How to Solve the Inaccurate Positioning of Stepper Motors?

/in , /by

Stepper motors play a critical role in automation control systems, but when it works, we may encounter issues of inaccurate positioning. This phenomenon can manifest as cumulative deviations, skipped steps, or misactions. In this article, we will explore common problems causing inaccurate positioning and their solutions.

1.Losing pulses when changing direction results in accumulated deviation with more direction changes.

Stepper drivers usually have specific requirements for direction and pulse signals. Failing to meet these requirements may cause the motor to rotate in the opposite direction to the intended one. To resolve this, adjustments can be made using software to alter pulse logic or introduce delays.

2.High initial speed and acceleration may lead to step losses.

To prevent step losses, it is crucial to avoid excessively high initial speeds, especially with heavier loads. Recommended initial speeds should be kept below 1 revolution per second. Additionally, a pause should be inserted between motor’s forward and reverse rotations to avoid overshooting due to excessive reverse acceleration.

3.Software compensation in synchronous belt applications may be excessive or insufficient.

In synchronous belt applications, the belt’s elasticity can significantly impact motor motion, especially when changing directions. Proper compensation is vital to minimize positioning errors. Adjusting compensation parameters based on the actual scenario and belt characteristics is key to achieving accurate positioning.

The key to solving this problem is to adjust compensation parameters based on the actual scenario and characteristics of the synchronous belt. Applying appropriate compensation when changing direction can offset the elastic deformation of the synchronous belt and reduce positioning errors. Different application scenarios may require varying compensation values, so it is necessary to conduct experiments and tests to find the optimal parameter settings.

4.Insufficient motor power.

Increasing motor current and drive voltage (while considering suitable driver selection) or choosing a motor with higher torque can address this issue.

5.Controller or driver interference causing misactions.

Reducing interference from external sources and enhancing self-interference resistance are crucial. Common measures are as below:

A.Use double-braided shielded cables to separate signal lines from high-current or high-voltage wires.

B.Implement power filters to remove interference from the grid.

C.Employ optocouplers for signal transmission between devices.

In conclusion, resolving issues of inaccurate positioning in stepper motors requires precise adjustments of direction and pulse signals, setting appropriate initial speed and acceleration, compensating for synchronous belt applications, and optimizing motor power. Reducing interference and enhancing interference resistance are equally important for reliable and accurate motor positioning.

 

overheating of brushless dc motor

How to deal with overheating of brushless dc motor?

/in /by

A brushless DC motor is a device composed of a motor and a driver, widely used in the mechanical industry. Many people encounter the issue of motor overheating when using such equipment and may not know how to handle it. Below, we will briefly explain how to deal with this situation.

1.Excessive power supply voltage leading to saturation of the core magnetic flux, resulting in excessive temperature rise in the brushless DC motor: If the power supply voltage exceeds the standard by a large margin, it is necessary to communicate with the power supply department to resolve the issue.

2.Low power supply voltage causing excessive temperature rise in the brushless DC motor under rated load: If the voltage drop a lot in power supply line, you can replace it with a thicker power supply line. If the voltage is too low, you can contact the power supply department to increase the power supply voltage.

3. If there is a case of burnt wire, the core has been burnt, resulting in increased iron losses. In this situation, a core inspection test is required to troubleshoot and repair the core.

4.Friction between the stator and rotor cores: Inspect the cause of the fault. If the bearing clearance exceeds the limit, the bearings should be replaced to solve the issue.

5.Accumulation of dust on the surface of the winding will directly affect the heat dissipation of the brushless DC motor. It is important to clean it promptly to avoid such situations.

The points mentioned above are the methods for dealing with the overheating phenomenon in brushless DC motors. If you encounter such a situation during actual use, it is important to address it promptly to ensure the normal operation of the equipment.

How a 200w bldc used for packing machine?

/in /by

A 200W brushless DC (BLDC) motor can be used in packaging machines to provide the necessary torque and speed control for various components of the machine. Here’s an example of how a 200W BLDC motor can be used in a packaging machine:
Conveyor belt system: A conveyor belt system is a key component of packaging machines, used to move products along the production line. A 200W BLDC motor can be used to power the conveyor belt, providing the necessary torque to move the products efficiently.


Labeling machine: In a labeling machine, a 200W BLDC motor can be used to power the label dispenser, providing precise speed control for accurate label placement. The motor can also be used to power the rollers that apply pressure to the label for proper adhesion.

Sealing machine: In a sealing machine, a 200W BLDC motor can be used to power the heat sealing rollers, providing the necessary torque to maintain consistent pressure and temperature during the sealing process.

