Installation precautions for hollow rotary actuators

 ‌‌1. Introduction to hollow rotary actuators

The hollow rotary actuator is a special rotary actuator with a hollow structure, which is convenient for installing air pipes and wires in the jig. Its working principle is to achieve the rotation effect through the meshing of the gears of the inner and outer rings. The gears on the inner and outer rings mesh with each other, and the rotation force is transmitted to the inner or outer ring through the transmission mechanism. This design is not only compact and comprehensive, but also has the characteristics of high repeatability, high rigidity and high rotation accuracy.

2. Components of hollow rotary actuators

1. Motor: Provides power source, usually a frameless torque motor with high torque output and high motion accuracy.

‌2. Reducer: Reduces the high-speed rotation of the motor and increases the output torque, so that the actuator can provide a large torque at a low speed. Common types of reducers include harmonic reducers and planetary gear reducers.

‌3. Sensor: Including torque sensors and encoders, which are used to monitor the motion state and position of the actuator to ensure precise control.

‌4. Bearings‌: Support and guide the rotational motion, reduce friction and wear, and improve the service life and precision of the actuator.

‌5. Hollow design‌: The hollow rotary actuator is characterized by its hollow structure inside, which can accommodate cables, water pipes or other pipelines that need to pass through, facilitating internal wiring and maintenance.

3. Main functions of hollow rotary actuators

1. Provide degrees of freedom‌: The hollow rotary actuator provides degrees of freedom for the robot, allowing the robot to move in multiple directions. The degree of freedom of a robot refers to the number of independent coordinate axis movements. The higher the degree of freedom, the more complex the tasks that the robot can perform.

‌2. Improve the load-bearing capacity and precision‌: The performance of the hollow rotary actuator directly affects the load-bearing capacity and precision of the robot. The load capacity of the robot and the precision of the end motion depend on the design and performance of the rotary actuator. High-precision rotary actuators can ensure the stability and accuracy of the robot when performing tasks.

‌3. Realize multi-dimensional precise motion control‌: The hollow rotary platform has high precision, stability and flexibility, and can achieve multi-dimensional precise motion control. This enables the robot to perform high-precision operations in various complex environments, such as high-precision welding, assembly, etc. ‌ .

‌4. Improve production efficiency and reduce costs ‌: By using a hollow rotating platform, the robot can rotate 360 ​​degrees without changing direction, which is very useful for robots that require visual monitoring and data collection, such as patrol robots or filming robots. In addition, in the manufacturing industry, the hollow rotating platform can help robots avoid collisions with conveyor belts and maintain effective operation, thereby improving production efficiency and reducing costs ‌.

4. Installation precautions for hollow rotary actuators ‌ 

1. Installation environment requirements ‌: The hollow rotating platform should be installed indoors to avoid direct sunlight and heat radiation. The working environment temperature should be between 0-50 degrees, and the temperature under the origin sensor should be between 0-42 degrees. The working environment humidity should be less than 85%, and flammable and explosive acidic gases and dust, oil stains, splashing water, etc. should be avoided ‌.

‌2. Installation location selection ‌: Choose a suitable location to install the hollow rotating platform to ensure that it will not be subjected to direct vibration and excessive impact. The installation surface of the equipment should be clean and can be wiped clean with anti-rust oil or gasoline, zinc-sodium water.

‌3. Installation and adjustment of the drive motor: Before installation, the motor input shaft, positioning boss and internal connection parts of the equipment should be cleaned, and avoid using tools such as hammers to prevent damage to bearings or gears. After installation, the drive motor needs to be carefully positioned and precision adjusted to ensure smooth and stable operation of the equipment.

‌4. Sealing inspection: Pay special attention to the sealing inside the equipment, especially the sealing of the rotating shaft of the servo hollow rotating platform. Ensure the sealing inside the equipment to prevent environmental pollution.

‌5. Installation of connecting parts: During the installation process, ensure that the concentricity of the motor input shaft and the output shaft of the hollow platform are consistent, and the outer flanges are parallel. When tightening with bolts, the bolts should be rotated diagonally first, and then tightened one by one to ensure the stability and precision of the equipment.

