Special Motor Drives

For more visit :- By: M. P. Girnari

www.mpgirnari.in (SSEC, Bhavnagar)
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Outlines
• Stepper motor drive
• Stepper motor
• Types of stepper motor
• Permanent magnet stepper motor
• Variable reluctance stepper motor
• Hybrid stepper motor
• Features of stepper motor
• Torque vs. Stepping rate characteristics
• Drive circuits for stepper motor
• Brushless DC motor
• DC Servo motor & its control
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Introduction to Stepper motor
• As it name implies, stepper motor rotates in discrete steps, each step
corresponding to a pulse that is supplied to its stator windings.
• A stepper motor is digital electromechanical device where each step
command pulse result in a movement of shaft by a discrete angle
called step angle of the motor.
• It is used when motion and position have to be precisely controlled.
• By keeping count of number of command pulse ?
• By changing frequency of command pulses ?
• Ideally suited to open loop position and speed control. How ?

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Cont..
• Some applications in which stepper motor is used…
• Printer
• Machine tools
• Robotics
• Disk drive
• X-Y recorder
• Textile industries
• Electrical watches etc.
• Mostly used because…
• Compatible to digital system
• Can be used in open loop configuration (no need of sensors)
• Accurate control of speed and position can be achieved

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Types of stepper motor
• Three types :
1. Variable reluctance motor
1. Single-stack type
2. Multi-stack type
2. Permanent magnet motor
1. 2-phase 4/2 pole
2. Disk type
3. Hybrid stepper motor

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Single Stack VR stepper motor : 4/2 pole VR motor
• Construction:
• As shown in the figure it has 4-poles in stator
and 2-poles in rotor .

• Four phases namely A, B, C, D are connected to

DC source through semi-conductor switches
(𝑆𝐴 , 𝑆𝐵 , 𝑆𝐶 , 𝑆𝐷 ) respectively.

• In order to rotate the rotor in particular

direction, the phases must be excited in proper
sequence with the help of semi-conductor
switches.
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Single Stack VR stepper motor : 4/2 pole VR motor
• Working :
• When phase-A is excited
• The rotor will turn and aligns with the axis of phase-A because
of reluctance torque.
• The rotor will be stable in this position and cannot move until
phase-A is de-energized.
• When phase-B is excited and phase-A is disconnected
• The rotor will turn (90°) and aligns with the axis of phase-B
because of reluctance torque.
• The rotor will be stable in this position and cannot move until
phase-B is de-energized.
• Thus
• As the phases are excited in the sequence as A, B, C, D, A…
rotor will turn in clockwise direction with step angle of (90°)
• The direction of rotation of rotor can be reversed by reversing
the excitation sequence of phases.
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Single Stack VR stepper motor : 4/2 pole VR motor
• To obtain small step angle
• The step angle can be reduced from 90° to 45° by exciting
phases in sequence A, A+B, B, B+C, C, C+D, , D, D+A, A…
• When phase-A excited, the rotor aligns with the axis of A.
• When both phases A & B are excited simultaneously, rotor
will turn by 45° in clock-wise direction.
• Similarly, rotor can be rotated in anti-clockwise direction
with step of 45° by switching phases in the sequence of A,
A+D, D, D+C, C, C+B, B, B+A, A…
• Micro-stepping
• It can be defined as the technique of gradually shifting
excitation from one phase to another in order to obtain
smaller step size (step angle) is known as micro-stepping.

