Along with the bipolar stepper motor, Anaheim Automation carries a comprehensive line of drivers and controllers, power supplies, gear motors, gearboxes, bipolar stepper motor linear actuators and integrated bipolar stepper motor/driver packages. Additionally, Anaheim Automation offers encoders, brakes, HMI couplings, cables and connectors, linear guides and X-Y tables. If the bipolar stepper motor is not ideal for your application, you might consider brushless DC, brush DC, servo, or AC motors, and their compatible drivers/controllers.

• Cost-effective*
• Simple designs
• High reliability
• Brushless construction
• Maintenance-free
• If windings are energized at standstill, the motor has full torque
• No feedback mechanisms required/br> • High acceleration and power rate/br> • A wide range of rotational speeds can be attained as the speed is proportional to the frequency of the input pulses
• Known limit to the dynamic position error Stepper motor products vary in cost based on the criteria for each application. Some criteria include options of 0.9°, 1.8°, 3.6° and 4.5° step angles, torque ranging from 1 to 5,700 oz-in, and NEMA frame sizes of 08 to 42. Additional attachments such as cables and encoders can be purchased separately for an additional cost. With our friendly customer service and professional application assistance, Anaheim Automation often surpasses customer expectations for fulfilling specific bipolar stepper motor and driver requirements, as well as other motion control needs.

One of Anaheim Automation Inc.'s customers provides services and products for the automobile industry, such as process automation, prototyping, engine test standards, and gauging equipment. At one point, our customer encountered a problem; popular cars were being redesigned, and they needed computer control of a bipolar stepper motor for their project. They had tried several other motion control manufacturers before deciding to have Anaheim Automation help them with their project. The project dealt with the cooling of an engine in a strange area. Anaheim Automation's assignment was to construct a prototype that would scoop air from beneath the car and redirect maximum air flow to this area.

It was almost impossible to predict an accurate shape that would allow precise airflow, due to the fact that in order to fit in the available space, the duct had to be in an extremely complex configuration. The solution to this problem involved making a flexible duct that, by moving its parts, allowed it to be reshaped. The duct would be mounted in a wind tunnel, and installed in the prototype of the car. Next, engineers experimented with the duct's shape until they discovered what shape allowed for the best air flow. This shape became the basic model to construct in the overall prototype.

Anaheim Automation needed to shape the duct without diverting from the project goal, and therefore needed 15 axes of motion and one easy-to-use controller. To meet this necessity, Anaheim Automation assembled five triple-axis bipolar stepper motor drivers, programmable indexers, an interface, and the necessary power supply into a compact package, along with 15 compatible bipolar stepper motor models.

When the computer was turned on, the program came up, so the system didn't require any knowledge of the computer operation. In addition, it reduced operation to simply answering three questions (prompting the user). The user could change the speed at any time; however, the operator did not need to know anything about base speed, acceleration, or deceleration, because the parameters for optimal motor speed was preloaded with the system program. While operating, the program prompted the operator with, "What axis, how many steps, and which direction?" The user only needed to press the F1 function key to produce the desired motion for the bipolar stepper motor to move.

With the experiment in full swing, engineers were able to manipulate the air duct in order to achieve maximum air flow underneath the vehicle. The required motion was easily produced at the press of a button, and the positions could be easily repeated. Ultimately, our customer's engineering staff was able to determine the exact shape of the duct that provided the car with maximum air flow. Simple, low-cost, and extremely efficient bipolar stepper motor products, and drivers provided the solution the customer required.

The stepper Motor is currently used all around the world for many types of applications. These motors provide as constant power devices. At low rpm's a high torque can be achieved the same cannot be said when the speed is increased. A high torque cannot be achieved at higher rpm's. These motors are great for positioning objects, such as conveyor belts, assembly lines, lathes, laser cutting, grinding and drilling machines, etc.

The bipolar stepper motors is ideal for precise positioning. You may have a fixed speed, variable speed, and position control. These motors are able to handle complex positions or movements. These devices offer power and precision in a compact sizes. These motors can take a great load. A good example to show this would be an escalator. Escalators are constantly worked and carry very heavy loads throughout the day. The step motor has to be able to take up to several hundreds of pounds maybe even thousands. The speed of the escalator is constant and never changes no matter how many people are on it.

A different type of application could be an assembly line. This typically requires precise quick and place movements. Most bipolar stepper motor products are open loop systems, meaning there is no feedback info needed about the position. By keeping track of the input step pulses, the position is known.

Some of the advantages of a bipolar stepper motor, but not limited to are:
• Its input pulse is proportional to angle rotation
• If windings are energized at stand sill the motor has full torque
• Different rotation speeds are available since the frequency of input pulses are proportional to the speed.
• It cost less to have open-loop control that responds to digital input pulses
• Precise response time to starting, stopping, and reversing
• No brushes within the motor making it more reliable.

There are three different types of bipolar stepper motor models to choose from, the variable -reluctance, the permanent-magnet, and last but not least the hybrid step motor. The three all have different qualities for certain applications. The bipolar stepper motor has been around for a long time and are currently and will continue to be used throughout the world. No matter what the application will be the step motor will always rise to the occasion.

One of the best, most flexible, computer-controlled positioning systems is one in which the bipolar stepper motor is integrated. Having more simple and hardy characteristics compared to a closed-loop servo system, bipolar stepper motor and driver systems are digitally controlled, and are a crucial element in the less costly open-loop system.

Industrial applications for the bipolar stepper motor are in high-speed pick-and-place equipment and multi-axis CNC machines frequently drive lead screws or ballscrews directly. Usually, a bipolar stepper motor is often used in precision positioning in the fields of lasers and optics, often being used in linear actuators, linear stages, goniometers, mirror mounts, and rotation stages. The bipolar stepper motor is also used for positioning valve pilot stages for fluid control systems, and in packaging machinery.

