Stepper motors &

modeling
mechatronic systems
KON-C2004 Mechatronics Basics
Tapio Lantela, Nov 10th, 2016
Steppers

10.11.2016
2
Magnetic reluctance
”Resistance” to magnetic flux
Reluctance force aligns objects
to minimize reluctance
Stepper motors
Takes discrete steps
- Direction depends on
coil energising order
- Step frequency determines speed
- Number of steps determines position
Maintains a position
without active control
- Requires constant phase current

10.11.2016
4
Stepper motors
Commonly 48 or 200 steps
per revolution
- Corresponds to 7,5°or 1,8°per step
Usually low power (<750 W)
Low cost
NEMA sizes common
Three main types
- Variable reluctance
- Permanent magnet
- Hybrid

10.11.2016
5
Variable reluctance stepper motor
Cheap
Light rotor -> fast
Simpler control electronics

https://en.wikipedia.org/wiki/Stepper_motor

Kenjo, T., Stepping motors and their microprocessor controls

10.11.2016
6
Permanent magnet stepper motor
Better torque
Worse resolution

Kenjo, T., Stepping motors and their microprocessor controls

http://www.robotiksistem.com/stepper_motor_types_properties.html

10.11.2016
7
Hybrid stepper motor
Permanent magnet inside laminated rotor
Good torque and resolution
More expensive

10.11.2016
8
Kenjo, T., Stepping motors and their microprocessor controls
Holding torque

10.11.2016
Kenjo, T., Stepping motors and their micro-processor controls 9
Settling time

10.11.2016
10
Kenjo, T., Stepping motors and their micro-processor controls
Dynamic properties of stepper motors

10.11.2016
11
Kenjo, T., Stepping motors and their micro-processor controls
Resonance frequencies

Speed-torque graph

10.11.2016
12
Lawrence & Mauch, Real-Time Microcomputer System Design
Stepping rate
Start and stop slower than pull-in rate
Stay below slew rate

10.11.2016
13
(Book: Fraser & Milne, Integrated Electrical and Electronic Engineering)

10.11.2016
14
Half stepping
Doubles resolution

10.11.2016
16
Micro stepping
More than two steps per full step
- over 10000 steps per revolution can be achieved
Resolution ≠ accuracy
- Smaller microsteps ->
worse relative repeatability

http://forums.parallax.com/discussion/136024/doing-microstepping-with-the-propeller

10.11.2016
17
Current control
Conflicting requirements
- High voltage recommended to overcome phase inductance
- Low voltage required to limit current and resistive losses
Solution: current control with variable voltage
Method: current measurement and PWM

10.11.2016
18
Stepper motor control example
Full stepping

A1 A2 B1 B2

Half stepping

A1 A2 B1 B2

10.11.2016
(Book: Bolton, Mechatronics) 19
Control systems for stepping motors

Direct
computer
control
Lawrence & Mauch, Real-Time
Microcomputer System Design

Computer control
with stepping circuit

Computer control with

intelligent indexer

10.11.2016
20
Stepper motor drivers
Takes care of correct coil energising order
- Commonly need just two signals: step and direction
Takes care of half or microstepping
Takes care of current control
Miniature drivers
- Phase current ~1 A
- Price starting from 5 $
Large drivers
- Current 10+ A

10.11.2016
21
Digital linear actuator

http://www.wikiwand.com/en/Screw_(simple_machine) 10.11.2016
22
XY table with steppers

10.11.2016
23
Linear stepper
Functional principle similar to hybrid motor
2D motion possible
Dual axis linear stepper

10.11.2016
25
Stepper summary
Fairly accurate positioning without position feedback
- Resolution from ~10 to 10000 steps per revolution
- Magnetic field acts as a spring
- Missed steps can be a problem
Stepper controller required
- Usually step and direction signals
- PWM current control recommended
Constant current consumption
- Usually low power applications

10.11.2016
26
Modeling

10.11.2016
27
Model
A simplified representation of a Is used to
- System - Estimate
- Physical object - Predict
- Process - Explain
- Thing - Describe
Theories are models of reality - Design

Better understanding leads to better results

Topology models
Energy
Singnaal
Folding Machine Functional Structure V 2
Material flow

Functional structure
User
- Abstract Protection

- Describes process
Signaal 1

Signaal’

• No concrete
Signaal 2
Power Supply Starting System
Energy Energy 1’

implementation Convert
Energy to Energy 2’
Convert
Motion
- Helps in thinking Monitor Raw
Energy to
Force

different ways of doing Material State

Convey Convey
the same Monitor
Process State
Motion to
Material
Force to
Material

Position and Convert Force to

Raw Material Dispense Raw Processed
Material Flow Control of Transformation End Product
Storage Material Product Storage
Material Energy
Mathematical Models
Formulas
- Found in Physics textbooks
- Analytical
Not all formulas can be analytically solved!
- Basic physics books tend to give simplified formulations

F=ma
Numerical Models - Simulations
Usually Differential equations
- Not all formulas can be analytically solved!
Adding more complexity makes it nearly impossible to solve
- Added accuracy brings new problems
• Solver errors etc.
• Aim is to be more accurate despite this
Several areas to be modeled
Control code
- Logic
- Controllers
Electronics
- Input circuits – amplifiers, filters
- Output circuits – power electronics
Mechanics
- Multi-body systems
- Fluid dynamics
Electric circuit simulation
SPICE = Simulation Program with Integrated Circuit Emphasis
- Analog electronic circuit simulation
Multibody simulation
Interaction of rigid or elastic bodies
- Kinematic coinstraints such as joints
- Force elements such as springs and dampers
Shape of part not relevant
- Only with collision detection

10.11.2016
34
Finite element modeling
Discretize the volume to very small elements
Fluid flow
Magnetic fields
Mechanical stresses
Heat flow

10.11.2016
35
HIL simulation
Hardware In the Loop
- The system is partly hardware partly software model

10.11.2016
36
Example: Modeling a digital hydraulic
valve system
Initial sketches
CAD model
Finite element model of electromagnetic actuator
Genetic optimization with the FEM model
Dynamic model in Simulink
Control electronics simulations
FEM (CFD) flow simulations

10.11.2016
37
Initial sketches
.

10.11.2016
38
CAD model
Solid Edge

10.11.2016
39
Finite element model of solenoid’s
magnetic circuit
Comsol Multiphysics

10.11.2016
40
Genetic solenoid optimization
Matlab

10.11.2016
41
Dynamic model of the system
Simulink

10.11.2016
42
Modeling electronics
KiCAD

10.11.2016
43
Electronic simulations
LtSpice

10.11.2016
44
Computational Fluid Dynamics
Fluent

10.11.2016
45
Resulting prototype

10.11.2016
46
Reminder about the
changed weekly exercise
DL 14:00 -> 12:00

10.11.2016
47