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Single Stack VR stepper motor : 8/6 pole VR motor
• Construction:
• As shown in the figure it has 8-poles in stator
and 6-poles in rotor .
• In order to rotate the rotor in particular
direction, the phases must be excited in proper
sequence with the help of semi-conductor
switches.
• For clockwise rotation, phases are switches in the
sequence of A, B, C, D, A and for anti-clockwise
rotation, the phase must be excited in the reverse
sequence as A,D,C,B,A...
• The rotor will rotate with step size of 15°.
• ℎ𝑜𝑤?
• Total number of steps to complete one rotation will be 24.
• So, 360/24  15° For more visit:- www.mpgirnari.in 9
Single Stack VR stepper motor: 8/6 pole VR motor
• Winding is shown only by phase-A.
• Working :
• When phase-A is excited
• The rotor will turn until a pair of poles (1 and 4) aligns with the
axis of phase-A.
• The rotor will be stable in this position and cannot move until
phase-A is de-energized.
• When phase-B is excited and phase-A is disconnected
• The rotor will turn in clockwise (𝑤𝑖𝑡ℎ 𝑠𝑡𝑒𝑝 𝑜𝑓 15°) and until
rotor poles 3 & 6 are aligns with the axis of phase-B.
• The rotor will be stable in this position and cannot move until
phase-B is de-energized.
• The step size can be reduced to 𝟕. 𝟓° by micro-stepping as discussed.
• For clockwise rotation  A, A+B, B, B+C, C, C+D, D, D+A, A…
• For anti-clockwise rotation  A, A+D, D, D+C, C, C+B, B, B+A, A…
• The direction of rotation of rotor can be reversed by reversing the excitation sequence of10phases
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Multi-stack VR stepper motor
• To obtain smaller step size typically in the range of 2° 𝑡𝑜 15°.
• A m-stack VRSM can have m number of identical single stack VR motors with
their rotors are mounted on a common shaft.
• The number of poles on the stator and rotor will be same, So same pole pitch.
• While the stator poles (or teeth) in all m stacks are aligned, the rotor poles
(teeth) are shifted by 1/m of the pole pitch from one another.
• All the stator pole windings in a given stack are excited simultaneously unlike
the single stack type VRM.
• The stator winding of each stack forms one phase as they are excited
simultaneously.
• Although 3-stack are common, a multi-stack motor can has as many as seven
stacks.

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 Multi-stack VR stepper motor
• Cross section of 3-stack (3-phase) motor is shown.
• In each stack, stator and rotor have 12 poles.
• Stator poles in all three stacks are aligned, but the
rotor poles are shifted by 1/3 of pole pitch (10°).
• When phase-A is excited, the relative position of
stator and rotor poles for 3-stacks is shown in the
figure.
• Rotor pole of stack-A are aligned with stator poles.

• When phase-A is de-energized and phase-B is energized, rotor poles of stack-B will
get aligned with stator poles.
• Thus, rotor will move by 1/3 of pole pitch in particular direction.
• Now, if phase-B is de-energized and phase-C is energized, the rotor will move
another 1/3 of pole pitch in particular direction.
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Multi-stack VR stepper motor

• Let N be the number of rotor poles (teeth) and m number of stacks or phases.
• Then
360
• 𝑃𝑜𝑙𝑒 𝑡𝑒𝑒𝑡ℎ 𝑝𝑖𝑡𝑐ℎ =
𝑁
360
• 𝑆𝑡𝑒𝑝 𝑎𝑛𝑔𝑙𝑒 =
𝑁∗𝑚

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Features of VR stepper motor
• High torque to inertia ratio
• High acceleration rates
• High speed of response
• Do not have detent or residual torque.

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Types of torques in VR stepper motor
• Detent torque:-
• When no current is flowing in the stator coil, there will be a torque acting on the rotor
which opposes its movement, this torque is known as detent torque.
• When power is switched off, its help the rotor to retain its position.
• Holding torque:-
• The amount of torque the motor produces at rest when it has rated current flowing
through its windings
• Pull-in torque:-
• The values of torque and speed that the motor can start, stop, or reverse in
synchronism with the input pulses.
• Pull-out torque:-
• The values of torque and speed that motor can run in synchronism with the input
phases. The maximum values the motor can provide without stalling.
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Permanent Magnet stepper motor
• 2-pole PMSM is shown in the figure.
• Construction:
• Stator of PMSM is similar to that of VRSM.
• Rotor is different from VRSM
• Rotor is cylindrical and radially magnetized permanent
magnet.
• Working:-
• When phase-A is excited with the direction of current as
shown in the figure, North pole aligns with phase-A.
• When phase-B is excited and phase-A is de-excited,
rotor turns through 90° in clockwise direction, N-pole is
now align with B-phase.
• Direction of rotation will be depends on the direction of
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Working : Permanent Magnet stepper motor
Phase-A ON Phase-A OFF