Filling machine: In a filling machine, a 200W BLDC motor can be used to power the pump or auger that dispenses the product into the packaging, providing precise speed control for accurate filling levels.


Overall, a 200W BLDC motor can be used in various components of a packaging machine to provide the necessary torque and speed control for efficient and accurate operation. The specific application and gearing requirements will depend on the specific design and operation of the packaging machine.

What application would be a 200w bldc motor used for?

/in /by

A 200W brushless DC (BLDC) motor with gear can be used in various applications where high torque and speed control are required. Here are a few examples:

Electric bicycles

A 200W BLDC motor with gear can be used in electric bicycles to provide the necessary torque to move the bike and overcome inclines. The gear system can also provide speed control and better efficiency.

Robotics

A 200W BLDC motor with gear can be used in robotics applications, such as for robotic arms and grippers. The gear system can provide the necessary torque and speed control for precise movement.

Medical equipment

A 200W BLDC motor with gear can be used in medical equipment such as surgical instruments, providing high torque and speed control for precise movements.

Industrial automation

A 200W BLDC motor with gear can be used in various industrial automation applications such as conveyor belts and packaging machines. The gear system can provide speed control and improve efficiency.

Overall, a 200W BLDC motor with gear can be used in a wide range of applications where precise torque and speed control are required. The specific gear ratio and type of gearing used will depend on the specific application and requirements.

Bldc motor specifications about motor selection

/in /by

Brushless motors are widely used in various industries, from robotic to aerospace engineering. When selecting a brushless motor, it is crucial to understand its specifications to ensure that it fits your application requirements. In this article, we will discuss some essential bldc motor specifications that you should be familiar with.

Motor Specifications

A brushless motor factory often has various brushless motor models represented by several digit number, while for different brushless motor manufacturers, the numbers mean differently. For example, ICAN company’s brushless motor 42BLF-0330NBB. 42 means flange size, which is 42mm. 03 means power, which is 3*10=30watt. 30 means rate speed, which is 30*100=3000rpm.

No-load Current

The working current of the motor without load at a specified voltage.

Torque

The driving force generated by the rotor in the motor that can drive mechanical loads.

KV Value

The value of speed per volt.  kv*voltage=speed(rpm)

Rotor Structure

Brushless motors have type of external rotor and internal rotor. An brushless inrunner motor has a stationary outer casing and a rotating rotor inside, with a permanent magnet on the rotor and electromagnets on the stator. An brushless outrunner motor has a stationary inner core and a rotating casing around it, with electromagnets on the rotor and a permanent magnet on the stator.

Speed

The rotational speed of the brushless motor per minute. The speed*torque=power*10. So, when it’s under certain power, when the speed is decreased, the torque is increased. It is impossible to expect a motor to have both high speed and high torque.

Operating Temperature Range

In many special application industries, there are very clear requirements for the working temperature of the brushless motor, such as high-temperature environments and low-temperature scenarios. Generally, the working temperature range of brushless motors is between -20 to +100 degrees, and more stringent ranges are between -40 to +140 degrees. Therefore, customers who are sensitive to temperature parameters need to pay special attention to this.

Waterproof Rating

The protection level of the motor is generally indicated by IP followed by a number. Customers who use the motor in a water environment should pay attention to this value. Generally, if the brushless motor does not explicitly state that it is a waterproof motor, then it is not. You can focus on the number after IP, which means that the higher the number, the higher the waterproof rating.

In conclusion, brushless motors come in various sizes, configurations, and specifications. Understanding their specifications is crucial in selecting the right motor for your application. By knowing the motor’s KV value, torque, rotor structure, and other specifications, you can determine its performance capabilities and ensure it is compatible with your application’s needs.

Characteristic and maintenance of brushless DC motor

/in , /by

Brushless DC motors are highly favored due to their compact size, lightweight design, and spark-free operation, making them ideal for use in explosive environments. In this article, we will explore the key characteristics of brushless DC motors. And give essential maintenance tips on how to keep them running smoothly.

Key Characteristics

1.Can replace DC motors, frequency conversion motors, and asynchronous motors.

2.Small size, lightweight, and high torque.

3.Excellent torque characteristics, good low-speed torque performance, large starting torque, and small starting current. Visit brushless motor sets by click here. 

4.Stepless speed regulation, wide speed regulation range, and strong overload capacity.

5.Soft start, soft stop, and good braking characteristics, eliminating the need for original mechanical or electromagnetic braking devices.

