inertia, and brushless DC motors are the ideal choice to meet these requirements.

3. UAV industry
Brushless DC motors are also widely used in the field of UAVs. The hovering and sharp turns of UAVs require high reaction speed and precision of the motor, and the high speed, high precision and low noise of brushless DC motors make it one of the mainstream motors for UAVs.
4. Industrial automation industry
Brushless DC motors are also widely used in various industrial automation fields, such as machine tools, stamping equipment, injection molding machines, etc. In these fields, precise control and high-speed movement of motors are also very important, so brushless DC motors are widely used.

3. Conclusion
The above is an introduction to the application industries and related products of brushless DC motors. Due to its advantages of high efficiency, low noise, and low electromagnetic interference, brushless DC motors are widely used in various fields and gradually replace traditional brushed DC motors and asynchronous AC motors.

The difference between two-phase stepper motors and four-phase stepper motors

1.Working principle

1.Two-phase stepper motors

Two-phase stepper motors refer to motors whose drive circuits have only two inputs, each of which controls a coil. When this motor rotates, one coil is activated first to generate a magnetic field, and then the other coil is activated to generate a magnetic field, thereby driving the motor to rotate. Two-phase stepper motors are usually simpler and easier to control, but because there are only two inputs, the step angle cannot be subdivided.

2.Four-phase stepper motors

Four-phase stepper motors refer to motors whose drive circuits have four inputs, each of which controls a coil. When this motor rotates, two coils are activated first to generate a magnetic field, and then the other two coils are activated to generate a magnetic field, thereby driving the motor to rotate. Since four-phase stepper motors have four inputs, they can be divided into smaller step angles, which are more precise than two-phase stepper motors.

 

2.Control method

1.Two-phase stepper motors

Since two-phase stepper motors have only two control inputs, their drive circuits are relatively simple, and only one H-bridge drive circuit is needed to control their operation. Among them, the H-bridge drive circuit is a circuit used to control the direction and size of the current, which consists of four switches. The size and order of the control current can determine the direction and speed of the motor rotation.

2.Four-phase stepper motor

Since the four-phase stepper motor has four inputs, it requires a more complex control circuit. It can be driven by an external controller such as a stepper motor controller or a microcontroller. In addition, since the four-phase stepper motor can be divided into smaller step angles, the requirements for the drive circuit are higher than those for the two-phase stepper motor.

3.Output efficiency

There are also differences in output efficiency between two-phase stepper motors and four-phase stepper motors. Since the step angle of the two-phase stepper motor is relatively large and the rotation speed is relatively slow, it is suitable for low-speed and low-precision applications. The four-phase stepper motor has a finer step angle and a faster rotation speed, which is suitable for high-speed and high-precision applications.

 

4.Application field

Two-phase stepper motors are mainly used to control low-speed and low-precision applications. If high-speed and high-precision control is required, four-phase stepper motors are usually used. Common applications include: electronic scales, printers, scanners, etc.

5.Conclusion

Although two-phase stepper motors and four-phase stepper motors both belong to the category of stepper motors, they have some differences in working principle, control method, output efficiency, etc. Understanding these differences can help readers better choose the type of motor suitable for their application field.

Source:https://www.steppernews.com/2024/07/the-difference-between-two-phase.html

How to realize speed regulation of three-phase stepper motor

1.Overview of three-phase stepper motor

The three-phase stepper motor is an actuator that converts electrical pulse signals into angular displacement. It has the advantages of simple structure, convenient control, high precision, and no cumulative error. It is widely used in automation equipment such as CNC machine tools, robots, printers, scanners, etc.

 

2.Speed ​​regulation principle of three-phase stepper motor

Speed ​​regulation refers to changing the speed of the motor to meet different working requirements. The speed regulation of three-phase stepper motors is mainly achieved in the following two ways:

1.Pulse frequency speed regulation: By changing the pulse frequency input to the motor driver, the speed of the motor can be changed. The higher the pulse frequency, the faster the motor speed.

2.Current control speed regulation: By adjusting the current in the motor winding, the torque of the motor can be changed, thereby affecting the speed. The larger the current, the greater the torque and the faster the speed.

3.Speed ​​regulation method of three-phase stepper motor

1.Microstep control: By subdividing the step angle of the motor, more precise control can be achieved. For example, subdividing the step angle of 1.8 degrees into 0.9 degrees can improve control accuracy and smoothness.

2.PWM control: Use pulse width modulation (PWM) technology to adjust the current size in the motor winding to achieve smooth speed regulation.

3.Vector control: By controlling the direction and size of the motor’s magnetic field, efficient and accurate speed regulation is achieved.

4.Current chopping control: By adjusting the on and off time of the current, the motor speed is controlled.

5.Hybrid control: Combine the above control methods to achieve better speed regulation performance.

 

4.Implementation steps of three-phase stepper motor speed regulation

1.Determine the speed regulation requirements: According to the application scenario, determine the required speed regulation range and accuracy.

2.Select a suitable driver: According to the motor parameters and speed regulation requirements, select a suitable stepper motor driver.

3.Design control circuit: Design a suitable control circuit to achieve control of the motor driver.

4.Write a control program: According to the control requirements, write a control program to achieve precise control of the motor.

5.Debug and optimize: Through actual operation, debug and optimize the control parameters to achieve the best speed regulation effect.

Three-phase stepper motor speed regulation technology has a wide range of applications and prospects in the field of automation. By choosing the appropriate speed regulation method and control strategy, the motor can be precisely controlled to meet the needs of different scenarios. With the continuous advancement of control technology, the speed regulation performance of three-phase stepper motors will be further improved, providing a stronger driving force for the development of automation equipment.

Source:https://www.steppernews.com/2024/07/how-to-realize-speed-regulation-of.html