Phase-B OFF Phase-B ON

Phase-A OFF Phase-A ON

Phase-B ON Phase-B OFF

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Working : Permanent Magnet stepper motor
Phase-A ON Phase-A OFF

Phase-B OFF Phase-B ON

Phase-A OFF Phase-A ON

Phase-B ON Phase-B OFF

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Disk Type Permanent Magnet stepper motor
• 2-pole PMSM is shown in the figure.
• Construction:
• Rotor is thin disk made of rare-earth magnetic material.
• The disk is magnetized with alternating North and South
poles up to 100 individual tiny magnets around the edge of
the disk
• C-shaped two stationary field poles.
• Working:-
• When one of the phase is energized, the rotor will align itself
with field-pole.
• When excitation is shifted to another phase rotor will turn
half the rotor pole pitch in order to align with field pole of
the second phase.
• In order to keep rotation in he same direction, 2nd phase
must be turned off and 1st phase must be turned on with its
direction reversed.
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Hybrid Stepper motor
• Combinations of PMSM and VRSM
• Combines the important features of both types
• Axial permanent magnet in the middle of the rotor.
Similar to the rotor of VRSM.

• Advantages :
• Small step angle 1.8°
• Greater torque per unit volume
• High detent torque.
• Disadvantages
• More expensive than VRSM

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Hybrid Stepper motor
• Construction :
• Stator has 8-poles, each has 5teeth and one
coil.
• Rotor has two end caps, each with 5 teeth
separated by permanent magnet.
• Teeth on the both end caps of the rotor have
the same pitch as teeth on stator poles.
• There will be an offset (of one tooth pitch)
between the teeth of the two end caps. So that
a tooth on one end cap coincides with a slot at
the other.
• The permanent magnet is axially magnetized.
• So, teeth on the left end of the rotor are given
the North polarity and on the right end the
south polarity.
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Hybrid Stepper motor
• Working :
• The phase-A formed by connecting coils 1,3,5,7 in series.
The phase-B formed by connecting coils 2,4,6,8 in series.
• When phase-A carries positive current
• Stator poles 1 & 5 will become south pole and 3 & 7 poles
will become north pole.
• The rotor teeth with north and south polarity align with
the teeth of stator poles 1 & 5 and 3 & 7 respectively.
• When phase-A is de-energized and B energized
• The rotor will move by one quarter of tooth pitch 1.8° .
• The rotor can be stepped anti-clockwise direction
• By energizing the phase in the sequence +A, +B, -A, -B, +A….
• The rotor can be stepped in clock-wise direction
• By energizing the phases in the sequence is +A, -B, +B, +A…
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Features of Stepper motor
1. Compatible with digital system
1. Do not need ADC at input as conventional servo system needs.
2. Wide range of step angles is available (1.8 to 90)
3. No need to use sensors and controller in order to control speed and position
control applications.
4. Can be used in open loop configuration.
5. Bidirectional control can be achieved.
6. Low speeds are possible without the use of reduction gears.
7. Maximum torque occurs at low pulse rates. So, load can be accelerate easily.
8. Moment of inertia is low.
9. Starting current is low.
10. By maintaining synchronization, multiple stepper motor can be driven by the same
source.
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Features of Stepper motor
• Disadvantages
1. Low efficiency
2. Low torque capacity
3. Proper matching is required between load, motor and its drive.
4. Resonance can be problem in case of VR stepper motor.