Source:https://plaza.rakuten.co.jp/yixing/diary/202503270000/

Working principle and maintenance method of permanent magnet stepper motor

1.A brief introduction to permanent magnet stepper motor

Permanent magnet stepper motor (PM stepper motor), also known as PM stepper motor, is a motor that uses the interaction between permanent magnet and electromagnetic coil to achieve stepping motion. Its core feature is that permanent magnet steel is used as the rotor material, and the stator is processed into claw-type tooth poles by stamping, usually using radial multi-pole magnetized permanent magnet steel. This design makes permanent magnet stepper motors have the advantages of low cost, simple structure and high reliability.

2.Working principle of permanent magnet stepper motor

The working principle of permanent magnet stepper motor is based on electromagnetic interaction. When the stepper motor driver receives the control pulse and direction signal, the internal logic circuit controls the winding to be energized in a certain sequence. For example, for a two-phase stepper motor, when both phase windings are energized and excited, the motor output shaft will be stationary and locked in position. If the current of one of the phase windings changes, the motor will rotate one step in a given direction. By changing the direction of the winding current in sequence, the motor can achieve continuous step rotation.

3.Performance advantages of permanent magnet stepper motors

1.High precision: The torque and position control accuracy of permanent magnet stepper motors are very high, and the rotation angle can be accurately controlled to achieve high-precision positioning and motion control. This makes it perform well in applications that require high-precision positioning, such as precision machining equipment, automated production lines, etc.

2.High reliability: Since the mechanical structure and control circuit of permanent magnet stepper motors are relatively simple, and there are no wearing parts such as brushes and commutation mechanisms, they have high reliability and stability and can operate stably for a long time. This is very important for equipment that requires long-term stable operation, such as industrial robots, automation equipment, etc.

3.No noise and pollution: Permanent magnet stepper motors do not generate noise or pollutants caused by friction and wear because they have no mechanical contact parts, so they are very suitable for applications with high environmental requirements. This is a significant advantage for equipment that requires a quiet operating environment, such as medical equipment, precision instruments, etc.

4.Controllable speed and acceleration: The speed and acceleration of permanent magnet stepper motors can be precisely controlled by the controller, and have broad application prospects. This is very useful for applications that require precise control of movement speed and acceleration, such as CNC machine tools, automated production lines, etc.

4.Maintenance methods for permanent magnet stepper motors

‌1.Keep the motor clean‌: Regularly remove dust from the surface of the stepper motor, use organic solvents that do not cause corrosion to clean it, ensure that the motor surface is clean, and avoid dust affecting the motor's aesthetics and heat dissipation effect‌.

‌2.Check the bearing wear‌: Regularly check the bearing wear and replace the severely worn bearings in time. Ensure that the bearings have an appropriate amount of lubricating oil to reduce friction and wear‌.

‌3.Check the wiring and screw looseness‌: Regularly check whether the motor wiring is loose, and tighten the loose screws in time. Ensure that the electrical and mechanical components inside the motor are firmly connected to avoid abnormalities caused by looseness‌.

‌4.Monitor the motor temperature‌: When the stepper motor is running, it is necessary to monitor whether its temperature is moderate. Avoid running the motor in a high temperature environment, ensure that the motor runs in a suitable application environment, and avoid the impact of high temperature on the motor‌.

‌5.Avoid overload operation‌: Reasonably control the power supply voltage and current to avoid damage to the motor caused by overload operation. Ensure that the motor runs under the specified load to avoid shortening the service life due to overload.

‌6.Check the insulation performance‌: Regularly check the insulation performance of the motor to prevent safety hazards such as leakage. Ensure the dryness of the motor windings to avoid the influence of humid environment on the motor insulation material.

‌7.Abnormal situation handling‌: If the stepper motor makes abnormal noise or other abnormal conditions during operation, it should be stopped and checked immediately. The inspection content may include whether the coupling, pulley, fastening screws, etc. are loose, and whether the slider, slide rail, positioning sensor and line connection are normal. If an abnormality is found, it should be handled in time and the equipment should be restored to normal operation.