6.High efficiency, the motor itself has no excitation loss and carbon brush loss, eliminating multi-stage reduction losses, with efficiency up to 70%.

7.High reliability, good stability, strong adaptability, and simple maintenance and repair.

8.Resistant to vibration and shock, low noise, small vibration, smooth operation, and long service life.

9.No sparks, especially suitable for explosive environments, with explosion-proof types available.

10.Can choose trapezoidal wave magnetic field motor or sine wave magnetic field motor according to requirements.

Maintenance of brushless DC motor

1.Before disassembling, blow the dust on the surface of the motor .

2.Choose a clean working environment .

3.Learn the structural characteristics of the motor and the maintenance technical requirements.

4.Prepare the tools (including special tools) and equipment needed for disassembly.

5.To further understand the defects in the motor during operation, a test should be performed before disassembly . Therefore, the motor should rotate under load for detailed inspection of the temperature, sound, vibration,  voltage, current, and speed should be tested. Then perform a separate no-load test to measure the no-load current and no-load loss and record the results.

6.Cut off the power supply, remove the external wiring of the motor, and make a record.

7.Use a megohmmeter with an appropriate voltage to test the insulation resistance of the motor. In order to compare the insulation resistance values measured during the previous maintenance to judge the trend of the insulation change and insulation status of the motor, the insulation resistance values measured at different temperatures should be converted to the same temperature, generally converted to 75℃.

8.Test the absorption ratio K. When the absorption ratio is greater than 1.33, it indicates that the motor insulation has not been dampened or the degree of dampness is not severe. In order to compare with previous data, the absorption ratio measured at any temperature should also be converted to the same temperature

In conclusion, brushless DC motors offer numerous advantages over traditional DC motors and are ideal for various applications. Proper maintenance is essential to ensure that your brushless DC motor operates optimally for an extended period. If you have any concerns or questions about maintaining your brushless DC motor, please do not hesitate to contact us.

How to customize DC motor ?

/in /by

DC motors is commonly used nowadays.It includes brushless motor, stepper motor, servo stepper etc. Because the applications are diversified, so are users’ requirements on motors. Therefore, users often need to customize DC motors. Due to varying degrees of knowledge about DC motors and industry products, customers may have many questions when communicating with manufacturers. In order to help everyone communicate with manufacturers more efficiently, the following points should be noted.

customize dc motor

1.The main specifications for customizing DC motors

For example, basic information such as motor diameter, length, shaft diameter, voltage, and speed. If there are drawings or parameter tables, they can be directly sent to the manufacturer. So the engineer can quickly confirm whether the motor can be made.

2.The specific application of the motor

That is, what product the motor will be used on, what actions it will perform, and the working environment, etc. This information can help the engineer search for motor solutions for the industry application, which can accelerate the technical evaluation process.

3.The expected quantity of motors

Customizing motors takes a long time (especially when molding is required) and involves many processes. Therefore, manufacturers have certain requirements for the quantity of customized projects. If the quantity is very small, the customer will be informed that it is not necessary to customize the motor.

4. A complete project schedule

The motor manufacturers have many customize projects running at the same time, and facing different customer requirements. If there is a schedule table, engineers can arrange mold opening time, material cycle, first sample time, experimental cycle, customer installation testing, small batch production, trial production, and other stages in advance to meet the customer’s project progress.

5. Target price

It is best to inform the manufacturer if there are expected cost requirements and target unit prices. In this way, when evaluating motor solutions, the engineer can choose a suitable solution based on the unit price, thus avoiding situations where the motor meets the requirements but the cost is not acceptable.

The above points hope to provide some help on dc motor customization requirements, improve communication efficiency, and find suitable manufacturers. ICAN company is specialized on customizing motors with 14 years of experience. If you want to get more information, please feel free to discuss with us.

General problems with stepper motor

/in /by

1.What is a stepper motor?

A stepper motor is an actuator that converts electrical pulses into angular displacement. In simple terms, when a stepper driver receives a pulse signal, it drives the stepper motor to rotate a fixed angle in a set direction. By controlling the number of pulses, you can control the angle displacement for precise positioning. You can also control the pulse frequency to adjust the speed and acceleration of the motor.

2.What is holding torque?

Holding torque refers to the torque that locks the rotor of a stepper motor when it is powered but not rotating. It is one of the most important parameters of a stepper motor. It is close to motor’s torque at low speed . As the output torque of the stepper motor decreases with increasing speed, and the output power varies with speed, holding torque becomes the most important parameter for measuring a stepper motor’s performance. For example, when people say a 2 N·m stepper motor, it usually means the holding torque is 2 N·m, unless otherwise specified.

