• Custom Motors (Lin Engineering White Paper)
  • Usually, stepper motor windings are customized for an application. In other words, it is NOT normal to use off-the-shelf stepper motor designs in a mass-produced product.
  • Given a ~fixed volume of copper, the tradeoff space is wire gauge vs number of windings → winding current, resistance, inductance, which affects how quickly the motor coils will charge and discharge, and average torque output at high speeds.
  • Typical lead-times for prototype custom motors are 2-4wks.
  • As you scale to production, you go from a prototype manufacturing line to [domestic manufacturing, depending on vendor] to overseas mfg at high volumes.
  • In general, stepper motors are commodity items governed by fundamentals:
  • How much copper you can fit in a given space
  • Properties of electrical steel
  • Strength of neodymium magnets
  • HOWEVER, there is still innovation in stepper motor design, along dimensions such as:
  • Lamination thickness
  • Air gap
  • ???
  • These enable some motors that yield better performance in the same package size, eg Lin Engineering G4518 Series, 98ozf-in holding torque for G4518L, vs 83ozf-in for 4118L.
  • Stepper Motor Manufacturers
  • Lin Engineering
  • Dings / Koco Motion
  • Nanotec
  • LDO Motors
  • NMB Minebea
  • Phase Current vs Peak Current (Lin Engineering White Paper)
  • Motors are rated in amps/phase, which is an RMS value, such that the total power dissipated by the motor (sum of both phases) is constant at any point in the microstepping commutation table.
  • Driver current is set as PEAK amps, which is ~1.4x amps RMS.
  • A common mistake is to equate these two, and set your drive current too low.
  • Caveat: if you park your motor at full-current in a position where only one phase is on, it can in theory overheat the winding, but in practice I haven’t seen indications of this being a real problem. Some drivers support lower current levels when stopped.
  • Motor Mechanical Compliance
  • The motors can represent a significant portion of the overall system compliance, especially in low-ratio (e.g. belt-driven) mechanisms.
  • From Acarnley (p. 26):  
  • Peak stiffness is when the electrical and mechanical positions of the motor are in phase.
  • Maximum torque output occurs at +/- 1 step. Deflections exceeding 1 step result in “skipping steps” to the next equilibrium point, which is 4 steps away.
  • Resources
  • Stepping Motors: A Guide to Theory and Practice, Paul Acarnley
  • This is the bible of stepper motors