‌Reasons for abnormal noises in Worm Gearbox

1.Definition of Worm Gearbox

Worm Gearbox is a power transmission mechanism that uses a gear speed converter to reduce the number of revolutions of the motor to the required number of revolutions and obtain a larger torque. It is widely used in the transmission systems of various machines, such as vehicles, heavy machinery, processing machinery, automated production equipment, and home appliances. ‌

2.Working principle of Worm Gearbox

Worm Gearbox achieves speed reduction and torque increase through the meshing of the worm and worm wheel. The worm is a cylinder with spiral teeth, and the worm wheel is a spiral gear. When the worm rotates, its spiral teeth mesh with the spiral teeth of the worm wheel, thereby achieving the effect of speed reduction and torque increase.

3.Main components and functions of Worm Gearbox

1.Worm gear: This is the core transmission component of the reducer, and its main function is to transmit motion and power between two staggered axes. The worm is usually made of a harder material (such as alloy steel) to improve wear resistance, while the worm wheel is made of a softer material (such as cast iron or specially configured wear-resistant nickel bronze) to reduce friction and improve transmission efficiency.

‌2.Shaft and bearings: The main functions of bearings and shafts are power transmission, operation and efficiency. The parts on the shaft are axially fixed by shaft shoulders, sleeves and bearing caps. Deep groove ball bearings are usually used to bear radial loads and small axial loads. When the axial load is large, angular contact ball bearings, tapered roller bearings or a combination of deep groove ball bearings and thrust bearings are used.

‌3.Housing: The housing is an important component of the reducer and the base of the transmission parts. It should have sufficient strength and rigidity. It is usually made of gray cast iron. For reducers with heavy loads or impact loads, cast steel housings can also be used. The housing is made horizontally split along the axis, and the upper housing cover and the lower housing are bolted together.

‌4.Accessories‌: including oil cap/breather, end cap, oil seal, drain plug, oil mark cap/oil mark, etc. These accessories play an important role in lubrication, sealing, oil drainage, and oil quantity observation in the operation of the reducer. ‌

4.Reasons for abnormal noise in Worm Gearbox ‌

1.Worm gear wear: After long-term use, the worm gear and worm gear may wear, resulting in poor meshing and noise. The degree of wear can be detected by visual inspection or using measuring tools. If the wear is severe, a new worm gear and worm gear need to be replaced. ‌

2.Bearing damage or poor lubrication: Bearing fatigue or insufficient lubrication can cause metal peeling on the bearing surface and produce abnormal noise. Ensure that the bearing is well lubricated, add or replace lubricating oil if necessary, and if the bearing is severely damaged, a new bearing needs to be replaced. 

‌3.Improper use of lubricating oil: Insufficient lubrication or use of the wrong lubricating oil will increase friction, resulting in noise. Check the oil level and oil quality to ensure that the lubricating oil is sufficient and of good quality. If the lubricating oil is deteriorated or contaminated, a new lubricating oil needs to be replaced. ‌ 

‌4.Improper installation‌: Unsteady installation of the Worm Gearbox or loose connections can cause vibration and noise. Make sure the Worm Gearbox is firmly installed and well-aligned to avoid vibration and noise caused by misalignment.

‌5.Overload‌: Worm Gearbox running at a load exceeding the rated load can cause overheating and increased noise. Check the load conditions to ensure that it is running within the normal range.

‌6.Mechanical failure‌: Some mechanical failures such as severely worn gears and loose connection parts can also cause noise in the Worm Gearbox. Perform a comprehensive inspection and repair or replace the faulty parts.

‌7.Foreign matter intrusion‌: When the Worm Gearbox is running, foreign matter such as dust and accumulated water in the surrounding environment may enter the reducer, causing poor meshing of the worm gear and noise. Make sure the environment around the Worm Gearbox is clean to prevent foreign matter from entering.

‌8.Design and manufacturing defects‌: Gear processing errors, unreasonable tooth shape design, etc. can cause poor meshing and noise. Choose a reliable quality reducer brand and model to avoid design and manufacturing defects.

