ASSIGNMENT

Stepper Motor Drives

EE 3032 - Electrical Machines and Drives III

Dinushi H.M.N. 100102P

Ekanayake E.M.H.A. 100116L
Gunawardana L.H.P.N. 100170U
Harshani B.C. 100177X
Jayasekara J.M.S.M. 100215N

September 02, 2013

 Abstract

This report consists of design of a stepper motor control circuit for a two phase full step
configuration.Control circuit was designed using JK flip flops, Darlington pair, diodes and resistors.
Logic sequence generator is designed using JK flip flop.Boolean equations were created based on truth
tables that were constructed to represent the operation of the state machine.The equations were
translated into a schematic diagram and a circuit was built based on the schematic.The resultant circuit
was able to start and stop the motor.
Contents

1 General Introduction 4
1.1 Stepper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Approach To The Design 8

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Calculations 11
3.1 Calculations for Logic Sequence Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Calculations for Current Limiting Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Control Circuit Design and Simulation 14

5 Conclusion 19

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List of Figures

1.1 Typical PM Stepper Motor view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Typical VR Stepper Motor cross sectional view . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Typical HB Stepper Motor cross sectional view . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Block Diagram of The Typical Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Dimension of the motor diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 SY42STH38-0406B Pull out torque curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Karnaugh Maps for input to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Karnaugh Maps for the JK flip flop inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Sequence Generator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Clock pulse Sequence from NE555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 Simulation Circuit of The Logic Sequence Generator . . . . . . . . . . . . . . . . . . . . . 15
4.3 Oscilloscope view of The Logic Sequence Generator . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Simulation Circuit of The Power Driver and Current Limiting Circuitry . . . . . . . . . . 16
4.5 Voltage Pulse Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Current through The Motor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Final Simulation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.8 Final Simulation Circuit with graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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List of Tables

2.1 Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Components list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Present(n) and Next(n+1) sequences calculation for JK flip flop output . . . . . . . . . . 11
3.2 Present(n) and Next(n+1) sequences states for JK flip flop . . . . . . . . . . . . . . . . . 12

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Chapter 1

General Introduction

1.1 Stepper motor

Stepper motor is a brushless, synchronous electric motor that converts digital pulses into mechanical
shaft rotation. Every revolution of stepper motor is divided in to a discrete number of steps. Motor must
be sent a separate pulse for each step and can only take one step at a time of same size steps. Motor’s
position can be controlled without any feedback.
There are three basic types of stepper motors which are commonly used. They are:

• Permanent magnet stepper motors

Often referred to as a ”tin can” or ”can stock” motor the permanent magnet step motor is a low
cost and low resolution type motor with typical step angles of 7.5 to 15 (48 - 24 steps/revolution).
PM motors as the name implies have permanent magnets added to the motor structure. The rotor
no longer has teeth as with the VR motor. Instead the rotor is magnetized with alternating north
and south poles situated in a straight line parallel to the rotor shaft. These magnetized rotor poles
provide an increased magnetic flux intensity and because of this the PM motor exhibits improved
torque characteristics when compared with the VR type. (Figure 1.1)

• Variable reluctance stepper motors

This type of stepper motor has been around for a long time. It is probably the easiest to un-
derstand from a structural point of view. This type of motor consists of a soft iron multi-toothed
rotor and a wound stator. When the stator windings are energized with DC current the poles
become magnetized. Rotation occurs when the rotor teeth are attracted to the energized stator
poles.(Figure 1.2)

• Hybrid stepper motors

The hybrid stepper motor is more expensive than the PM stepper motor but provides better per-
formance with respect to step resolution, torque and speed. Step angles for the typical HB stepper
motor range from 3.6 to 0.9 (100 - 400 steps per revolution). The hybrid stepper motor combines
the best features of both the PM and VR type stepper motors. The rotor is multi-toothed like the
VR motor and contains an axially magnetized concentric magnet around its shaft. The teeth on
the rotor provide an even better path which helps guide the magnetic flux to preferred locations in
the air gap. This further increases the detent, holding and dynamic torque characteristics of the
motor when compared with both the VR and PM types.(Figure 1.3)

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 Figure 1.1: Typical PM Stepper Motor view

Figure 1.2: Typical VR Stepper Motor cross sectional view

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 Figure 1.3: Typical HB Stepper Motor cross sectional view

Stepper motors are most widely used in both the industrial and commercial application. Here are a
few applications where stepper motors are often found:

• Hard drives

• Printers

• CNC machines

• 3D printer/prototyping machines

• Pick and place machines

• Linear actuators

• Laser cutters

There are so many advantages in using the stepper motor. Advantages are as follows:

• Precise positioning

• Low cost

• Higher reliability since there are no brushes

• High torque at low speed

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1.2 Control Circuit
In a control circuit of the stepper motor consists of,

• Logic Sequence Generator

Generates programmed logic sequences required for operation of a stepper motor. It is possible
to design a logic sequence generator using logic gates, JK flip flop or microcontrollers.

• Power Drivers

Output of the logic sequence generator is connected to the power driver circuit which ensure fast
rise of current through the phase winding which are to be turn on at a particular step in the logic
sequence.

• Current Limiting Circuitry

These are meant to ensure rapid decay of current in the phase winding that is turned off at a
particular step in the logic sequence.

Figure 1.4: Block Diagram of The Typical Control Circuit

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Chapter 2

Approach To The Design

2.1 Introduction
Control circuit design procedure was carried-out for the Unipolar Stepper Motor using JK flip - flop,
Darlington pairs, Diode, Resistors and timer.

