Life has depended mostly on advanced machinery, especially in manufacturing industry. The introduction of computer numerical control (CNC) equipment transformed the manufacturing business
by allowing nearly endless sorts of shape to be programmed. When you look at the history of computer numerical...
Closed Loop Control of a Stepper Motor
Abstract
Life has depended mostly on advanced machinery, especially in manufacturing industry. The
introduction of computer numerical control (CNC) equipment transformed the manufacturing business
by allowing nearly endless sorts of shape to be programmed. When you look at the history of computer
numerical control, you can see not only how important it is, but also how quickly manufacturing is
changing. Stepper motors and servo motors are the two most common motors used in CNC machine
tools [1]. A stepper motor can start, reverse, and brake fast. This report is based on the design of a closed
loop control of a stepper. Stepper motors have low-cost, high-reliability, high torque at low speeds, and
they have simple structure. In this design, stepper motors will be used to transform a non-linear input
from the controller into linear movement. This is done by twisting a screw-like shaft to move the load
[2]. The model will be designed using proteus, and it will be controlled using GRBL.
i
,Contents
Abstract .................................................................................................................................................... i
List of figures .......................................................................................................................................... iii
List of tables ........................................................................................................................................... iii
1.Introduction ......................................................................................................................................... 1
2.Problem description............................................................................................................................. 1
2.1. Problem definition ................................................................................................................... 1
2.2. Aims and objectives ................................................................................................................. 1
3.Literature review.................................................................................................................................. 2
4.Theoretical background ....................................................................................................................... 2
4.1. Types of closed-loop control for stepper motors .................................................................... 3
4.2. Working principle of a stepper motor ..................................................................................... 3
4.3. Construction of a stepper motor ............................................................................................. 4
4.4. Types of stepper motors .......................................................................................................... 5
4.5. Types of wiring ......................................................................................................................... 6
4.6. Motor sizes ............................................................................................................................... 7
4.7. Motor shaft design ................................................................................................................... 7
5. Design specifications ........................................................................................................................... 8
5.1. Functional specifications .......................................................................................................... 8
5.2. Non-functional specifications .................................................................................................. 8
6. Design methodology ........................................................................................................................... 9
Block diagram.................................................................................................................................. 9
G code ............................................................................................................................................. 9
G code sender ................................................................................................................................. 9
Connecting the G code sender with the model ............................................................................ 10
Simulation model .......................................................................................................................... 10
Results and discussion .......................................................................................................................... 11
Project management ............................................................................................................................ 12
Cost estimation ............................................................................................................................. 12
Profit or loss analysis .................................................................................................................... 13
Feasibility study .................................................................................................................................... 13
Conclusion ............................................................................................................................................. 13
References ............................................................................................................................................ 14
Appendix .................................................................................................. Error! Bookmark not defined.
ii
, List of figures
Figure 1: stepper motor .......................................................................................................................... 4
Figure 2: cross-section of a stepper motor ............................................................................................. 4
Figure 3: Two-Phase Stator Winding....................................................................................................... 5
Figure 4: Three-Phase Stator Winding .................................................................................................... 5
Figure 5: Two-Phase, Single-Pole Pair Stator .......................................................................................... 5
Figure 6: Two-Phase, Dipole Pair Stator ................................................................................................. 5
Figure 7: cross-section of two-Phase Permanent Stepper Motor .......................................................... 5
Figure 8: cross-section of the two-Phase Variable Reluctance Stepper Motor ...................................... 6
Figure 9: Two phase Hybrid Motor ......................................................................................................... 6
Figure 10: Internal Structure of Magnetic Rotor in Hybrid Motor.......................................................... 6
Figure 11: unipolar stepper motor, 6-lead.............................................................................................. 7
Figure 12: unipolar stepper motor, 5-lead.............................................................................................. 7
Figure 13: unipolar stepper motor, 8-lead.............................................................................................. 7
Figure 14: bipolar stepper motor............................................................................................................ 7
Figure 15: Block diagram of a closed loop control of a stepper motor ... Error! Bookmark not defined.
Figure 16; F-Engrave software ................................................................. Error! Bookmark not defined.
Figure 17: Universal G code sender software ....................................................................................... 10
Figure 18: Virtual serial ports emulator software................................................................................. 10
Figure 19: complete circuit diagram of a closed loop control of a stepper motor . Error! Bookmark not
defined.
Figure 20: X+ movement .......................................................................... Error! Bookmark not defined.
List of tables
Table 1: component costs ..................................................................................................................... 12
Table 2: Direct labour costs .................................................................................................................. 13
Table 3: Profit or loss analysis ............................................................................................................... 13
Table 4: GANTT CHART............................................................................. Error! Bookmark not defined.
iii
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