Traditionally, the bipolar stepper motor has been used commercially in floppy disk drives, and continues to be used for flatbed scanners, computer printers, plotters, slot machines, and a myriad of other devices. A bipolar stepper motor can be used to generate power as well, often designed in wind turbines and solar positioning systems.

Time is the centralized theme at the New Mexico Museum of Natural History in Albuquerque. At one point, the museum wanted to convey the idea that traveling through the exhibit is as if one is traveling through time. The museum depicted the conditions of New Mexico during the time periods of the Cretaceous period (75 million years ago) and the Tertiary period (37 million years ago), and how the area has evolved since. However, the museum did so with less than a satisfactory effect on the visitor. The idea they constructed to improve this was known as the "Evolator."

Derived from a combination of the words EVOLutionary and elevATOR, the evolator was an elevator-like vehicle that allowed visitors to be transported through time as evolution took place. It was designed by Art & Technology, Inc., in California, and is located between two exhibit areas in the museum. Allowing up to twenty people to enter from one exhibit into one door, experience time travel, and exit out the second door into another exhibit, it allows the passengers to experience 30 million years of time travel in six minutes.

During time travel, the guests can view the "outside world" via TV screens, and see the two ports and the evolator traveling through rock strata on both sides of them. They can feel the vehicle moving throughout the tour, as it stops frequently throughout the trip for the computer to evaluate the rocks that are visible through the ports.

In order to create the full time travel illusion, five laser disks, special lighting, a sound system, a hydraulic system for rocking the evolator floor and two silicon belts are needed. The 18 foot long silicon belts run as long continuous loops at a high speed during evolator movement, and slow to a stop as the evolator stops. In order for the operation to appear realistic, the belts have to operate in synchronism, a condition that is met by means of using large bipolar stepper motors.

Due to the fact that the belts are very heavy, Anaheim Automation needed to develop a high- performance bipolar stepper motor Driver Pack (known as DPK Series) for the job. A computer was selected to coordinate the bipolar stepper motor, driver and controller system that makes the evolator work. The computer provides the DPK with clock and direction signals that trigger the bipolar stepper motor Driver Pack to operate the bipolar stepper motors, according to the required movements of the silicon belts. Time travel visitors were as thrilled with the success of the Evolator as were!

Automation and Material Handling specialists create products for a broad range of businesses, including automotive, pharmaceutical, packaging and electronics companies. Anaheim Automation, Inc. has been a supplier to these companies for over 40 years. When it comes to automating equipment, machinery and processes, some methods are efficient, while others are not. Anaheim Automation has an outstanding record for choosing sensible methods and cost-effective designs, but when we recommend multi-axis bipolar stepper motor Driver Packs and boards for moderately straightforward machines, they maximize their cost effectiveness even further.

For single-axis applications that are redundant and require accurate positioning, the economical DPD72451 Preset Indexer Driver Pack is ideal, and has been a long-time favorite. Each compact bipolar stepper motor Driver Pack contains a preset indexer, a bi-level bipolar stepper motor driver, a power supply, and a cooling fan. The preset indexer has such abilities as Home, Hard and Soft Limit inputs, two Homing modes, Jog/Run, Fast Jog, and switch selectable Base Speed, Maximum Seed, and Acceleration/Deceleration. The DPF72452 Bipolar Stepper Motor Driver Pack offers the same performance for two axes. It is a larger unit with twice the capacity.

The companion Quad Board is consists of four banks of digital pots mounted on a PC board, along with the supplementary circuitry. According to what the user desires, the board has the capacity to "dial in" up to four different move lengths. Anaheim Automation simplifies installation by offering the Quad Board connected to and mounted on the bipolar stepper motor Driver Pack.

A classic example of this inventive production is a machine that rivets stiffeners on the edge of up to 800 circuit boards per hour. In this practical application, wherein bipolar stepper motor products are used, Anaheim Automation, Inc. helped a machinery manufacturer build equipment for a telephone company. This particular machine had the requirement of automatically installing stiffeners along the edge of circuit boards. A stiffener is added from a magazine, to each board that is positioned on a linear table. The bipolar stepper motor, operated by the Driver Pack, positions a table so the rivets can be inserted through the stiffener and the board in three different areas: a distance of 1-1/2 in. from the first hole, 4-1/2 in. to the second hole, and 4-1/2 in. to the third hole, and return to home. The Quad Board settings were used in order to keep two additional settings available to handle any prospective complex arrangements. Despite how simple the machine was, it was also capable of extraordinary tasks; one example being its ability to turn out 800 boards in one hour.

Anaheim Automation used the same idea for other, very different machines. In the case of a pharmaceutical company; they used a flutter valve maker. For this machine, a roll of vinyl was advanced to a dimension, heat sealed, and cut along the seal. Each of the two rolls provide two valve sizes. In this case, the bipolar stepper motor controlled a drive-roller against a pinch roller, and the Quad Board settings controlled the length of the material. This left two settings for further expansion.

Just like our other machines, efficiency coincides with simplicity. In this example, we can turn out 15 flutter valves a minute. This approach not only provided the benefits of simple and efficient productivity, but it only required a simple interface with a machine's PLC. There was no need for high level software; therefore Anaheim Automation was able to maintain lower costs, and simplify service considerations.

Stepper motor products are versatile motion control components that can be applied to several different industries, from entertainment and film, to the business world, to science and medicine.

Aircraft: A bipolar stepper motor is frequently used in aircraft instruments, scanning equipment, and sensing devices, such as antennas.

