A stepper motor, also known as step motor or stepping motor, is a brushless DC electric motor that rotates in a series of small and discrete angular steps. Stepper motors can be set to any given step position without needing a position sensor for feedback. The step position can be rapidly increased or decreased to create continuous rotation, or the motor can be ordered to actively hold its position at one given step. Motors vary in size, speed, step resolution, and torque. Switched reluctance motors are very large stepping motors with a reduced pole count. They generally employ closed-loop commutators.
Mechanism
Brushed DC motors rotate continuously when DC voltage is applied to their terminals. The stepper motor is known for its property of converting a train of input pulses (typically square waves) into a precisely defined increment in the shaft’s rotational position. Each pulse rotates the shaft through a fixed angle. Stepper motors effectively have multiple "toothed" electromagnets arranged as a stator around a central rotor, a gear-shaped piece of iron. The electromagnets are energized by an external driver circuit or a micro controller. To make the motor shaft turn, one electromagnet is first given power, which magnetically attracts the gear's teeth. When the gear's teeth are aligned to the first electromagnet, they are slightly offset from the next electromagnet. This means that when the next electromagnet is turned on and the first is turned off, the gear rotates slightly to align with the next one. From there the process is repeated. Each of the partial rotations is called a "step", with an integer number of steps making a full rotation. In that way, the motor can be turned by a precise angle. The circular arrangement of electromagnets is divided into groups, each group called a phase, and there is an equal number of electromagnets per group. The number of groups is chosen by the designer of the stepper motor. The electromagnets of each group are interleaved with the electromagnets of other groups to form a uniform pattern of arrangement. For example, if the stepper motor has two groups identified as A or B, and ten electromagnets in total, then the grouping pattern would be ABABABABAB. Electromagnets within the same group are all energized together. Because of this, stepper motors with more phases typically have more wires (or leads) to control the motor.
Types There are three main types of stepper motors: permanent magnet, variable reluctance, and hybrid synchronous. Permanent magnet motors use a permanent magnet (PM) in the rotor and operate on the attraction or repulsion between the rotor magnet and the stator electromagnets. Pulses move the rotor clockwise or anticlockwise in discrete steps. If left powered at a final step, a strong detent remains at that shaft location. This detent has a predictable spring rate and specified torque limit; slippage occurs if the limit is exceeded. If current is removed, a lesser detent still remains, holding shaft position against spring or other torque influences. Stepping can then be resumed while reliably being synchronized with control electronics. Permanent magnet stepper motors have simple DC switching electronics, a power-off detent, and no position readout. These qualities are ideal for applications such as paper printers, 3D printers, and robotics. Such applications track position simply by counting the number of steps that each motor has been instructed to take. Variable reluctance (VR) motors have a soft iron rotor and operate based on the principle that minimum reluctance occurs with minimum gap, so the rotor points are attracted toward the stator's magnetic poles. Variable reluctance motors have detents when powered on, but not when powered off. Hybrid synchronous motors are a combination of the permanent magnet and variable reluctance types, to maximize power in a small size.
Phases
Two phase There are two basic winding arrangements for the electromagnetic coils in a two phase stepper motor: bipolar and unipolar.
Unipolar motors A unipolar stepper motor has one winding with center tap per phase. Each section of windings is switched on for each direction of magnetic field. Since in this arrangement a magnetic pole can be reversed without switching the polarity of the common wire, the commutation circuit can be simply a single switching transistor for each half winding. Typically, given a phase, the center tap of each winding is made common: three leads per phase and six leads for a typical two phase motor. Often, these two phase commons are internally joined, so the motor has only five leads. A microcontroller or stepper motor controller can be used to activate the drive transistors in the right order, and this ease of operation makes unipolar motors popular with hobbyists; they are probably the cheapest way to get precise angular movements. For the experimenter, the windings can be identified by touching the terminal wires together in PM motors. If the terminals of a coil are connected, the shaft becomes harder to turn. One way to distinguish the center tap (common wire) from a coil-end wire is by measuring the resistance. Resistance between common wire and coil-end wire is always half of the resistance between coil-end wires. This is because there is twice the length of coil between the ends and only half from center (common wire) to the end. A quick way to determine if the stepper motor is working is to short circuit every two pairs and try turning the shaft. Whenever a higher-than-normal resistance is felt, it indicates that the circuit to the particular winding is closed and that the phase is working.
Bipolar motors
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