RAYMING PCB & ASSEMBLY

Servo Motors Vs. DC Stepper: What is Difference

Introduction to Motors

Motors are electro-mechanical devices that convert electrical energy into mechanical
energy. They come in a variety of types depending on their construction, working
principle, and applications. The two most common types of motors used in industrial
and automation applications are servo motors and stepper motors.

Both servo and stepper motors provide precise motion control, but they have some
key differences in their design and operation. This article will compare servo and
stepper motors in detail in terms of their construction, working principle, performance
characteristics, applications, advantages and disadvantages.

Overview of Servo Motors

A servo motor is a rotary or linear actuator that allows for precise control of angular
or linear position, velocity and acceleration. It consists of a motor coupled to a sensor
for position feedback. It also requires a relatively sophisticated controller, often a
dedicated module designed specifically for use with servo motors.

Servo Motor

The key components of a servo motor are:

 Motor – Provides the motive force for the actuator. Common motor types
used in servo systems include DC brushed, brushless DC, AC induction, and
AC synchronous motors.
 Gearbox – Used to increase the torque output from the motor. Often equipped
with high ratio gears to allow slower motor speeds but higher torque.
 Encoder – Sensor that provides position and speed feedback to the controller.
Resolvers and optical encoders are commonly used.
 Controller – Compares the actual position to the desired position and
calculates the required drive signals for the motor. Uses PID control
algorithms.
 Potentiometer – Measures position of output shaft and provides position
feedback to controller.

The controller commands the motor to rotate to the desired position as fast as possible.
Once the motor reaches the desired position, it stops. If an external force pushes
against the motor, it will hold the position due to the servo control system.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Servo motors provide closed-loop control with high accuracy and fast response times.
As a result, they are ideal for applications requiring precise position control such
as robotics, CNC machines, pick-and-place equipment, and other factory automation
machinery.

Request PCB Manufacturing & Assembly Quote

Overview of Stepper Motors

A stepper motor is a type of brushless DC electric motor that divides a full rotation
into a number of equal steps. Unlike servo motors which rotate continuously, stepper
motors move in discrete increments or steps.

Stepper Motor

The key components of a stepper motor are:

 Stator – The stationary part consisting of stacked steel laminations with

winding coils around the poles.
 Rotor – The output shaft along with a magnetized part that interacts with the
magnetic field from the stator coils.
 Driver – The driver energizes the motor coils in the proper sequence to cause
rotation. Open-loop control.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Stepper motors operate on the principle of electromagnetism. The motor coils are
energized in a specific sequence, creating magnetic poles that attract and repel the
permanent magnets on the rotor. This causes the rotor to turn a precise angle or “step”
each time a coil set is energized.

By controlling the sequence and coils energized, the motor can be turned in precise
increments. No closed loop feedback is required, though often an encoder can provide
position verification.

Stepper motors provide excellent low speed torque and position control without
requiring encoders or servo control. They are commonly used in 3D printers, CNC
machines, plotters, and other applications requiring high precision motion.

Construction and Design

Both servo and stepper motors have unique construction characteristics optimized for
their particular applications and operating principles.

Servo Motor Construction

The construction and design of a servo motor can vary greatly depending on the
motor power, torque, speed, and accuracy requirements. But in general servo motors
consist of the following components:

 Stator – Usually made up of laminated steel with winding coils around the
stator poles. The number of pole pairs determines the number of magnetic
poles.
 Rotor – Made of permanent magnets alternating in polarity around a rotor
shaft or core. Often high energy rare earth magnets are used.
 Shaft – Heavy duty output shaft with high stiffness for minimal deflection
under load. Supported by precision ball bearings.
 Housing – Cast iron or steel housing provides structural support and protects
internal components. Often thermally conductive to aid cooling.
 Feedback device – Resolvers, encoders or potentiometers are attached to
monitor rotor position.
 Gearbox – High ratio gearboxes are often integrated to increase torque
capacity. Spur, planetary, and harmonic gears are commonly used.