Source:https://plaza.rakuten.co.jp/stepperonline/diary/202502100000/

‌‌Precautions for using waterproof stepper motors

1.Brief description of waterproof stepper motors

Waterproof stepper motors are stepper motors that can work normally under a certain waterproof level. It effectively prevents water, dust, etc. from entering the motor through special shell design and waterproof shaft seal and other technical means, so as to maintain normal operation in harsh environments. Waterproof stepper motors have the advantages of high efficiency, stability and reliability, and are widely used in home appliances, machinery, automobiles and other industries.

2.Design features of waterproof stepper motors

1.Insulation material: The motor winding adopts polyethylene insulation and nylon household waterproof electromagnetic wire. The cable connection method is based on cable joint technology. The seam insulation is removed from the scraped paint layer, the welding is firm, and the raw rubber is wrapped around the layer to ensure waterproofing.

‌2.Anti-corrosion material: The outer part of the motor is made of anti-corrosion material or anti-corrosion coating, and the sealing mechanism blocks the cracks or channels that may exist inside and outside to ensure that water does not enter the motor and cause short circuit failure. 

3.IP protection level: The motor industry has a standardized liquid protection measure called IP protection level, which power engineering and motor manufacturers need to meet the application specification requirements.

3.Structural composition of waterproof stepper motors

1.Housing: Made of stainless steel, it has good waterproof and dustproof performance and can work normally in harsh environments.

2.Motor drive part: It includes the motor body, circuit board and power supply, providing efficient and stable power output.

3.Bearing: High-strength bearings are used to withstand high loads and high speed requirements.

4.Sealing ring: Made of high-strength materials, it effectively prevents corrosion and moisture from penetrating into the motor.

5.Stator: The stator is the stationary part of the stepper motor, usually composed of multiple poles, which can be permanent magnets or electromagnets. Its main function is to generate a magnetic field and drive the rotor to rotate.

6.Rotor: The rotor is the rotating part of the stepper motor, usually made of magnetic materials, which can be permanent magnets or soft magnetic materials. Its main function is to generate torque under the action of the magnetic field generated by the stator to rotate the motor.

7.Winding: The winding is the conductive part of the stepper motor, usually wound around the magnetic poles of the stator, generating an electromagnetic field to drive the rotor to rotate.

‌8.Controller: The controller is the control part of the stepper motor, responsible for receiving pulse signals and converting them into motor rotation, usually including drive circuits, pulse distributors and microprocessors, etc.

‌9.Encoder: The encoder is the feedback part of the stepper motor, used to detect the rotation position and speed of the motor, usually including photoelectric encoders, magnetic encoders or Hall sensors.

‌4.Precautions for the use of waterproof stepper motors

1.Control signal line and power supply connection: Make sure that the control signal line is firmly connected, and it is best to consider shielding issues at industrial sites. The power supply voltage should be appropriate, and the +/- polarity of the DC input must not be connected incorrectly. The motor model or current setting value on the drive controller should be appropriate.

‌2.Grounding method: Be sure to understand the grounding method. Using floating without connection may cause the motor to work unstably. Closely observe the status of the motor within half an hour of starting operation, such as whether the movement is normal, the sound and temperature rise, and stop and adjust immediately if any problems are found.

‌3.Use environment‌: Although waterproof stepper motors can be used in dusty, humid or oily places, it does not mean that they can work in water. Try to place them in a relatively clean environment and avoid long-term immersion in water‌.

‌4.Maintenance and care‌: Regularly check the exterior, fixed parts, output shaft, encoder connection cable, power connector, cooling fan, etc. of the stepper motor to ensure that they are firmly connected and operate normally. Clean dust and oil in time to ensure that the motor is in normal condition‌.

‌5.Cable protection‌: Ensure that the cable is not subjected to torque or vertical load due to external bending force or its own weight, especially at the cable outlet or connection. In the case of moving stepper motors, the cable should be firmly fixed to a stationary part, and it should be extended with an additional cable installed in the cable support to reduce bending stress‌.

‌6.Load control‌: Ensure that the radial and axial loads applied to the stepper motor shaft during installation and operation are controlled within the specified values ​​for each model. It is best to use a flexible coupling to reduce load damage or wear on the shaft end and bearings‌.

‌7.Installation precautions‌: When installing/removing the coupling component to the stepper motor shaft end, do not hit the shaft end directly with a hammer to avoid damaging the encoder. Try to align the shaft end to the best state to avoid vibration or bearing damage‌.