Automotive: SUV's and RV's, as well as some high-end automobiles, use the bipolar stepper motor to receive telecommunication signals. A bipolar stepper motor is also used for cruise control, automated dashboards gauges and electronic window equipment, as well as in automobile factories on their production lines.

Cameras - Filming and Projection: Not only does the bipolar stepper motor operate filming cameras and projectors, in the entertainment industry, but automatic digital cameras and mobile phone camera modules utilize tiny bipolar stepper motor for focusing and zooming functions as well. The security industry also uses a bipolar stepper motor for zooming, tilting and scanning operations in surveillance and security cameras.

Entertainment and Gaming: Slot machines, lottery machines, raffles, card shufflers, and wheel spinners can all be operated by cost-effective and reliable bipolar stepper motor. You can also find the bipolar stepper motor in stage productions to control curtains and lighting functions, for plays and concerts, as well as seminars and rallies.

Laboratory and Factory Improvements and Upgrades: A bipolar stepper motor is employed to perform tedious movements pertaining to mixing chemicals in laboratories, and operating equipment for controlled environmental testing. The bipolar stepper motor is used in retrofit kits (bipolar stepper motor, drivers, controllers and power supplies) for CNC machine control, factory automation and assembly processes. The bipolar stepper motor can also be found in scientific study, used to position observatory telescopes, and in many different types of scientific equipment, i.e. spectrographs, analyzers, and diagnostic machines.

Medical: The bipolar stepper motor provides a wide variety of functions for the medical and dental world. The bipolar stepper motor is used within medical scanners, multi-axis bipolar stepper motor microscopic or nanoscopic motion control of automated devices, auto-injectors, samplers, dispensing pumps, respirators, blood analysis machinery and chromatographs. In the dental industry, a bipolar stepper motor operates fluid pumps, and are often found inside digital dental photography equipment.

Office Equipment: PC based scanning equipment, optical disk drive head driving mechanisms, bar-code printers, label and box printers, scanners, and data storage drives all utilize the bipolar stepper motor for their motion control operation.

Anaheim Automation's tremendous versatility of control systems is evident in their new program titled, Musical Motors. They have utilized bipolar stepper motor, stepper drivers, and stepper controllers to operate at speeds that coincide with musical notes and pitches to produce a number of different tunes. Each tune is performed by simply running the program that converts each music note into a certain step-per-second. All of the different bipolar stepper motor are programmed to produce an appropriate pitch based on how many steps-per-second they run, and for how long. Typically played at a trade show, the program provides the element of surprise; most people do not expect to hear music that is being played by bipolar stepper motor!

Employees were hired at a local packaging plant, for the sole purpose of making sure bottles were packaged with their labels facing outward in their packages. They were employed to manually adjust the positioning of the bottles and send them to the blister pack machine. Anaheim Automation helped expedite that process using bipolar stepper motor and drivers. With the new automated design, bottles were sensed with a photo-electric sensor that stops the belt and notifies the pulse generator in an Anaheim Automation Driver Pack. The bipolar stepper motor Driver Pack controls a bipolar stepper motor, which rotates the bottle by turning a rubber drive wheel. An orientation indicator is placed on the bottle that, when sensed, prompts the pulse generator and activates a discharge solenoid, which then places the bottle into the awaiting package. The packaged bottle then allows the photo sensor to trigger the next bottle to come into position to repeat the process. Implementing this process using a bipolar stepper motor Driver Pack resulted in quicker packaging with viewable bottles, at a considerably lower cost! Both the customer and its intended end-users were quite pleased with this development.

The new DPD72451 Driver Pack is an individual preset indexer module, complete with Control Link (Indexer), BLD75 bi-level driver, and matched power supply. In order to handle all aspects of positioning on a single axis, it is ready to connect between an input device such as a thumbwheel switch counter, with a bipolar stepper motor.

The preset indexer board was originally built around the capabilities of a single-chip indexer. The chip is derived from the SMC 20BC, a programmable bipolar stepper motor controller chip. It features hard and soft limit outputs, three homing modules, jog/run, fast jog, and programmable base speed, maximum speed, and acceleration/deceleration. The Driver Pack therefore provides extended capabilities that make it applicable to a broad range of functions, the most popular being cut-to-length.

The necessary buffering and other circuitry required to support the chip is also included. However because the units are mounted separately in most installations, a thumbwheel switch is not included on the indexer. Anaheim Automation offers numerous different input devices for use with the DPD72451, including three-, four-, five-, and six-decade thumbwheel switch encounters; two-, four-, and six-decade rotary switches; and two-, four-, and six-quad rotary switches.

The high-performance bi-level driver BLD75 operates four-, six- or eight-lead bipolar stepper motors. Due to its characteristic of being a bi-level driver, it provides high torque (power) output and high start-stop speed. The power supply in the DPD72451 is fan-cooled and matched to the requirements of the PCL451 and the BLD75 bi-level driver.

Together, the indexer, bi-level driver, and matched power supply provide a complete, concise package with exceptional price and performance for a myriad of different applications. When two axes are required, two PCL451's can be housed in a larger Driver Pack, along with dual bi-level drivers and the appropriate power supply.

Although the bipolar stepper motor has been overshadowed in the past by servo systems for motion control, it has emerged as the preferred technology in more and more areas. The major factor in this trend towards the bipolar stepper motor is the prevalence of digital control, the emergence of the microprocessor, improved designed (i.e. high?torque models), and lower cost. Today, bipolar stepper motor applications are all around us: they are used in printers (paper feed, print wheel), disk drives, clocks and watches, as well as used in factory automation and machinery. A bipolar stepper motor is most often found in motion systems requiring position control.