The stator, rotor, bearings, and housing make up the actual motor section. The
feedback device and gearbox augment the motor capabilities for high performance
servo applications.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Stepper Motor Construction

Stepper motors have a relatively simple electromechanical construction optimized for

open-loop positioning control. The basic components include:

 Stator – Made up of stacked steel laminations with winding coils around the
poles. The number of phases determines the number of coil sets.
 Rotor – A permanent magnet with alternating north and south poles arranged
radially around a central shaft.
 Shaft – Usually an integrated shaft machined as part of the rotor. Supported by
bushings or ball bearings.
 Housing – Lightweight aluminum or thermoplastic housings enclose the stator
and rotor. Air or liquid cooling may be integrated.
 Bearings – High speed sleeve bearings, bushings or ball bearings support the
rotor shaft.

Stepper motors do not require an encoder or gearbox for most applications. The
simple stator and rotor design allows rapid manufacturing at low cost.

Comparison of Construction

Comparison Servo Motor Stepper Motor

Stator design Laminated steel with concentrated Stacked laminations with
windings distributed windings
Rotor design Salient pole or permanent magnet Permanent magnet
Housing Heavy cast iron or steel Light aluminum or plastic
Bearings High precision ball bearings Bushings, sleeve or basic ball
bearings
Feedback Encoder, resolver or Often none, sometimes encoder
device potentiometer
Gearbox Often integral high-ratio gearbox Rarely used
In summary, servo motors have a robust stator, rotor and housing designed for high
torque, speed and continuous duty operation. Stepper motors use lightweight materials
and simple construction aimed at low cost and open-loop control.

Request PCB Manufacturing & Assembly Quote

Working Principle

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

While both servo and stepper motors produce rotational motion, their internal
operating principle and control methods differ significantly.

Servo Motor Working Principle

Servo motors operate on the basis of a closed-loop control system. A controller

provides a drive signal to the servo that is proportional to the difference between the
commanded position and actual position.

Servo Motor Working Principle

The working principle involves:

 An input command to the controller indicating the desired position. This is

compared to the position feedback.
 Error between actual and desired position is calculated. The controller sends a
proportional drive signal to the servo amplifier.
 Motor is driven proportionally faster or slower to minimize position error.
 Encoder or resolver provides continuous position feedback to complete the
control loop.

This closed loop control allows a servo motor to quickly and precisely rotate to a
commanded angular position. Servo motors use PID control algorithms to optimize
the dynamic response.

Stepper Motor Working Principle

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Stepper motors operate on the principle of electromagnetism and discrete stepping of

the rotor. Rotation is achieved by energizing coil windings in a specific sequence.

The stepper motor working principle:

 Applying current to a motor coil creates an electromagnetic pole. Opposite

poles attract, similar poles repel.
 Alternating current to the motor coils moves the rotor. As the rotor teeth align
with the energized stator pole, they lock in position.
 The driver sequentially energizes the motor coils to rotate the rotor in
increments or steps. No closed loop control is used.
 Step angle is determined by rotor construction. Number of steps per revolution
depends on step angle.

The open loop stepping operation allows the motor to move in controlled discrete
increments without requiring a position sensor.

Comparison of Working Principles

Comparison Servo Motor Stepper Motor

Control method Closed loop PID control Open loop stepping
Feedback Encoder or resolver Not required
device
Accuracy Very high with closed loop control Limited by step resolution
Speed Wide speed range with rapid Typically lower speed operation
acceleration
Torque High and continuous torque capability High holding torque, lower power
torque
In summary, servo motors use closed loop control for high accuracy while stepper
motors operate open loop in discrete steps. Servo systems are more complex but offer
better dynamic performance.

Performance Characteristics

The design and operating principles of servo and stepper motors impart distinct
performance characteristics.