Source:https://plaza.rakuten.co.jp/yixing/diary/202412260000/

Debugging steps and optimization methods of closed-loop stepper motors

1.Brief introduction of closed-loop stepper motors

Closed-loop stepper motors are high-precision servo motors. By installing position sensors such as encoders or resolvers on the motor shaft, the actual position of the motor is fed back to the control system to achieve closed-loop control. This design makes the closed-loop stepper motor have the advantages of high precision, high stability and low vibration, and is suitable for occasions with high precision requirements.

2.Working principle of closed-loop stepper motors

The working principle of closed-loop stepper motors is similar to that of open-loop stepper motors. Both control the rotation angle of the motor by receiving pulse signals. The difference is that closed-loop stepper motors add a position feedback link to the control system. When the motor rotates, the position sensor detects the actual position of the motor and sends this feedback signal back to the control system. The control system adjusts the drive current and phase of the motor by comparing the input signal and the feedback signal, thereby more accurately controlling the position and speed of the motor.

3.Debugging steps of closed-loop stepper motors

1.Initialization parameters: Before wiring, the parameters need to be initialized. This includes selecting the appropriate control mode on the control card, clearing the PID parameters, ensuring that the default enable signal is off when the control card is powered on, and saving this state. Set the control mode, enable external control, encoder signal output gear ratio, and the proportional relationship between the control signal and the motor speed on the stepper motor.

2.Wiring: Power off the control card and connect the stepper motor driver and the stepper motor according to the instructions. Make sure all connections are firm and not loose.

3.Debug the stepper motor driver: Set the subdivision number, start-up speed, single-axis acceleration, and cornering acceleration of the stepper driver as needed. The higher the subdivision number, the higher the control resolution, but it will affect the maximum feed speed. The start-up speed is the highest frequency at which the stepper motor can start working directly without acceleration. Single-axis acceleration and cornering acceleration describe the acceleration and deceleration capabilities of a single feed axis and multiple feed axes when linked, respectively.

4.Use encoder feedback: In a closed-loop control system, use the encoder to feedback the real-time speed of the motor, and adjust the output of the pulse frequency after comparing it with the set value to achieve accurate speed tracking and enhance control accuracy. ‌5. S-type acceleration curve‌: Use S-type acceleration curve for smooth acceleration and deceleration control, so that the speed increases or decreases smoothly according to the set slope, and realizes smooth start and stop‌.

4.Optimization method of closed-loop stepper motor ‌

1. Subdivision control‌: By increasing the number of teeth on the rotor, the accuracy of the stepper motor can be improved. Subdivision control can make the stepper motor move a smaller step size under each pulse, thereby improving positioning accuracy‌.

‌2.Closed-loop control‌: Closed-loop control is a key method to improve the accuracy and stability of stepper motors. By adding position feedback to the motor control system, the closed-loop control system can detect the actual position of the motor in real time during the motor movement and compare it with the target position. If a deviation is found, the system will send instructions for correction to ensure that the motor runs according to the expected path and speed. This method can effectively prevent step loss and vibration and improve the stability and accuracy of the system‌.

3‌.Configure a reducer‌: By configuring a reducer on the stepper motor, the speed of the motor can be reduced and the torque can be increased, thereby improving the stability and accuracy of the system. The function of the reducer is to reduce the rotation speed of the motor and increase the output torque. It is suitable for scenarios that require high torque and low-speed operation.

‌4.Use a cost-effective drive solution: For example, use the TMC4361 stepper closed-loop drive solution, which combines the TMC2130/TMC5130 (low power) or TMC2160/TMC5160 (high power) driver chip, built-in closed-loop algorithm and current control, supports S-shaped ramp acceleration and deceleration, and has the characteristics of high response, high speed and high precision.

‌5.Optimize current control: The performance of the stepper motor can be further improved by optimizing the current control strategy. For example, using an absolute encoder or an incremental encoder can achieve more precise position control.