Anaheim Automation’s cost?effective bipolar stepper motor product line is the wise choice for both OEM and user accounts. Anaheim Automation's customers for the bipolar stepper motor product line is diverse: industrial companies operating or designing automated machinery or processes involving food, cosmetics or medical packaging, labeling or tamper?evident requirements, cut?to?length applications, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, camera tracking, inspection and security devices, aircraft controls, pump flow control, metal fabrication (CNC machinery), and equipment upgrades.

Anaheim Automation, Inc. bipolar stepper motor product line integrates a matched bipolar stepper motor, driver and controller in one unit. This design concept makes selection easy, thus reducing errors and wiring time. With friendly customer service and professional application assistance, Anaheim Automation often surpasses the customer's expectations for fulfilling specific bipolar stepper motor and driver requirements, as well as other motion control needs.

Bipolar Stepper Motors are Used in Many Industries

Stepper motors have become an essential component to applications in many different industries. The following is a list of industries making use of bipolar stepper motors:
• Aircraft – In the aircraft industry, bipolar stepper motors are used in aircraft instrumentations, antenna and sensing applications, and equipment scanning
• Automotive – The automotive industry implements bipolar stepper motors for applications concerning cruise control, sensing devices, and cameras. The military also utilizes bipolar stepper motors in their application of positioning antennas
• Chemical – The chemical industry makes use of bipolar stepper motors for mixing and sampling of materials. They also utilize bipolar stepper motor controllers with single and multi-axis bipolar stepper motors for equipment testing
• Consumer Electronics and Office Equipment – In the consumer electronics industry, bipolar stepper motors are widely used in digital cameras for focus and zoom functionality features. In office equipment, bipolar stepper motors are implemented in PC-based scanning equipment, data storage drives, optical disk drive driving mechanisms, printers, and scanners
• Gaming – In the gaming industry, bipolar stepper motors are widely used in applications like slot and lottery machines, wheel spinners, and even card shufflers
• Industrial – In the industrial industry, bipolar stepper motors are used in automotive gauges, machine tooling with single and multi-axis bipolar stepper motor controllers, and retrofit kits which make use of bipolar stepper motor controllers as well. Stepper motors can also be found in CNC machine control
• Medical – In the medical industry, bipolar stepper motors are utilized in medical scanners, microscopic or nanoscopic motion control of automated devices, dispensing pumps, and chromatograph auto-injectors. Stepper motors are also found inside digital dental photography (X-RAY), fluid pumps, respirators, and blood analysis machinery, centrifuge
• Scientific Instruments –Scientific equipment implement bipolar stepper motors in the positioning of an observatory telescope, spectrographs, and centrifuge
• Surveillance Systems – Stepper motors are used in camera surveillance

Each type of bipolar stepper motor varies per application by its construction and functionality. The three most common bipolar stepper motor types are Variable Reluctance, Permanent Magnet, and Hybrid Bipolar Stepper Motors.

Variable Reluctance (VR) Bipolar Stepper Motor
VR bipolar stepper motors are characterized as having multiple soft iron rotors and a wound stator. VR bipolar stepper motors generally operate on the basic principle of the magnetic flux finding the lowest reluctance pathway through a magnetic circuit. In general operation, VR bipolar stepper motors have relatively high step rates of 5 to 15 degrees and have no detent torque. The step angles taken in VR bipolar stepper motors are related to the number of teeth the stator and rotor have. The equation relating these two variables can be found in the formula section of this guide.

How Does a Variable Reluctance Bipolar Stepper Motor Work?
Referring to Figure 1 on Page 2, the poles become magnetized when the stator windings are energized with DC current. With the poles becoming magnetized, the rotor teeth are now attracted to the energized stator poles and rotate to line up. With the windings around stator A becoming energized the rotor teeth become attracted allowing the poles to line up. When A’s windings become de-energized and B’s windings become energized, the rotor rotates to line its teeth with the stator teeth. This process continues in sequence with C, followed by D being energized allowing for the rotor to rotate.

Brief Summary of Variable Reluctance Bipolar Stepper Motors:
• The rotor has multiple soft iron rotors with a wound stator
• Least complex and expensive bipolar stepper motor
• Large step angles
• No detent torque detected in hand rotation of a de-energized motor shaft

Permanent Magnet (PM) Bipolar Stepper Motor
PM bipolar stepper motors are comprised of permanent magnet rotors with no teeth, which are magnetized perpendicular to the axis of rotation. By energizing the four phases in sequence, the rotor rotates due to the attraction of magnetic poles. The bipolar stepper motor shown in Figure 2 on page 3 will take 90 degree steps as the windings are energized in clockwise sequence: ABAB. PM bipolar stepper motors generally have step angles of 45 or 90 degrees and step at relatively low rates. However, they exhibit high torque and good damping characteristics. Anaheim Automation carries a wide selection of PM bipolar stepper motors, ranging from 15 to 57mm in diameter.

Brief Summary of Permanent Magnet (PM) Bipolar Stepper Motors:
• The rotor is a permanent magnet
• Large to moderate step angle
• Often utilized in computer printers as a paper feeder

Hybrid Bipolar Stepper Motors
Hybrid bipolar stepper motors incorporate the qualities of both the VR and PM bipolar stepper motor designs. With the Hybrid bipolar stepper motor’s multi-toothed rotor resemblance of the VR, and an axially magnetized concentric magnet around its shaft, the Hybrid bipolar stepper motor provides an increase in detent, holding and dynamic torque. In comparison to the PM bipolar stepper motor, the Hybrid bipolar stepper motor provides performance enhancement with respect to step resolution, torque, and speed. In addition, the Hybrid bipolar stepper motor is capable of operating at high stepping speeds. Typical Hybrid bipolar stepper motors are designed with step angles of 0.9°, 1.8°, 3.6° and 4.5°; 1.8° being the most common step angle. Hybrid bipolar stepper motors are ideally suited for applications having stable loads with speeds under 1,000 rpm. There are key components which are influential of the running torque of a Hybrid bipolar stepper motor which are laminations, teeth and magnetic materials. Increasing the amount of laminations on the rotor, precision and sharpness of the rotor and stator teeth, and strength of magnetic material are all factors taken into account in providing optimal torque output for Hybrid bipolar stepper motors.