Servo Motor Performance Metrics

Key performance characteristics of servo motors include:

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

 Speed – Servo motors can operate over a wide speed range, often exceeding
6000 rpm for brushless servo motors. Rapid acceleration and deceleration is
possible.
 Torque – Servo motors produce high torque, especially at lower speeds. Peak
torque ranges from 10 Nm to over 1000 Nm depending on motor size.
 Power – Motor output power ranges from under 100 Watts to over 15 kW for
large industrial servos. Power density is high.
 Accuracy – Position accuracy is very high, reaching 0.01 degree or better with
high resolution encoders. Helped by tuned PID control gains.
 Repeatability – Positional repeatability is excellent, with consistent
positioning under 0.01 degree. Benefits from closed loop control.

High torque density, acceleration, accuracy and repeatability make servo motors well
suited for demanding automation applications. Advanced control algorithms allow
optimized motion.

Stepper Motor Performance Metrics

The performance characteristics of a stepper motor include:

 Speed – Maximum speed ranges from 100 to 2000 RPM. Higher speeds
require reduced torque and incremental microstepping.
 Torque – Stepper motors have very high holding torque but weaker power
torque at higher speeds. Holding torque can exceed 3 Nm for small motors.
 Power – Typical motor power output ranges from below 100 Watts up to
around 750 Watts. High speed operation results in lower power.
 Accuracy – Positioning accuracy depends on stepper resolution. Full step
resolution is typically 1.8 degrees. Microstepping divides steps further.
 Repeatability – Excellent repeatability thanks to inherent step resolution.
Positional error is limited to less than one step.

Stepper motors excel at slow speed, high precision positioning applications. Their
relatively simple construction provides robustness at low cost.

Comparison of Performance Metrics

Comparison Servo Motor Stepper Motor

Speed range Very wide, thousands of RPM Narrow, typically below 2000 RPM
Torque density Very high High holding torque, lower running torque
Power output Up to 15 kW+ Typically below 750 Watts
Accuracy 0.01 degree or better 1.8 degrees full step, higher with
microstepping

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Comparison Servo Motor Stepper Motor

Repeatability Excellent, less than 0.01 Very good, limited to step resolution
degree
In summary, servo motors are designed for high speed and power operation with very
high accuracy. Steppers trade off speed and power for high precision motion in an
open loop control system.

Applications and Uses

The performance characteristics and capabilities of servo and stepper motors make
them suitable for different applications.

Servo Motor Applications

Servo motors are designed for high power, high precision motion control applications
including:

 Industrial robotics – Multi-axis articulated robot arms require high torque

servo motors to handle dynamic payloads.
 CNC machines – High precision machining relies on fast, accurate
servo motor control of linear and rotary axes.
 Medical equipment – MRI scanners, CT scanners, and lab automation use
servo positioning.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

 Semiconductor manufacturing – Integrated circuit production involves

extensive servo-controlled motion.
 Printing presses – Servo systems position printing plates and control tension.
 Packaging – High speed coordinated motion is needed for packaging
equipment.

Servo motors handle the most demanding motion control applications where speed,
accuracy, and flexibility are critical performance requirements.

Stepper Motor Applications

Stepper motors are ideal for applications requiring high precision open loop
positioning:

 3D printers & CNC machines – Stepper motors precisely position print

heads and machine tools.
 Textile manufacturing – Stepper motors control threading and weaving
patterns.
 Medical syringes – Stepper motors provide metered dispensing of fluids in
analyzers.
 Wafer scanners – Precise positioning of optics for integrated circuit
photolithography.
 Telescopes – Stepper motors orient telescope mounts to track celestial objects.
 Robotics – Used in cost-sensitive robots requiring modest position control
performance.

Stepper motors may not match servos in speed and power, but they provide excellent
control in open loop positioning machines.

