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Electrical Mechanical
energy Motor energy
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Rotor and stator magnetic fields 3
Brot
Rotation
Bsta
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Magnetic field generation 4
=
B
Iph
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Torque 5
Brot
Rotation
Bsta
sin() ()
The angle between the two magnetic field is named load angle.
The maximum output torque, and then the maximum efficiency, is
obtained when the load angle is 90.
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Back electro-motive force 6
The rotation of the Brot magnetic field causes a variation of the magnetic
flux in the solenoid.
Brot
Rotation Bsta
=
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Basic principle 7
The phase relation between the rotor and stator magnetic field (i.e.
the load angle) must be always greater than 0 in order to keep the
motor in motion (negative angles reverse the rotation).
Output torque depends on both the solenoid current and load angle.
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Brush DC motor
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Brush DC motor basics 9
D
A The stator
magnetic field is
generated by a
permanent
magnet
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Brush DC motor basics 10
N S
D
D
A
Bsta
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Brush DC motor basics 11
Iph
The brushes connect
the motor leads to the
next coil (B), keeping
the load angle almost Brot
equal to 90 during
rotation
B
N S
E
E
B
Bsta
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Brush DC motor basics 12
Iph
Changing the
direction of the
current reverses Brot
the direction of
the motor B
N S
E
E
B
Bsta
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Brush DC motor basics 13
Phase impedance
= +
+
Zph BEMF
Back electromotive
force generator
=
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Voltage mode driving
The brush DC motor is driven by directly applying a voltage to the
motor leads.
Iph
+
Brush
V DC Tqload
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Voltage mode driving 15
Tqload
Operating Speed
speed
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Voltage mode driving 16
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Voltage mode driving
At maximum torque limit, the current into the motor is maximum.
Iph
+
Zph BEMF
+
V
Speed = 0 BEMF = 0
Iph = Vph/Rph
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Voltage mode driving
At maximum speed limit, the current into the motor is minimum
(in theory it is zero)
The maximum speed is limited by the supply voltage of the motor driver:
Iph
+
Zph BEMF
+
V
BEMF = Vph
Iph = (Vph BEMF)/Rph = 0
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Extending maximum speed 19
Motor current
rating
Vph = 8 V
Vph = 5 V
Speed
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Extending maximum speed 20
Speed
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Brush DC motor summary 21
The magnetic field intensity is proportional to the current forced into the motor leads.
The magnetic field rotation is automatically obtained commutating the active coil
through mechanical switches (brushes).
The load angle is almost constant and it is about 90 allowing the maximum efficiency
(current vs. torque proportion).
The motor is controlled by applying a voltage to the motor leads. The higher the
voltage, the higher the speed. The direction is changed by reversing the polarity on the
leads.
The maximum torque is limited by the current rating of the motor and it is obtained at
zero speed (start-up).
The maximum speed is limited by the supply voltage and it is obtained when no load
torque is present.
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Three-phase brushless motor
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Brushless motors overview
There are different types of brushless motors:
Single-phase
Two-phase
Three-phase
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Three-phase brushless motor basics 24
N S
The windings are
connected by one
of the sides.
W The sum of the
currents is zero.
V
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Three-phase brushless motor basics 25
W V
Bsta
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Three-phase brushless motor basics 26
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Three-phase brushless motor basics 27
Back electromotive
Phase impedance
force (BEMF)
= + generators
are three sinewave
voltages(*) delayed
+ from each other by
U Zph
120.
The sinewave
+ amplitude is
V Zph proportional to the
motor speed:
+ =
W Zph
(*) Some motors have a BEMF with trapezoidal shape instead of sinusoidal 20/06/2016
6-step driving 28
6-step driving imposes a current between two of the three phases leaving the
third one floating.
In this way the stator magnetic field can be positioned in 6 discrete directions.
U U U
Iph Iph
V W V W V
W
Iph
U U U
Iph Iph
W V W V W
Iph
V
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6-step driving 29
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6-step driving 30
1 2 3 4 5 6
IU
IV
IW
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6-step driving 32
U When the
magnetic field of
the rotor crosses
Bsta the unloaded
Iph phase, the
respective BEMF
Brot voltage changes
polarity (zero-
crossing)
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6-step driving 33
= +
Iph
+
U Zph
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Sinusoidal driving 34
By applying three sinusoidal voltages with a delay of 120 in the motor phases it
is possible to obtain three sinusoidal currents generating a rotating magnetic
field.
This method, named sinusoidal driving, allows a smoother operation
compared to the 6-step method.
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Sinusoidal driving 35
6 1 2 3 4 5
H3
VUV
VU
VWU
VV H1
W H2 V
VW
VVW
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Sinusoidal driving 36
5
6 1 2 3 4 5 U
H3
4 6
VU
VV H1
W V
3 H2
1
VW
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Sinusoidal driving 37
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Field Oriented Control 38
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Field Oriented Control 39
Field Oriented Control (FOC) can be represented through this block diagram
id
Park Clark
iq transf. transf.
i,i iU,iV,iW
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Field Oriented Control 40
STEP 1) Using the Clark transformation, the currents of the 3-phase system
(U,V,W) are projected in an orthogonal system (,).
=
1 2
Is = +
3 3
Is NOTE: Considering iU + iV + iW = 0, the projection
can be obtained using only two currents
=U
iq + PI Vd,Vq V,V VU,VV,VW
Inverse Space
id + PI Park Vector
id
V iq
Park
transf.