Brief Summary of Hybrid Bipolar Stepper Motors:
• Smaller step angles in comparison to VR and PM bipolar stepper motors
• Rotor is made of a permanent magnet with fine teeth
• Increase in detent, holding and dynamic torque
• 1.° is the most common step angle

NOTE: At Anaheim Automation, the 1.8 degree Hybrid bipolar stepper motor is the most widely stocked bipolar stepper motor type, ranging in NEMA frame sizes, 08 to 42. The Hybrid bipolar stepper motor can also be driven two phases at a time to yield more torque, or alternately one then two then one phase, to produce half-steps or 0.9 degree increments.

A bipolar stepper motor (also referred to as a step or stepping motor) is an electromechanical device achieving mechanical movements through conversion of electrical pulses. Stepper motors are driven by digital pulses rather than by a continuous applied voltage. Unlike conventional electric motors which rotate continuously, bipolar stepper motors rotate or step in fixed angular increments. A bipolar stepper motor is most commonly used for position control. With a bipolar stepper motor/driver/controller system design, it is assumed the bipolar stepper motor will follow digital instructions. One important aspect of bipolar stepper motors is their lack of feedback to maintain control of position. It is this lack of feedback which classifies bipolar stepper motors as open-loop systems.

NOTE: Always read the specification sheet/user’s guide accompanying each product.

Problem: Stepper motor wires were disconnected while the driver was powered up. Solution: Avoid performing any service to the bipolar stepper motor, driver or controller while the power is on, especially in regard to the motor connections. This precaution is imperative for both the driver and the technician/installer.

Problem: The bipolar stepper motor has a shorted winding or a short to the motor case.
Solution: It is likely you have a defective bipolar stepper motor. Do not attempt to repair motors. Opening the bipolar stepper motor may cause the motor to lose its magnetism, causing poor performance. Opening of the bipolar stepper motor case will also void your warranty. The motor windings can be tested with an ohmmeter. As a rule of thumb, if the bipolar stepper motor is a frame size of NEMA 08, 11, 14, 15, 17, 23, or 34 and the warranty period has expired, it is not cost-effective to return these bipolar stepper motors for repair. Contact the factory if you suspect a defective bipolar stepper motor that is still under warranty, or if the bipolar stepper motor is a NEMA frame size 42 or a K?series motor.

Problem: Environmental factors are less than ideal.
Solution: Environmental factors such as welding, chemical vapors, moisture, humidity, dust, metal debris, etc., can damage the electronic components and the bipolar stepper motor. Protect drivers, controllers and bipolar stepper motors from environments that are corrosive, contain voltage spikes, or prevent good ventilation. Anaheim Automation offers products in several line voltage ranges, as well as splash?proof, IP65 rated bipolar stepper motors. For wash?down or explosion?proof motors, contact the factory directly. For AC lines containing voltage spikes, a line regulator (filter) will likely be required. NOTE: If your application requires welding, or if welding is done in the same work environment, contact the factory for advice on how to protect the bipolar stepper motor driver and controller.

Problem: The bipolar stepper motor is back?driving the stepper driver.
Solution: A bipolar stepper motor being turned by a load creates a back EMF voltage on the driver. Higher speeds will produce higher voltage levels. If the rotational speed gets excessively high, this voltage may cause damage to the driver. This is especially dangerous when the motor is back?driven while the driver is still on. Place a mechanical stop or brake in applications which may be subject to these phenomena.

Several choices for customization options for Bipolar Stepper Motor products are accessible through Anaheim Automation. The variety of modifications includes, but is not confined to: shaft, brake, oil seal for an IP65 rating, mounting dimensions, speed, torque, and voltage. Contact Anaheim Automation today to set up an order for utilities with Bipolar Stepper Motor products that require customization: 1-714-992-6990.

• Low efficiency (Motor attracts a substantial amount of power regardless of the load)
• Torque drops rapidly with speed (torque is inversely proportional of speed
• Prone to resonance* (Microstepping allows for smooth motion)
• No feedback to indicate missed steps
• Low torque-to-inertia ratio
• Cannot accelerate loads very rapidly
• Motor gets very hot in high performance configurations
• Motor will not “pick up” after momentary overload
• Motor is noisy at moderate to high speeds
• Low output power for size and weight
Resonance-is inherent in the design and operation of all stepping motors and occurs at specific step rates. It is the combination of slow stepping rates, high rotor inertia, and elevated torque which produce ringing as the rotor overshoots its desired angular displacement and is pulled back into position causing resonance to occur. Adjusting either one of the three parameters –inertial load, step rate, or torque- will reduce or eliminate resonance. In practical practice, the torque parameter is more controllable using microstepping. In microstepping mode, power is applied to the stator windings incrementally which causes torque to slowly build, reducing overshoot and therefore reducing resonance.

The following environmental and safety considerations must be observed during all phases of operation, service and repair of a bipolar stepper motor system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the bipolar stepper motor, driver and controller. Please note that even with a well?built bipolar stepper motor, products operated and installed improperly can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the bipolar stepper motor system.