3.What is detent torque?

Detent torque refers to the torque that locks the rotor of a stepper motor when it is not powered.

4.What is the accuracy of a stepper motor, and does it accumulate?

The accuracy of a stepper motor is typically 3-5% of the step angle and does not accumulate.

5.What is the allowable external temperature of a stepper motor?

If the temperature of a stepper motor is too high, the motor’s magnetic material will demagnetize, causing a decrease in torque and even missed steps. Therefore, the maximum allowable temperature of the motor’s external surface should depend on the demagnetization point of the motor’s magnetic material. Generally, the demagnetization point of magnetic materials is above 130 degrees Celsius, and some are even above 200 degrees Celsius. Therefore, an external temperature of 80-90 degrees Celsius is completely normal for a stepper motor.

6.Why does the torque of a stepper motor decrease as the speed increases?

When a stepper motor rotates, the inductance of each phase winding of the motor will produce a counter electromotive force (EMF) in the opposite direction. The higher the frequency, the greater the counter EMF. Under its influence, the phase current of the motor decreases as the frequency (or speed) increases, leading to a decrease in torque.

7.Why can a stepper motor operate normally at low speeds, but fail to start and emit a whistling sound at a high predetermined speed?

Stepper motors have a technical parameter called “no-load starting frequency,” which refers to the pulse frequency at which the stepper motor can start normally under no load. If the pulse frequency is higher than this value, the motor cannot start properly, and stepping errors or blockages may occur. When the motor is under load, the starting frequency should be lower. To achieve high-speed rotation of the motor, the pulse frequency should increase with a certain acceleration, starting at a lower frequency and increasing gradually to the desired high frequency (the motor speed increases from low to high).

8.How to overcome the vibration and noise of a hybrid stepper motor when it operates at low speeds?

The inherent drawback of stepper motors when operating at low speeds is large vibration and noise. The following solutions can be adopted to overcome this issue:

  1. Avoid the resonance zone by changing the mechanical transmission, such as the reduction ratio if the stepper motor is in the resonance zone;
  2. Use a driver with subdivision function, which is the most commonly used and convenient method;
  3. Replace the stepper motor with a smaller step angle, such as a three-phase or five-phase stepper motor;
  4. Replace it with an AC servo motor, which can almost completely overcome vibration and noise but is more expensive;
  5. Add magnetic dampers on the motor shaft. Such products are already available on the market, but they require significant changes in the mechanical structure.

9.How to determine the DC power supply for the stepper motor driver?

  1. Voltage determination: The voltage of the power supply for the hybrid stepper motor driver generally has a relatively wide range. The voltage is usually selected according to the motor’s working speed and response requirements. If the motor’s working speed is high or the response requirement is fast, the voltage should be higher. However, the ripple of the power supply voltage should not exceed the maximum input voltage of the driver, or the driver may be damaged.
  2. Current determination: The power supply current is generally determined based on the output phase current I of the driver. If a linear power supply is used, the power supply current is usually 1.1-1.3 times I. If a switching power supply is used, the power supply current is usually 1.5-2.0 times I.

10.Under what circumstances is the offline signal FREE of the hybrid stepper motor driver generally used?

When the offline signal FREE is low, the current output from the driver to the motor is cut off, and the motor rotor is in a free state (offline). In some automated equipment, if the motor shaft needs to be directly rotated (manually) without powering off the driver, the FREE signal can be set low to disconnect the motor and perform manual operations or adjustments. After the manual operation is completed, the

Closed loop vs open loop stepper motor

/in /by

The stepper motor system is the foundation of the motion control industry. It has a long history from PWM driver and microstepping to digital signal processors (DSPs) and anti-resonance algorithms. Now, new closed-loop stepper motor has become a new trend.

Closed-loop stepper motors is a stepper motor with encoder feedback. They achieve precise position and speed control by using position feedback sensors. Compared to open-loop stepper motors, closed-loop system have significant advantages in terms of acceleration, efficiency, position precision, heat generation, and noise level.

Closed loop vs open loop stepper motor

Higher Acceleration

Closed-loop stepper motors have higher acceleration due to their feedback mechanisms, such as encoders or Hall sensors. They detect speed and position and feed the results to the controller, which adjusts the current signal to keep acceleration within the preset range.

Stepper motor open loop control lacks real-time feedback and can’t precisely control acceleration. Stepping errors occur if the input signal is incorrect or the load changes, reducing acceleration and accuracy.

