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Stepper motors and controllers work together to create precise motion in various applications. The stepper motor generates an electromagnetic field, while the stepper controller supplies power to the motor windings. The system can be pre-programmed or adjusted on the fly. They are used in robotics, manufacturing, and even in computer printers and scanners. They are often designed for specific tasks and can replace expensive servo drives.
While stepper motors and controllers work together to form a single system, they are separate components. The stepper controller, or stepper drive, is the “smart” component. It is programmed to coordinate the linear movements of the crankshaft. However, the stepper motor does the actual work. Independent of each other, neither is able to perform a useful function, but together the two components form a technologically very advanced piece of machinery.
The difference between stepper motors and controllers lies in the basic function and purpose of each. The stepper motor is designed for precision movement and does the physical work of the system. Unlike direct current (DC) powered motors, which use brushes, the stepper motor uses windings that generate an electromagnetic field when energized. The stepper controller is a programmable circuit that supplies power to the stepper motor windings at certain times. This controlled delivery of electrical energy powers the windings and rotates the motor shaft in the correct direction.
The stepper controller can be pre-programmed with the information needed to perform a precise, repeating function. The real benefit of the system, however, is the ability to program on the fly. An operator can adjust the stepper controller programming using a computer. These alterations change the direction or speed of movement in the stepper motor shaft.
Stepper motors and controllers are used together to create precisely measured motion in a variety of mechanical applications. This has allowed the stepper motor and controller setup to replace expensive servo drives in many applications. Model building enthusiasts use stepper motors and controllers to create remote-controlled model vehicles that can perform a wide range of motion. Robotics engineers can use these components to create robots that can navigate around obstacles, climb stairs, or perform tasks deemed dangerous to human workers. Stepper motors and controllers are also found in the office and home as components of computer printers and scanners.
When used in an industrial application, stepper motors and controllers are often designed for a specific task. The precise movements of robotics and manufacturing equipment are made possible with single-phase or two-phase step windings in the stepper motor. The stepper controller is pre-programmed or manually programmed by the operator to control the movements of the stepper motor shaft. This type of technology is used to create machines to operate welding machines or laser cutting equipment that may be too dangerous for human workers.
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