The atmosphere in which a bipolar stepper motor is used must be conducive to good general practices of electrical/electronic equipment. Do not operate the bipolar stepper motor in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the bipolar stepper motor, driver and controller must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the bipolar stepper motor, driver and controller in an environment which is free from condensation, dust, electrical noise, vibration and shock.

Additionally, it is preferable to work with the bipolar stepper motor/driver /controller system in a non?static, protective environment. Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while power is applied. Don’t plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the bipolar stepper motor system after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the bipolar stepper motor driver.

Plan the installation of the bipolar stepper motor, driver and/or controller in a system design that is free from debris, such as metal debris from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry. Failure to prevent debris from entering the bipolar stepper motor system can result in damage and/or shock.

The main use of the bipolar stepper motor is to control motion, whether it is linear or rotational. In the case of rotational motion, receiving digital pulses in a correct sequence allows the shaft of a bipolar stepper motor to rotate in discrete step increments. A pulse (also referred to as a clock or step signal) used in a bipolar stepper motor system can be produced by microprocessors, timing logic, a toggle switch or relay closure. A train of digital pulses translates into shaft revolutions. Each revolution requires a given number of pulses and each pulse equals one rotary increment or step, which is only a portion of one complete rotation. There are numerous relationships between the motors shaft rotation and input pulses. One such relationship is the direction of rotation and the sequence of applied pulses. With proper sequential pulses being delivered to the device, the rotation of the shaft motor will undergo a clockwise or counterclockwise rotation. Another relation between the motor’s rotation and input pulses is the relationship between frequency and speed. Increasing the frequency of the input pulses allows for the speed of the motor shaft rotation to increase.

The following safety considerations are required to be observed during all phases of operation, service and repair. Failure to conform with these safety measures violates safety standards of design, manufacture, and designated use of Bipolar Stepper Motor, drivers and controllers. Anaheim Automation, Inc. assumes no responsibility for the customer's incapacity to comply with theserequirements. Even well-built products, operated or installed improperly, can be hazardous. Safety precautions must be observed by the user with regard to the load and operating environment. The customer is liable for appropriate selection, installation and operation of the products purchased from Anaheim Automation, Inc.

• Use caution when handling, testing, and adjusting during installation, set-up and operation
• Service must not be performed with power applied
• Make sure the motor/driver has plenty of heat dissipation and air flow
• Exposed circuitry should be properly guarded or enclosed to counteract unauthorized human contact with live circuitry
• All products should be firmly mounted and effectively grounded
• Elements such as flammable gases, vapors, liquids or dust should not interact with a bipolar stepper motor in operation

NOTE: Please Use a RMA Form should you need to return a product for REPAIR. This form can be found in Support, Forms, RMA Request on this web site.

A bipolar stepper motor performs the conversion of logic pulses by sequencing power to the bipolar stepper motor windings; generally, one supplied pulse will yield one rotational step of the motor. This precision is provided by a stepper driver, which is able to control speed and positioning of the motor. The bipolar stepper motor increments a precise amount with each control pulse, converting digital information into exact incremental rotation without the need for feedback devices, such as tachometers or encoders. Since the bipolar stepper motor/driver is an open-loop system, the problems of feedback loop phase shift and resultant instability, common with servo motor/drive systems, are eliminated.

There are several important criteria involved in selecting the proper bipolar stepper motor:
1. Desired Mechanical Motion
2. Speed Required
3. Load
4. Stepper Mode
5. Winding Configuration

With appropriate logic pulses, bipolar stepper motors can be bi-directional, synchronous, provide rapid acceleration, run/stop, reversal, and can interface easily with other digital mechanisms. Characterized as having low-rotor moment of inertia, no drift, and a noncumulative positioning error, a bipolar stepper motor is a cost-effective solution for many motion control applications. Generally, bipolar stepper motors are operated without feedback in an open-loop fashion and sometimes match the performance of more expensive DC Servo Systems. As mentioned earlier, the only inaccuracy associated with a bipolar stepper motor is a noncumulative positioning error measured in % of step angle. Typically, bipolar stepper motors are manufactured within a 3-5% step accuracy.

Motion requirements, load characteristics, coupling techniques, and electrical requirements need to be understood before the system designer can select the best bipolar stepper motor/driver/controller combination for a specific application. While not a difficult task, several key factors need to be considered when determining an optimal bipolar stepper motor solution. The system designer should adjust the characteristics of the elements under his/her control, to meet the application requirements. Anaheim Automation offers many options in its broad line of bipolar stepper motor products, allowing for the maximum amount of design flexibility. Although it may appear overwhelming to choose, the result of having a large number of options is a high-performance system that is cost-effective. Elements needed to be considered include the bipolar stepper motor, driver, and power supply selections, as well as the mechanical transmission, such as gearing or load weight reduction through the use of alternative materials. Some of these relationships and system parameters are described in this guide.

Inertial Loads
Inertia is a measure of an object’s resistance to a change in velocity. The larger an object’s inertia, the greater the torque is required to accelerate or decelerate it. Inertia is a function of an object’s mass and shape. A system designer may wish to select an alternative shape or low-density material for optimal performance. If a limited amount of torque is available in a selected system, then the acceleration and deceleration times must increase. For most efficient bipolar stepper motor systems, the coupling ratio (gear ratio) should be selected so the reflected inertia of the load is equal to, or greater than, the rotor inertia of the bipolar stepper motor. It is recommended that this ratio not be less than 10 times the rotor inertia. The system design may require the inertia to be added or subtracted by selecting different materials or shapes of the loads.

NOTE: The reflected inertia is reduced by a square of the gear ratio, and the speed is increased by a multiple of the gear ratio.