Speed ​​regulation method and selection conditions of AC gear motor

1.A brief introduction to AC gear motor

AC gear motor is a device that converts high-speed and low-torque motor output into low-speed and high-torque output, and is widely used in industrial production. The components of AC gear motor include AC motor, reducer and output shaft. The AC motor provides power, the reducer reduces the speed through the transmission of gears, and the output shaft connects the mechanical equipment to provide torque. The reducer is usually composed of components such as gears, worm gears, transmission shafts and bearings. Its working principle is to reduce the speed of the input shaft to the output shaft through the transmission of gears, while increasing the output torque of the output shaft.

2.Characteristics of AC gear motor

‌1.High efficiency: AC gear motor adopts an efficient gear transmission system, which can provide efficient mechanical conversion and reduce energy waste.

‌2.Low noise and vibration: Through precision manufacturing and optimized design, AC gear motor can reduce noise and vibration and provide smooth and quiet operation.

‌3.High reliability: Made of high-quality materials and advanced processes, it has good mechanical strength and durability and can operate reliably under various working conditions.

‌4.Precision control‌: Equipped with precision encoders, it provides accurate speed and position feedback, enabling the control system to accurately control motor movement‌.

‌5.Multiple configuration options‌: Provide different voltages, speeds, output powers and axial mounting methods to meet different application requirements‌.

3.Requirements for AC gear motor selection

1.Load characteristics‌ is one of the key factors in selection. The reduction ratio and output torque need to be determined based on the actual load characteristics of the equipment. If the load is large, a gear reduction motor with a larger reduction ratio needs to be selected to increase the output torque; if the load is small, a gear reduction motor with a smaller reduction ratio needs to be selected to improve operating efficiency‌.

2.Output speed‌ is another important factor. The output speed of the motor needs to match the working requirements of the equipment. If the output speed is too high or too low, it will affect the stability and operating efficiency of the equipment. Therefore, when selecting a gear reduction motor, the output speed needs to be determined based on the working requirements and load characteristics of the equipment‌.

3.Motor power‌ is also an important parameter for selection. The rated power of the motor needs to be determined based on the actual power requirements of the equipment. If the motor power is too low, it cannot meet the working requirements of the equipment; if the motor power is too high, it will waste electricity and cause unnecessary costs. Therefore, when selecting a gear reduction motor, it is necessary to determine the rated power of the motor according to the actual power demand of the equipment.

4.Environmental conditions are also a factor that needs to be considered. The protection level and corrosion resistance of the motor need to be determined according to the working environment of the equipment. If the working environment of the equipment is harsh, it is necessary to select a gear reduction motor with a higher protection level and corrosion resistance to ensure the safe operation of the equipment.

4.Speed ​​regulation method of AC gear motor

‌1.Speed ​​regulation by changing the number of motor poles: The speed of the motor is adjusted by changing the number of motor poles. This method is suitable for application scenarios that require a wider speed regulation range.

‌2.Speed ​​regulation by changing the motor slip rate: The speed is adjusted by changing the slip rate of the motor. This method is suitable for wound asynchronous motors, but the speed regulation range is small, and the resistance consumes power and the efficiency is low.

‌3.Speed ​​regulation by changing the power supply frequency of the motor: The speed is adjusted by changing the power supply frequency of the motor. This method is suitable for occasions that require higher speed regulation accuracy and dynamic performance.

‌4.Serial speed regulation: The speed is adjusted by introducing additional electromotive force in the rotor circuit. It is suitable for wound asynchronous motors and can improve the speed regulation efficiency.

5.Speed ​​regulation of wound motor rotor series resistance: The speed is adjusted by inserting resistance in series in the rotor circuit. This method has a small speed regulation range, but a simple structure and is suitable for some specific equipment such as cranes.

‌6.Stator voltage regulation speed regulation: The speed is adjusted by changing the power supply voltage of the motor. This method is suitable for single-phase motors and some special applications.

‌7.Electromagnetic speed regulation: The speed is adjusted steplessly and smoothly by changing the current of the excitation coil. It is suitable for slip motors, but the control power is small and not suitable for long-term low-speed operation.

‌8.Hydraulic coupling speed regulation: The output speed of the motor is adjusted by the hydraulic coupling. This method is suitable for occasions that require smooth speed regulation.