Efficiency

Closed-loop stepper motors have higher efficiency compared to open-loop systems, as shown by experimental data. The average power consumption of the open-loop stepper system is one-third of the closed-loop stepper system. This significant difference in power consumption indicates a higher efficiency of the closed-loop system.

Reduced Heat Generation

Closed-loop stepper motors can adjust the driving current in real-time according to changes in the load, avoiding excessive current passing through the motor and reducing the motor’s heat generation. In contrast, after setting the driver to the motor’s rated current, open-loop stepper motors will continuously supply the current to the motor, regardless of the load and required torque, which usually leads to high heat generation. The significant reduction in motor heat generation means that machine manufacturers can reduce component costs because of no need of additional protection and cooling subsystems.

Noise

Another common issue with open-loop stepper systems is noise, as they are known to produce a lot of audible noise. In some environments, such as laboratories, hospitals, and offices, this noise can cause problems.

In a closed-loop system, the controller can dynamically adjust the motor’s current to control its operation by monitoring the motor’s movement and load. This precise control can reduce the vibration and noise generated by the motor due to overload or underload.

In the test, the noise of each system was measured in a soundproof room. Compared to speeds of 0 to 20 rpm, closed-loop systems are much quieter than open-loop options. This speed range matches the actual application speed range of most stepper motor , meaning that most stepper motor applications can benefit from the reduced noise by switching to a closed-loop system.

Improved Precision and Position Accuracy

Closed-loop stepper motors can achieve greater precision and position accuracy by using encoder feedback in the position loop to achieve servo control. In this way, the closed-loop system can automatically compensate for increased torque demands, avoiding position errors caused by increased torque demands in open-loop systems. This design greatly improves the accuracy of the entire system, especially for applications that require high-precision dynamic control, such as pick-and-place systems and 3D printers.

Upgrading Stepper Systems

The addition of high-performance feedback devices is the main cost difference between open-loop and closed-loop stepper systems. However, with technological improvements, the prices of these devices are becoming lower, making closed-loop stepper motor systems more accessible to a wider range of applications. Additionally, the energy-saving of closed-loop systems quickly offsets the slight increase in feedback device costs, making closed-loop stepper motor systems a cost-effective choice for many applications.

In conclusion, closed-loop stepper motor systems provide numerous benefits, including greater accuracy, reduced motor noise, and improved system performance. As technology continues to advance, the cost of these systems will continue to decrease, making them more accessible to a wider range of applications.

Why Brushless motor is better?

/in , /by

Brushless motors is becoming increasingly popular in recent years for a good reason. Compared to traditional AC motors, brushless motors have several advantages that make them a better choice for a wide range of applications. In this article, we will explore the reasons from the following aspects.

Stable speed control

Brushless motors have the ability to maintain a stable speed, even under varying loads. This is achieved through the use of feedback control systems. The system continuously monitors the motor’s speed, and adjusts the voltage and current supplied to the motor as needed to maintain the desired speed.

In contrast, AC motors typically rely on mechanical systems to regulate speed, such as changing the number of poles in the motor or adjusting the frequency of the AC power supply. These methods are less precise and can result in speed fluctuations under varying loads.

As a result, brushless DC motors are recommended for applications that require stable speed control regardless of the load fluctuation.

Higher torque at low speeds

Brushless motors have a higher torque at low speeds, which makes them well-suited for applications that require high starting torque, such as robotics, electric vehicles, and industrial machinery.

 

Space-saving design

Brushless DC motors have a slim body and provide high power due to the use of permanent magnets in the rotor. This compact design makes them an excellent choice for applications where space is limited. For example, brushless motors are commonly used in drones, where weight is a crucial factor in determining flight time and maneuverability.

Saving Energy

Brushless DC motors use permanent magnets in the rotor, which reduces the secondary loss of the rotor. This results in a reduction in power consumption and increased energy efficiency compared to traditional AC motors.  According to research, brushless motors can reduce power consumption by up to 35% compared to frequency conversion control of three-phase induction motors. This makes brushless motors an excellent choice for applications where energy consumption is a significant concern, such as in electric vehicles.

AC and DC Power Supply

One of the unique advantages of brushless motors is that they can use both AC and DC power supplies. In contrast, AC motors can only use AC power. This versatility makes brushless motors an excellent choice for applications where power supply options are limited .

 

In conclusion, brushless motors offer several advantages over traditional AC motors, including stable speed control, higher torque at low speeds, space-saving design, energy efficiency, and versatility in power supply options. These advantages make brushless motors an excellent choice for a wide range of applications, from robotics and automation to electric vehicles and aerospace engineering.