Smooth Motor is specialized in high precision stepper motor and customized assembly for 30 years.
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Smooth Motor is specialized in high precision stepper motor and customized assembly for 30 years.
Stepper motors are used in robots, automation systems, 3D printers, CNC machines, and many other consumer and industrial devices.
Because of system inertia, a stepper motor will marginally exceed (or undershoot) the desired step angle with each discrete step. After that, it "rings" or oscillates until it reaches the desired position. These gradual oscillations might cause vibrations and noise if their frequency is close to or equal to the natural frequency of the motor, which will lengthen the settling period of the motor. This phenomenon is known as resonance, and it can lead to the motor losing steps or even stalling if it gets too bad.
If there is no external force to prevent the vibration of an object, then the thing will vibrate at its natural, or resounding, commonness. The spring constant and mass relationship determines the resonant frequency for a traditional spring-mass system. The resonance frequency of a stepper motor is determined by the motor's torque constant and the system's inertia. (Remember that in stepper motor and controller systems, the inertia of the motor-load combination is critical, not the rotor inertia, which determines the resonance frequency of the motor.)
The stepper motor's Inertia
Modifying the system's inertia is frequently the simplest way to decrease resonance in a stepper motor system, although there are other approaches as well. Users have the option of incorporating a gearbox or a mechanical damper between the load and the motor to achieve this.
Small stepper motor mechanical dampers can be as basic as elastomer rings, which dissipate vibration energy, or as complex as tuned mass dampers, which are engineered to match and counteract the system's natural frequency.
Including a gearbox has two advantages. Lessening the load inertia is the first step in reducing the overall system inertia. In the case of a gearbox, the load inertia is calculated by dividing it by the square of the gear ratio. Additionally, there is less likelihood of the motor operating at or near its natural frequency when power is delivered from the motor to the load through a gearbox, which forces the motor to spin faster to achieve a certain output speed.
The degree of vibration experienced by the motor can also be affected by the stepper motor and controller method. For example, because the current in the windings builds up and decays more gradually while operating a motor with micro-stepping control, the torque variance with each step is less. With microstepping, overshooting or undershooting is still conceivable, but it won't be as bad as with full-step operation, which means less vibrations and settling time.
Step angles are narrower in five-phase stepper motors compared to two-phase motors in general. The reduced step angle reduces the current required for each step, similar to microstepping, which in turn reduces the severity of any vibrations that may occur. There is less torque ripple and vibration in the motor because more phases are contributing to the output torque (five instead of two).
Suppose you want to make a stepper motor and controller that doesn't vibrate too much. In that case, you can change the torque stiffness of the motor by adjusting the air gap between the stator and motor and by changing the rotor inertia, either by changing the material or the design. To further ensure silent operation, less vibration, and no resonance, manufacturers additionally provide stepper motor drivers that precisely regulate the current flowing through the motor's windings.
Common Solutions
Choosing the right driver
Lessening the motor's vibration and noise is as simple as picking the right driver. A micro-step driver is a good choice for making the stepper motor and controller run more smoothly. It divides the stepper motor's pulse intoer micro steps.
Raising current
Motor vibration and noise can be amplified at low speeds due to the reduction in current. An effective way to decrease vibration and noise is to increase the current in order to improve the motor's torque and stability.
Lightening the load
Carrying a heavy load might amplify the motor's vibration and noise levels, but lightening the load can diminish these.
Shock Absorbers
Shock absorbers can be installed to effectively limit vibration and noise transfer between the motor and external structures.
Motor Bearing and Mechanic Structure Check
If the motor's bearings and mechanical structure are damaged or poorly designed, it could make more noise and vibration than usual. You can successfully lessen vibration and noise by inspecting and fixing broken bearings and structures or by reworking the mechanical structure.
Low-noise Materials
When making the motor and mechanical structure, using low-noise materials is another great way to reduce vibration and noise. The use of rubber, for instance, can lessen the amount of noise and vibration that reaches the outside of the building.
To sum up, many options exist for lessening motors' audible and vibrational effects. It is important to consider many alternatives based on the real circumstance and choose the right one.
Smooth Motor is an industry leader in providing individualized motion solutions, and its speciality is supplying customized stepper motor and controller assemblies to a broad range of businesses. Thanks to our extensive knowledge and state-of-the-art technology, we provide bespoke integrated products that are unmatched in accuracy, dependability, and performance.
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Our extensive experience in diverse motion applications and industries, combined with our in-depth knowledge of the components used in motion control will make us an invaluable resource for your next motion control project.