Reasons for overheating of hybrid stepper motors

1.What is a hybrid stepper motor

A hybrid stepper motor is a motor that combines the advantages of a permanent magnet stepper motor and a reactive stepper motor. ‌ It achieves the complementary advantages of high torque and high precision through a specific structural design, thus providing a high-precision, combined stepper drive. Hybrid stepper motors are divided into two-phase, three-phase and five-phase, of which the two-phase step angle is generally 1.8 degrees, the three-phase step angle is generally 1.2 degrees, and the five-phase step angle is generally 0.72 degrees. The rotor of this motor itself is magnetic, so the torque generated under the same stator current is greater than that of a reactive stepper motor, and its step angle is usually smaller. This makes hybrid stepper motors widely used in occasions that require high-precision control, such as economical CNC machine tools.

2.Design ideas for hybrid stepper motors

‌1.Structural design‌: The structural design of the hybrid stepper motor combines the advantages of variable reluctance (VR) stepper motors and permanent magnet (PM) stepper motors. Specifically, it adopts the gear-shaped iron core rotor of the VR motor, which can achieve a smaller step angle, and combines the strong permanent magnet of the PM motor to enhance the torque output, achieving the coexistence of miniaturization and high torque. This structural layout optimizes the magnetic field distribution and torque characteristics of the motor, allowing the hybrid stepper motor to provide stronger power output without sacrificing step accuracy.

‌2.Number of phases and step angles‌: Hybrid stepper motors are divided into two-phase, three-phase and five-phase, of which the two-phase step angle is generally 1.8 degrees, the three-phase step angle is generally 1.2 degrees, and the five-phase step angle is 0.72 degrees. This design enables the hybrid stepper motor to have a higher step angle resolution and can achieve higher positioning accuracy.

3.Operating conditions of hybrid stepper motors

1.Power supply‌: The hybrid stepper motor needs to be connected to an appropriate power supply to provide the necessary power to drive the motor. The voltage and current of the power supply should meet the specifications of the motor to ensure the normal operation of the motor.

‌2.Control signal‌: The operation of the hybrid stepper motor also requires external control signals. These signals are usually generated by a microcontroller or a special stepper motor driver, which controls the number of steps and direction of the motor by changing the direction and size of the current in the coil.

3‌.Drive circuit‌: In order to convert the control signal into a drive signal that the motor can understand, a special drive circuit is required. These circuits can change the direction of the current in the coil in a timely manner according to the instructions of the control signal, thereby guiding the motor to rotate according to the preset mode.

4.Reasons for the high temperature of the hybrid stepper motor

1.Excessive current‌: When the stepper motor is working, if the current setting is too large, it will cause too much heat energy to be generated inside the motor, thereby increasing the temperature. Excessive current may be because the current set by the driver is larger than the rated current of the motor, or because the speed of the stepper motor is too fast, causing the motor to heat up. ‌ 

2‌.Improper drive method‌: The stepper motor needs to be controlled by the driver. If the driver is improperly set, such as excessive current, unreasonable subdivision settings, etc., it will cause the motor to heat up. Improper driving mode will cause the motor to generate additional heat during operation.

‌3.Long-term operation: If the stepper motor works continuously for too long without proper heat dissipation measures, the heat cannot be dissipated in time, which will cause the temperature to rise. Long-term operation at high voltage or high frequency will also increase the temperature.

‌4.Magnetic material loss: The magnetic material in the stepper motor will generate additional heat due to hysteresis loss and eddy current loss during operation. These losses are inevitable, but can be reduced by optimizing the design and material selection.

‌5.High ambient temperature and poor heat dissipation conditions: The temperature of the operating environment is relatively high, the heat dissipation conditions are relatively poor, or the installation contact area does not meet the standards, which will also cause the stepper motor temperature to rise.

‌6.The working state does not meet the technical requirements: If the three-phase six-beat motor is changed to double three-beat operation, the temperature rise will become higher. This shows that improper adjustment of the working state will increase the temperature rise of the motor.

7.Drive circuit failure: The stepper motor drive circuit fails, and the motor works at a single high voltage or a high frequency for a long time, which also causes the temperature to rise.