When a stepper motor starts running, it may fail to move or only move back and forth in the same spot. In some cases, it might also lose steps during operation. This issue can be caused by several factors, so it's important to check the following areas:
First, ensure that the motor has sufficient torque to drive the load. It’s generally recommended to choose a motor with at least 50% more torque than what is actually needed. Stepper motors are not designed for overload, even for short periods, and this can lead to step loss, stalling, or erratic movement.
Second, check if the current from the upper controller’s pulse input is strong enough—ideally above 10mA. This ensures the optocoupler operates reliably. If the input frequency is too high, the signal may not be received properly. Also, if the controller uses a CMOS output, you’ll need a compatible CMOS driver to ensure proper signal transmission.
Third, consider the starting frequency. If it's set too high, the motor may not start smoothly. It’s better to begin at the motor’s specified minimum frequency and gradually increase to the desired speed. Even a short acceleration phase can cause instability or the motor to idle without moving.
Fourth, if the motor isn’t securely mounted, it can sometimes vibrate or resonate, leading to synchronization issues. This is normal in some cases, but it’s essential to fix the motor in place to prevent such problems.
Fifth, for a 5-phase motor, incorrect wiring of the phases can prevent it from operating properly. Always double-check the connections to ensure they match the motor’s specifications.
If you're still experiencing issues after checking these points, it could be a sign of a deeper problem, such as a faulty driver, power supply issues, or mechanical binding. In such cases, further diagnostics or professional assistance may be required.
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