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Torque vs. Stepping rate characteristics
• From the torque-stepping rate characteristics:
• As stepping rate increases  load torque decreases
• Rotor have less time to drive the load from one
position to another
• After some stepping rate rotor can not able to
follow command
• Starting to miss pulse
• For starting of stepper motor
• Value of torque and stepping rate such that the
point of operation lies in the left side of curve-I
• Then motor can start.
• Rotor can follow the step command without missing
(synchronized motion)
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Torque vs. Stepping rate characteristics
• For the load torque 𝑻𝑳𝟏 & stepping rate < 𝒔𝟏
• motor can start and synchronise without missing a
stepping pulse command
• Once motor has been started and synchronized, the
stepping rate can be increased for same load torque
𝑇𝐿1 without missing a pulse command
• For the load torque 𝑇𝐿1 , stepping rate can be
increased up to 𝑠2 without missing a pulse
command or synchronism.
• What if stepping rate is beyond 𝒔𝟐 ?
• Motor will not be able to follow pulse commands
• So, motor will loose the synchronism.
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Torque vs. Stepping rate characteristics
• Slew range concept:
• The area between the curve-I and curve-II
represent the various values of load torque
and stepping rate which a motor can follow
without loosing a pulse command
• It is necessary that motor has been started
and synchronized already.
• This area is known as slew range.
• The knowledge of slew-range is useful for speed
control.
• At stepping rate corresponding to slew range
• Motor can not be started or reversed without loosing
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Ramping :
• When a stepper motor is carrying a load at rest.
• If you want to run at particular stepping rate?
• It can not suddenly run on desired stepping rate.
• Thus, in order to run stepper motor at desired stepping rate it must be accelerated
gradually.

• Similarly, if Stepper motor is running at particular stepping rate.

• If you want to stop it?
• It cannot be brought to rest immediately.
• Thus, in order to stop the stepper motor it must be decelerated gradually.
• Thus, the ramping is the process by which motor is accelerated or
decelerated.
• During the acceleration phase ramping consists of a progressive increase in the
number of driving pulse per second.
• During the acceleration phase ramping consists of progressive decrease in the number
of driving pulse per second.

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Drive circuits for Stepper motor
• Driven by low dc voltage source
• Consider the figure.
• When switch is closed
• The phase will be energized by dc source.
𝑅
• 𝐼𝑝ℎ𝑎𝑠𝑒 builds up at a rate decided by the electrical time constant of phase winding.
𝐿
• When switch is opened
• The phase will be de-energised.
• Transferring the current to freewheeling diode 𝐷𝐹 .
• 𝐼𝑝ℎ𝑎𝑠𝑒 will start decreasing at a rate decided by the electrical time constant of phase
𝑅
winding until it becomes zero.
𝐿
• Motor torque T ∝ (𝐼𝑝ℎ ) phase current
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Unipolar drive circuit
• Can supply current in only one direction.
• Consider the drive circuit (used for two phases)
shown in the figure.
• When switch 𝑆1 is closed
• Phase-A will get connected to DC source.
• Phase current is builds up.
• When switch 𝑆1 is opened
• Phase-A will get dis-connected to DC source.
• Phase current decays in the freewheeling path (phase-A,
𝐷𝐹 𝑎𝑛𝑑 𝑅𝐹 ).
• The external resistance 𝑅𝐸 used to reduce electrical
time constant. (improvement in building up and
decaying of phase current).
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Unipolar drive circuit
• How to produce rated phase current?
• Value of 𝑅𝐸 is chosen according to required electrical
𝐿
time constant 𝜏 =
𝑅
• Then, in order to produce required rated current, the
value of DC source is calculated as..
• 𝑉𝑑 = 𝐼𝑅 (𝑅𝐸 + 𝑅𝑃 )
• Where, 𝑅𝑃 𝑖𝑠 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑝ℎ𝑎𝑠𝑒 𝑤𝑖𝑛𝑑𝑖𝑛𝑔

• Unipolar drive is not efficient.

• When switch is closed, the phase current is flows through 𝑅𝐸 causing dissipation of energy
across it.
• When switch is opened, the phase current flows thorough free-wheeling circuit resistance.
Also there will be dissipation of energy that was stored in the phase.
• Because of these energy losses, this drive circuit is highly inefficient.
• Can be used for low power stepper motor.
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Unipolar drive for VR Stepper motor
• Efficient drive circuit
• Which can provide fast build-up and decay of phase current.
• Working is based on the chopper principle.
• Circuit is shown for only one phase. Each other phase
will have similar drive circuit.
• The DC source voltage can now be much larger than
previous circuit.
• Figure-a :- Drive circuit
• Figure-b :- Phase voltage switching
• Figure-c :- Current waveforms