Frictional Loads
All mechanical systems exhibit some frictional force. The designer of a bipolar stepper motor system must be able to predict elements causing friction within the system. These elements may be in the form of bearing drag, sliding friction, system wear, or the viscosity of an oil filled gear box (temperature dependent). A bipolar stepper motor must be selected that can overcome any system friction and still provide the necessary torque to accelerate the inertial load.

NOTE: Some friction is desired, since it can reduce settling time and improve performance.

Positioning Resolution
The positioning resolution required by the application may have an effect on the type of transmission used, and/or selection of the bipolar stepper motor driver. For example: A lead screw with 5 threads per inch on a full-step drive provides 0.001 inch/step; half-step provides 0.0005 inch/step; a microstep resolution of 25,400 steps/rev provides 0.0000015 inch/step.

The typical lifetime for a bipolar stepper motor is 10,000 operating hours. This approximates to 4.8 years; given the bipolar stepper motor operates one eight-hour shift per day. The lifetime of a bipolar stepper motor may vary in regards to user application and how rigorous the bipolar stepper motor is run.

Stepper motors are driven by waveforms which approximate to sinusoidal waveforms. There are three excitation modes commonly used with bipolar stepper motors which are full?step, half?step and microstepping.

Bipolar Stepper Motor ? Full?Step (Two Phases are on)
In full?step operation, the bipolar stepper motor steps through the normal step angle, e.g. with a 200 step/revolution the motor rotates 1.8° per full step, while in half?step operation the motor rotates 0.9° per full step. There are two kinds of full?step modes which are single-phase full-step excitation and dual-phase full-step excitation. In single-phase full?step excitation, the bipolar stepper motor operates with only one phase energized at a time. This mode is typically used in applications where torque and speed performances are less important, wherein the motor operates at a fixed speed and load conditions are well defined. Typically, bipolar stepper motors are used in full?step mode as replacements in existing motion systems, and not used in new developments. Problems with resonance can prohibit operation at some speeds. This mode requires the least amount of power from the drive power supply of any of the excitation modes. In dual-phase full?step excitation, the bipolar stepper motor operates with two phases energized at a time. This mode provides excellent torque and speed performance with minimal resonance problems.

NOTE: Dual excitation provides about 30 to 40 percent more torque than single excitation, but does require twice the power from the drive power supply. Many of Anaheim Automation’s microstepping drivers can be set to operate at full?step mode if necessary.

Bipolar Stepper Motor ? Half?Step
Stepper motor half?step excitation mode alternates between single and dual-phase operations resulting in steps that are half the normal step size. Therefore, this mode provides twice the resolution. While the motor torque output varies on alternate steps, this is more than offset by the need to step through only half the angle. This mode had become the predominately used mode by Anaheim Automation beginning in the 1970’s, because it offers almost complete freedom from resonance issues. The bipolar stepper motor can operate over a wide range of speeds and drive almost any load commonly encountered. Although half?step drivers are still a popular and affordable choice, many newer microstepping drivers are cost?effective alternatives. Anaheim Automation’s BLD75 series is a popular half-step driver and is suitable for a wide range of bipolar stepper motors.

Bipolar Stepper Motor ? Microstepping
In the bipolar stepper motor microstepping mode, a bipolar stepper motor's natural step angle can be partitioned into smaller angles. For example: a conventional 1.8 degree motor has 200 steps per revolution. If the motor is microstepped with a 'divide?by?10,' then each microstep moves the motor 0.18 degrees, which becomes 2,000 steps per revolution. The microsteps are produced by proportioning the current in the two windings according to sine and cosine functions. This mode is widely used in applications requiring smoother motion or higher resolution. Typical microstep modes range from 'divide?by?10' to 'divide?by?256' (51,200 steps per revolution for a 1.8 degree motor). Some microstep drivers have a fixed divisor, while the more expensive microstep drivers provide for selectable divisors. For cost?effective microstep drivers, see Anaheim Automation’s MBC and MLA Series.

NOTE: In general, the larger the microstep divisor provided, the more costly will be the bipolar stepper motor driver. Should you prefer, Anaheim Automation also manufactures a series of Integrated Bipolar Stepper Motors/Drivers, meaning the bipolar stepper motor and driver are in one unit. This design approach takes the guesswork out of motor and driver compatibility. For more information, please see the 17MD, 23MD and 34MD Series.

Stepper motors are wound on the stator poles in either a unifilar or bifilar configuration. The term unifilar winding refers to the winding configuration of the bipolar stepper motor where each stator pole has one set of windings; the bipolar stepper motor will have only 4 lead wires. This winding configuration can only be driven from a bipolar driver. The term bifilar winding refers to the winding configuration of a bipolar stepper motor where each stator pole has a pair of identical windings; the bipolar stepper motor will have either 6 or 8 lead wires, depending on termination. This type of winding configuration simplifies operation in that transferring current from one coil to another, wound in the opposite direction, will reverse the rotation of the motor shaft. Unlike the unifilar winding which can only work with a bipolar driver, the bifilar winding configuration can be driven by a unipolar or bipolar driver.

The main components used in a bipolar stepper motor are the shaft, rotor and stator laminations, magnets, bearings, copper wires and lead wires, washers, and front and end covers. Most shafts of a bipolar stepper motor are made of stainless steel metal, while the stator and the rotor laminations are comprised of silicon steel. The silicon steel allows for higher electrical resistivity which lowers core loss. The various magnets available in bipolar stepper motors allow for multiple construction considerations. These magnets are ferrite plastic, ferrite sintered and Nd-Fe-B bonded magnets. The bearings of a bipolar stepper motor vary with size of the motor. The housing materials are composed of various other metals like aluminum, which allow for high resistance to heat.

