Common Errors When Using Stepper Motor And How To Fix Them

By Author: mctt
Total Articles: 2
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Common errors when using Stepper Motor and how to fix them

1. Problem: Motor or driver overheats.

Solution: The rated current is set too high, there is no current reduction mode when stopping. Set the RMS current according to the motor's specifications, use the idle current reduction function.

2. Problem: The stepper motor or Drive operates intermittently or unstably.

Solution: First, make sure that all connections between the stepper motor and the driver and controller are tight. When replacing the stepper motor, stepper driver or controller or controller in the motion control system, be sure to check all terminal blocks and connectors. Check the accuracy of the cable/wiring system. Apply tension to the motor's wiring to confirm that the connections are secure and check the resistance with an ohm meter.

3. Problem: Poor system performance (EMI issues, motor skipping steps intermittently/low repeatability, motor stalling, abnormal motor behavior – running forward, running in one direction then the other, wires heating up)

Solution: ...
... Check if the wires/cables are too long and if the connections between the wires are too long. Keep the wires/cables under 8m in length. For applications where the length of the lead from the stepper motor to the controller exceeds 8m, please contact the factory for instructions. Another possibility is that the motor leads are too small. A common mistake is to match your cables to the lead size. Also, check the motor age, as over time and use, stepper motors lose some of their magnetism, affecting performance. Typically, one can expect 10,000 hours of operation for a stepper motor (about 4.8 years, running one eight-hour shift per workday) or as much as 20,000 hours of operation assuming high-quality components and ideal operating conditions. Also, make sure your stepper motor/driver combination is appropriate for your application. Contact your supplier if you have any concerns.

4. Problem: The stepper motor stalls.

Solution: In some cases, the stalling of the stepper motor causes a large voltage spike that damages the phase transistors on the driver. Some drivers are designed to protect themselves from such events. External transient protection can be added.

5. Problem: The stepper motor driver no longer functions.

Solution: Disconnecting the stepper motor wires while the driver is powered will create a current surge that is fed to the driver and may cause the driver to fail. Avoid performing any service on the stepper motor, driver, or controller while powered up, especially regarding the motor connections. This precaution is mandatory for both the driver and the technician/installer.

6. Problem: The stepper motor has a shorted coil or a shorted circuit in the motor housing.

Solution: Your stepper motor is likely defective. Do not attempt to repair the motor. Opening the motor may cause the motor to lose magnetism, resulting in poor performance. Opening the motor housing will also void your warranty. The motor coil can be tested with an ohm meter.

7. Problem: Non-ideal environmental factors.

Solution: Environmental factors such as electrical noise (from welding, etc.), chemical vapors, humidity, moisture, dust, metal debris, etc., can damage electronic components and stepper motors. Protect drivers, controllers, and stepper motors from environments that are corrosive, poorly ventilated, or contain voltage spikes. You can choose products in a wide range of line voltages as well as IP65-rated, splash-proof stepper motors. For explosion-proof or washout-proof motors, contact the factory directly. For AC lines containing voltage spikes, a line regulator (filter) may be required.

8. Problem: Stepper Motor is Driving in Reverse with Drive

Solution: A loaded stepper motor rotating will generate back-EMF voltage on the driver. Higher speeds will generate higher voltage levels. If the rotation speed is too high, this voltage can damage the driver. This is especially dangerous if the motor is driven in reverse while the driver is still on.

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