2.2 Motor Configuration

• Specification

Soyo 12V 0.4A 36oz-in Unipolar Stepper Motor (double shaft) Specifications:

– Step Angle 1.8

– Step Angle Accuracy 5
– Resistance Accuracy 10
– Inductance Accuracy 20
– Temperature Rise 80C Max.(rated current,2 phase on)
– Ambient Temperature -20C +50C
– Insulation Resistance 100M Min. ,500VDC
– Dielectric Strength 500VAC for one minute
– Shaft Radial Play 0.02Max. (450 g-load)
– Shaft Axial Play 0.08Max. (450 g-load)
– Max. radial force 28N ( 20mm from the Flange )
– Max. axial force 10N

Model No SY42STH38-0406B Rated Voltage 12V

Current per phase 0.4A Resistance per phase 30ohm
Inductance per phase 30mH Holding Torque 2.6kg-cm
No. of loads 6 Rotor Inertia 54g-cm-cm
Weight 0.28kg Detent Torque 150g-cm

Table 2.1: Motor Specifications

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• Dimension

Figure 2.1: Dimension of the motor diagram

• Wiring Diagram

Figure 2.2: Wiring diagram

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 • Operating Curve

Figure 2.3: SY42STH38-0406B Pull out torque curve

2.3 Components

Item No. of items

JK Flip Flop 2
Darlington Pairs (ULN2003) 1
Diodes 4
Resistors(90 ohm) 4
Timer (NE555) 1

Table 2.2: Components list

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Chapter 3

Calculations

3.1 Calculations for Logic Sequence Generator

We use the 2-phase unipolar full step sequence to calculate logic sequence.
Here A, B, C, D are inputs to the power drive circuit.

Qn Qn+1
A B C D A B C D Qx Qy
1 0 0 1 1 1 0 0 0 0
1 1 0 0 0 1 1 0 0 1
0 1 1 0 0 0 1 1 1 1
0 0 1 1 1 0 0 1 1 0

Table 3.1: Present(n) and Next(n+1) sequences calculation for JK flip flop output

Figure 3.1: Karnaugh Maps for input to the Motor

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 Qx(n) Qy(n) Qx(n+1) Qy(n+1) Jx Kx Jy Ky
0 0 0 1 0 x 1 x
0 1 1 1 1 x x 0
1 1 1 0 x 0 x 1
1 0 0 0 x 1 0 x

Table 3.2: Present(n) and Next(n+1) sequences states for JK flip flop

Figure 3.2: Karnaugh Maps for the JK flip flop inputs

Figure 3.3: Sequence Generator Circuit

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3.2 Calculations for Current Limiting Circuitry
Calculations using theoretical values

T imeConstant(ON ) = Lm /Rm
= 0.03/30
= 1ms

RiseT ime = 5.T imeConstant

= 5 ∗ 1ms
= 5ms

T imeConstant(OF F ) = Lm /(Rm + Rf )

= 0.03/(30 + Rf )

Select Time Constant (OFF) as 0.25 ms.

30/(30 + Rf ) = 0.25

Rf = 90ohm

EnergyStoredinthephaseW inding = (1/2)LI 2

= (1/2) ∗ 0.03 ∗ 0.42

= 2.4mJ

EnergyDissipatingintheF reeW heelingResistor = (2.4 ∗ 9)/12

= 1.8mJ

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Chapter 4

Control Circuit Design and Simulation

Circuit was designed and simulated using proteus 7 proffesional software. We attached the
figures which are related to the simulation of the design of a stepper motor control circuit
for a two phase full step configuration.

• Clock Pulse Sequence from NE555

Figure 4.1: Clock pulse Sequence from NE555

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• Logic Sequence Generator

Figure 4.2: Simulation Circuit of The Logic Sequence Generator

Figure 4.3: Oscilloscope view of The Logic Sequence Generator

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• Power Driver and Current Limiting Circuitry

Figure 4.4: Simulation Circuit of The Power Driver and Current Limiting Circuitry

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 Figure 4.5: Voltage Pulse Sequences

Output voltage of the logic sequence generator is indicated in red and output voltage
of the power drive and current limiting circuit is indicated in blue.

Figure 4.6: Current through The Motor Winding

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• Final Design

Figure 4.7: Final Simulation Circuit

Figure 4.8: Final Simulation Circuit with graphs

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Chapter 5

Conclusion

The designed circuit was performed as we expected. The above chapter 4 shows how the
simulation was carried out. There were some limitations during implementation of the cir-
cuit. Though the rated voltage was 12 V, here we designed for 11V to avoid large voltage
spikes. Those spikes are due to the back emf of the motor and it will be harmful to the other
components of the system. And also in theoretically it is possible to reduce rise time using
a suppression resistor, but practically there is no point of including any resistor as no any
significant reduction was happened in rise time. However by adding a freewheeling resistor
of 90 ohms decay time was reduced from 5ms to 2ms theoreticaly. But it has been deviated
from that theoretical value to 1.25ms. Also, for rising time we obtained value 6ms which
is more than theoretical value 1ms. Though we tested the decay time by increasing the
freewheeling resistance beyond 90 ohms, no any significant reduction was occurred. There-
fore we designed our circuit without a suppression resistor and 90 ohm freewheeling resistor.

By improving the logic sequence it is possible to add more features such as changing the
direction of rotation of the motor, increasing the speed of the motor but the circuit be-
comes complicated. If JK flip flops are replaced by a Programmable IC, the task gets easier.

Through this design assignment we obtained practical knowledge about designing a stepper
motor controller and improved our software based skills such as dealing with Proteous. And
also we were able to learn a professional report writing method, Latex beyond Microsoft
word.

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