Stepper motors are a type of electromagnetic actuator that convert digital input pulses into precise rotational or linear motion. Each pulse causes the motor to move by a fixed step angle, making the total rotation proportional to the number of pulses applied. The speed of the motor is determined by the frequency of these pulses. These motors play a crucial role in mechatronics systems and are commonly used for position control and maintaining constant speeds. They offer advantages such as low inertia, high accuracy, no cumulative error, and straightforward control. Stepper motors are widely used in various electromechanical devices, including CNC machines, packaging equipment, computer peripherals, photocopiers, and fax machines. When selecting a stepper motor, it's essential to ensure that its output power exceeds the power required by the load. Calculating the load torque of the mechanical system is the first step, followed by verifying that the motor’s torque-frequency characteristics can handle the load with some margin for reliable operation. The load torque at different frequencies should remain within the motor’s torque curve. The step angle of the motor should match the mechanical system to achieve the desired pulse equivalent. To reduce the pulse equivalent, you can adjust the screw lead or use subdivision drives. However, subdivision only increases resolution, not accuracy, which is determined by the motor’s inherent design. In addition, when choosing a motor, consider the load inertia and the machine tool’s starting frequency. Ensure that the motor’s inertial frequency characteristics align with the system requirements to support fast movement. Key calculations involved in selecting a stepper motor include: 1. **Gear Reduction Ratio**: Calculate based on the required pulse equivalent using the formula: $ i = \frac{\phi \cdot S}{360 \cdot \Delta} $, where $ \phi $ is the step angle, $ S $ is the screw pitch, and $ \Delta $ is the pulse equivalent. 2. **Load Inertia Calculation**: Convert the inertia of the table, screw, and gears to the motor shaft: $ J_t = J_1 + \frac{1}{i^2}[(J_2 + J_s) + \frac{W}{g}(\frac{S}{2\pi})^2] $ 3. **Total Motor Torque**: Sum the acceleration, friction, and cutting torques: $ M = M_a + M_f + M_t $ 4. **Starting Frequency Estimation**: Estimate based on load torque and inertia: $ F_q = f_{q0} \sqrt{\frac{1 - (M_f + M_t)/M_l}{1 + J_t/J_m}} $ 5. **Maximum Frequency and Acceleration Time**: Ensure the motor can maintain sufficient torque at high speeds. 6. **Load Torque vs. Maximum Static Torque**: Verify that the sum of friction and cutting torque remains within 20% to 40% of the motor’s maximum static torque. By following these steps, you can effectively select a suitable stepper motor that meets the performance and reliability requirements of your application.
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