Clark
transf.
i,i iU,iV,iW
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Field Oriented Control 41
= cos + sin
= sin + cos
Isd d
Where r is the rotor position
Isq
r
iq + PI Vd,Vq V,V VU,VV,VW
Inverse Space
id + PI Park Vector
r
id
Park Clark
iq transf. transf.
i,i iU,iV,iW
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Field Oriented Control 42
STEP 3) The direct (d) and quadrature (q) components of the current can be
controlled using a standard PI system.
The direct component gives information about the load angle of the motor.
The maximum efficiency is obtained when id = 0.
id
Park Clark
iq
transf. i,i transf. iU,iV,iW
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Field Oriented Control 43
STEP 4) Using the inverse Park transformation, the output of the PI controller,
which are the direct and quadrature voltages, are re-projected on the
orthogonal system (,).
= cos sin
= sin sin
Where r is the rotor position
r
id
Park Clark
iq
transf. i,i transf. iU,iV,iW
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Field Oriented Control 44
STEP 5) The voltages projected on the (,) system are converted to (U,V,W)
voltages using the space vector modulation.
id
Park Clark
iq transf. transf.
i,i iU,iV,iW
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Field Oriented Control 45
Pros Cons
Can control the efficiency of the Implies complex calculations which
system imposing a load angle cannot be performed by low-level
(direct component of the current) microcontrollers
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Three-phase brushless motor summary 46
The magnetic field rotation is obtained driving in the proper way the
phases.
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Bipolar stepper motor
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Stepper motors overview
There are different types of stepper motors:
Three-phase
Five-phase
The presentation will describe the basics of the bipolar stepper motor
because it is one of the most common versions.
In most cases, the considerations can be extended to the other types.
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Bipolar stepper motor basics 49
The stator is B+
composed of two coils, A permanent
named phases, magnet generates
positioned at 90 from the magnetic field
each other of the rotor
A+ A-
N S
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Bipolar stepper motor basics 50
Each step represents a stable position where the motor shaft can be
easily kept forcing the proper current into the phases.
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Bipolar stepper motor basics 51
B-
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Bipolar stepper motor basics 52
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Bipolar stepper motor basics 53
Back electromotive
Phase impedance
force (BEMF)
= + generator are two
sinewave voltages(*)
delayed from each
+ other by 90.
A+ Zph A-
The sinewave
amplitude is
+ proportional to the
B+ Zph B- motor speed:
=
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Step angle 54
4
This effect is obtained through a proper
2
shaping of the rotor and stator cores: as
a consequence, at each position of the
magnetic field, more mechanical
positions correspond. 3
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Full step 55
Forcing the phase currents according to the following sequence, the motor rotates
performing one step at a time.
This is named Full-step 1 phase on driving or Full-step wave mode.
B+ B+ B+ B+
A+ A- N A+ A-
S
A+ A- S N A+ A-
N S
N
S
B- B- B- B-
1 2 3 4
IphA = + IphA = 0 IphA = - IphA = 0
IphB = 0 IphB = + IphB = 0 IphB = -
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Full step 56
It is also possible to perform the sequence forcing the same current in both
phases. In this case, the stator magnetic field is the geometric sum of two
components and is 2 times stronger.
This is named Full-step 2 phase on driving or Full-step normal mode.
B+ B+ B+ B+
A+ A- A+ A- A+ A- A+
A-
B- B- B- B-
1b 2b 3b 4b
IphA = + IphA = - IphA = - IphA = +
IphB = + IphB = + IphB = - IphB = -
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Half step 57
subsequent steps. 1 1b
Half-step is performed.
1ph ON 2ph ON Half-step
1 1
N S
1b 1b
2 2 2 2b
2b 2b
3 3
N S
3b 3b
4 4 3 3b
4b 4b
B+
= ()
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Microstepping 59
The pairs of currents which are applied to the phases depends on the number of
microsteps in which the step is divided:
() =
() =
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Microstepping 60
= 2
This is because in microstepping the motor phases are driven with the
maximum current one at a time (the sine peak corresponds to the
cosine zero-crossing and vice-versa), whereas in full-step, both phases
can be driven at maximum current at the same time.
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Torque vs Angle characteristic 61
The torque vs displacement angle (i.e. the angle between the ideal step position and the
actual rotor position) is sinusoidal:
Torque
4 x STEP
Displacement
L STEP
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Torque vs Angle characteristic 62
Torque
TqMAX
Unstable region
TqLOAD
4 x STEP Displacement
L+STEP
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Torque vs Angle characteristic 63
If the starting displacement is about one step angle (i.e. the load torque approaches the TqMAX), the
output torque after the step could be lower than the load and the new stable position will be a 4-step
angle away from the target position.
This is a step-loss condition which could also cause the de-synchronization of the motor (stall).
Torque
TqMAX
Unstable region
TqLOAD
4 x STEP Displacement
4 x STEP + L
L L+STEP
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Stall and step-loss 64
When the stepper motor is loaded with a torque exceeding its torque
vs. speed characteristic, a stall or a step-loss event could occur.
When a step-loss occurs, the motor loses the synchronism for a short
period and then resumes.
As result, the rotor continues its rotation, but the actual position is
different from the ideal one.
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Torque vs. Speed characteristic 65
Holding torque
The maximum torque the
motor can sustain when Pull-out torque
Torque stopped The maximum output
Holding torque vs speed when the
Pull-out curve
torque motor is in motion
Slew region
Max speed
Pull-in curve The maximum speed the
motor can reach when
unloaded
Start-Stop region
NOTE: The curves change with driving method and phase current.
Most manufacturers provide the curve @ rated current in full-step.
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Resonances 66
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Resonances 67
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Bipolar stepper motor summary 68