When a stepper motor starts, it may not move at all or just vibrate in place. Sometimes it loses steps during operation. What could be the cause? Here are some common issues to check:
1. Is the motor’s torque sufficient to drive the load? It's generally recommended that the selected motor should have a torque greater than 50% of the actual required torque. Stepper motors cannot handle overload, even for a short time, which can result in lost steps, stalling, or erratic movement.
2. Is the current from the upper controller’s pulse input strong enough (typically >10mA)? If the current is too low, the optocoupler might not turn on properly, causing signal loss. Also, if the input frequency is too high, the signal might not be received. If the upper controller uses a CMOS output, you’ll need a CMOS-compatible driver circuit.
3. Is the starting frequency set too high? The acceleration process should be properly configured in the startup program. Ideally, the motor should start from the specified minimum frequency and gradually increase to the target speed. Even a short acceleration phase can lead to instability or idle motion.
4. If the motor isn’t properly mounted, this issue can occur. This is normal in some cases because the motor may experience strong resonance, leading to a loss of synchronization. Make sure the motor is securely fixed to avoid such problems.
5. For a 5-phase motor, incorrect wiring of the phases can prevent it from operating correctly. Double-check the wiring connections to ensure they match the motor’s specifications.
By addressing these factors, you can improve the performance and reliability of your stepper motor system. Always refer to the manufacturer’s guidelines for proper installation and configuration.
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