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Unipolar drive for VR Stepper motor
• Working:-
• When 𝑆1 and 𝑆2 are closed, phase get energized by 𝑉𝑑𝑐 and 𝐼𝑝ℎ
builds up.
• When 𝐼𝑝ℎ > 𝐼𝑅 by predefined amount, 𝑆1 is switched off.
• The 𝐼𝑝ℎ freewheels through 𝑆2 and 𝐷2 and decreases below 𝐼𝑅 .
• After fixed interval, 𝑆1 is turned on 𝐼𝑝ℎ will increase.
• When 𝐼𝑝ℎ > 𝐼𝑅  𝑆1 is turned off again.
• Thus, turning 𝑆1 ON and OFF alternately, the 𝐼𝑝ℎ is maintained
to be nearly 𝐼𝑅 .
• At 𝑡 = 𝑡𝑜 + 𝑇, the phase is de-energized by turning off both 𝑆1
and 𝑆2 .
• Phase current will flows through the freewheeling path
(𝐷1 , 𝑉𝑑 , 𝐷2 ) causing restoring of the energy stored in the phase
winding into source 𝑉𝑑 .
• Also, 𝐼𝑝ℎ 𝑑𝑒𝑐𝑎𝑦𝑠 faster because current is flowing against a
large 𝑉𝑑 .
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Bipolar drive for PM Stepper motor
• Consider the drive circuit (used for one phase)
shown in the figure.
• When switches 𝑆1 and 𝑆2 are closed
• Phase winding carries positive current
• When switches 𝑆3 and 𝑆4 are closed
• Phase winding carries negative current

• When switches 𝑆1 and 𝑆2 are closed

• Phase winding carries positive current
• Rapid build up of phase current by selecting 𝑅𝐸
• When switches 𝑆1 and 𝑆2 are opened
• Phase winding is de-energized
• Phase current will flows through path (𝐷3 , 𝑉𝑑 𝑎𝑛𝑑 𝐷4 ).
• The major part of energy stored in the phase winding is
fed back to the source 𝑉𝑑 .
• Phase current will decays to zeros at rapid rate.
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Bipolar drive for PM Stepper motor
• Because of 𝑅𝐸 , there will be a dissipation of energy.
• So, drive circuit is inefficient. Although it is more
efficient than the unipolar drive circuit.
• How to obtain efficient performance?
• By eliminating 𝑅𝐸 and using chopper principle, an
efficient bipolar drive circuit is obtained.
• Working is as follows:-
• To energise the phase winding with a positive current, 𝑆1 and 𝑆2 are turned ON.
• The 𝐼𝑝ℎ builds up rapidly.
• When 𝐼𝑝ℎ > 𝐼𝑅  𝑆1 − 𝑂𝐹𝐹.  𝐼𝑝ℎ flywheels through 𝑆2 and 𝐷4 .
• After fixed interval, 𝑆1 is turned ON again.
• Thus current fluctuates around the rated value 𝐼𝑅 .
• When phase is to be de-energized, both 𝑆1 𝑎𝑛𝑑 𝑆2 are required to be turned off.
• Winding current flows through the path consisting of 𝐷3 , 𝑉𝑑 𝑎𝑛𝑑 𝐷4 . Rapid decay of 𝐼𝑝ℎ and recover of energy.
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GTU Previous Years Questions
1. Explain the operation of a variable reluctance stepper motor.
2. Explain unipolar drive circuit for stepper motor.
3. Explain basic working theory of brushless DC motor.
4. Explain basic working theory of DC servo motor.
5. Draw and explain the block diagram and working of Servo Motor Drives.
6. Enlist various requirements for implementation of servo motor drive.

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Tutorial :- 6 Special motor drive
1. What are the features of stepper motor? Also writes the advantages and
disadvantages of stepper motor.
2. Describe the operation of variable reluctance stepper motor. What is its micro-
stepping?
3. Describe the operation of Permanent magnet stepper motor.
4. Describe the operation of Hybrid stepper motor.
5. Discuss about the torque versus stepping rate characteristics of a stepper motor.
What is the slew range and ramping ?
6. Explain unipolar drive circuit for stepper motor.
7. Explain bipolar drive circuit for stepper motor. Which stepper motor needs bipolar
drive.
8. Explain basic working theory of brushless DC motor.
9. Explain basic working theory of DC servo motor.
10. Draw and explain the block diagram and working of Servo Motor Drives.
11. Enlist various requirements for implementation of servo motor drive.
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