Comparison of Applications

Comparison Servo Motor Stepper Motor

Performance reqs High speed, power, torque Modest speed with high precision
Control Closed loop feedback Open loop stepping
principle
Example apps CNC machines, robotics, 3D printers, telescopes, medical
packaging dispensing
Industries Manufacturing, robotics, Manufacturing, medical, aerospace
industrial
In summary, servo motors meet the demands of high power, high speed automation
applications while steppers excel at slower speed open-loop positioning tasks.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Request PCB Manufacturing & Assembly Quote

Advantages and Disadvantages

Both servo and stepper motors provide excellent motion control capabilities. But they
each have certain advantages and disadvantages to consider.

Servo Motor Pros and Cons

Servo motor advantages include:

 Extremely accurate position, speed and acceleration control

 High power density and torque-to-inertia ratio
 Fast dynamic response and tuning through PID gains
 Advanced control capabilities and flexibility
 Wide speed range operation
 High efficiency

Disadvantages of servo motors:

 More complex requiring closed loop control

 Higher costs than stepper motors
 Requires maintenance of brushes and contacts (for brushed DC servos)
 Encoder or resolver feedback device adds cost
 Control electronics are complex and expensive

In summary, servo motors provide high performance and flexibility but at higher
complexity and costs than alternatives like stepper motors.

Stepper Motor Pros and Cons

Stepper motor advantages:

 Excellent position control and repeatability without feedback device

 Low cost and simple construction
 Open loop control eliminates tuning complexity
 Extremely reliable with long service life
 High holding torque prevents loss of steps
 Available in a wide range of sizes and torque levels

Stepper motor disadvantages:

 Lower power and torque during running operation

 Limited high speed capability compared to servo motors
PCB Manufacturing & Assembly Services https://www.raypcb.com/
 RAYMING PCB & ASSEMBLY

 Open loop nature limits control accuracy

 Can lose steps at high speeds or accelerations
 Torque ripple can cause vibrations in some cases
 Audible noise during operation

In summary, stepper motors are simple, inexpensive, and reliable, but lack the speed,
power, and accuracy of closed loop servo systems.

Comparison of Advantages and Disadvantages

Comparison Servo Motor Stepper Motor

Accuracy Extremely high with encoder feedback Limited by open loop control
Complexity High due to closed loop control Very simple open loop operation
Cost Expensive; electronics, encoder Low component cost
Reliability Brush and contact wear over time Very reliable and long service life
Speed/power High speed, power and acceleration Lower speed and power capabilities
In summary, servo motors provide unmatched performance while stepper motors
excel at simple, low-cost, open-loop positioning tasks.

Servo Motors vs. Stepper Motors

Servo Motors Stepper Motors

Construction Robust mechanical design, precision Simple lightweight construction,
gears and bearings, encoders for open-loop control
feedback
Principle Closed loop PID control with encoder Open loop stepping operation
feedback without feedback
Performance High speed and power output, very high High precision but lower speed and
accuracy and repeatability power, modest accuracy
Applications High performance tasks like CNC Simpler positioning tasks like 3D
machines and robotics printers or telescopes
Advantages Extreme precision control, fast Low cost, simple operation,
dynamics, advanced control excellent repeatability, high
capabilities reliability
Disadvantages Complexity, high cost, maintenance Lower power and speed, limited
accuracy

Frequently Asked Questions

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

1. What is the main difference between a servo motor and a stepper

motor?

The main difference is that servo motors use closed loop control with position
feedback while stepper motors operate open loop without requiring position sensors.
This allows servo motors to achieve very precise, high speed control while steppers
offer simpler operation at lower speeds and accuracy.

Related Posts:

1. Stepper Motors Basics: Types, Uses, and Drive Schematic Diagram

2. What’s the Difference between EMI EMS and EMC ?

3. SMD Vs SMT: What’s the Difference?

4. Raspberry Pi 4 vs 3:What’s the Difference?

https://www.raypcb.com/dc-stepper-vs-servo-motors/

PCB Manufacturing & Assembly Services https://www.raypcb.com/