The bipolar stepper motor is a component used in functions pertaining to open loop positioning and velocity. Ultimately, the system's accuracy depends on the bipolar stepper motor and the drive's precision and behavior, because there is not feed-back transducer.

Microstepping, precision sine/cosine current references, and second order damping have allowed the bipolar stepper motor to become the ideal candidate for applications dealing with precision control. Disregarding the drive, the bipolar stepper motor has distinct qualities that must be considered in regard s to accuracy in any application.

A bipolar stepper motor is assembled to a certain tolerance. Usually, a standard bipolar stepper motor has a tolerance of +/- 3% non accumulative error regarding any step's location. In other words, on a typical 200 step per revolution bipolar stepper motor, teach step will be within 0.18-degree error range. The bipolar stepper motor can essentially resolve 2000 radial locations, accurately. Incidentally, this is the 10 microstep drive's resolution.

Beyond the resolution of 10, i.e. 125, there is no real additional accuracy (there may be more smoothness, but no increase in accuracy). Similarly, a voltmeter that displays 6 digits while having 1% accuracy only contains significant information in the first two digits. Two exceptions allow for higher resolutions: a bipolar stepper motor that runs in a closed-loop application with a high-resolution encoder, or an application that needs to operate smoothly at extremely low speeds (fewer than 5 full steps per second).

Motor linearity is another factor that affects accuracy. Motor linearity is how the bipolar stepper motor operates between step locations. For every step pulse sent to a 10 microstep drive, a typical 1.8 per step motor should move precisely 0.18 degrees. Every bipolar stepper motor does face non-linearity; microsteps refuse to evenly spread themselves over a full step, and instead bunch together. Typically two effects may occur: deceleration where the microsteps bunch up and cyclic acceleration where the microsteps spread apart cause dynamically low speed resonances. Statically, the bipolar stepper motor position is not optimum.

• Step motors are constant power devices.
• As the step motor speed increases, torque decreases.
• Maximum torque for most step motors is when the motor is stationary, but the important aspect of the step motor is the torque when rotating (spinning).
• Torque curves (performance curve of a specific step motor) can be extended by current limiting step motor drivers (see our web site for compatible step motor and driver models).
• Step motors exhibit some vibratory characteristics, more than other motor types. (If vibration is a problem, consider another technology).
• The vibration seen in a step motor is due to the fact that the takes discrete ?steps? and this tends to create a snap in the step motor rotor, as it moves from one position to the other.
• Proper sizing and pairing the step motor with the step motor driver will help reduce vibration
• Failure to correctly size a bipolar stepper motor application can cause the motor to lose torque and change direction, at certain speeds. (This problem can be greatly reduced or eliminated by accelerating quickly the speeds that are problematic. Frictional damping the step motor system or using a micro step motor driver combination may completely solve this problem.
• Motor stepper types that are constructed with a high amount of phases are capable of smoother operation, or the same effect can be accomplished using a microstep drive technique.

Anaheim Automation carries a broad line of step motor, as well as step motor drivers and controller. Specials and customization services are also available, should your application require an exact step motor specification.

Have you wondered why Anaheim Automation carries the most stock in the eight-lead bipolar stepper motor configuration than the six or four lead configurations? An eight-lead bipolar stepper motor is wound like a unipolar bipolar stepper motor, but the difference is that the leads are not connected (joined) to the common internally to the motor. The flexibility of the eight-lead bipolar stepper motor is in that it can be configured in several different ways:
• Unipolar
• Bipolar with single winding per phase, which will run the bipolar stepper motor on half of the windings available, reducing the available low speed torque, but requires less current to operate.
• Bipolar with SERIES windings, which provides higher inductance, but lower current per winding
• Bipolar with PARALLEL windings, which requires a higher current, but outperforms because the winding inductance is reduced.

The many configurations of the eight-lead bipolar stepper motor make it a logical choice for Anaheim Automation to stock, as it is cost-effective to manufacture and serves a wide range of customers and bipolar stepper motor applications.

Electric motors are typically classified by motor type, i.e. Alternating Current (AC) versus Direct Current (DC). This distinction is not always so rigid, in that many classic DC motors run on AC power. This type of electric motor is referred to as universal motors.

Some industries used the rated output power specification of the motor to categorize motor types. For example, those motor of less than 746 Watts are often referred to as fractional horsepower (FHP). In more recent years, the trend toward electronic control further muddles the electric motor distinctions, as modern motor drivers and controllers have moved the commutator out of the motor casing. For this newer type of motors, driver and controller circuits are relied upon to generate sinusoidal AC drive currents. Examples of such are: the Blushless DC Motor (BLDC) and the Bipolar Stepper Motor, both being poly-phase AC motors requiring external electronic control. Although historically, bipolar stepper motors (such as for maritime and naval gyrocompass repeaters) were driven from DC switched by contacts.

Considering all rotating (or linear) electric motors require synchronism between a moving magnetic field and a moving current sheet for average torque production, there is a clearer distinction between an asynchronous and synchronous types. An asynchronous motor requires slip between the moving magnetic field and a winding set to induce current in the winding set by mutual inductance; the most ubiquitous example being the common AC Induction Motor which must slip to generate torque. In the synchronous types, induction (or slip) is not a requisite for magnetic field or current production. See the chart below to help determine if a bipolar stepper motor, Brush or BLDC motor, AC or Servo is the correct motor choice for your application.

A bipolar stepper motor in open-loop systems can provide accurate, dependable speed and positioning that can equal the best servo performance if installed correctly. Their simplicity allows them to function without tachometers, encoders, or other drawbacks that add to the cost of operation. Proper installation also makes it easy to pinpoint the exact effect of the operation, since they increment a precise amount with each control pulse. Likewise, the rate of control pulses determines motor speed so it too is totally predictable. Therefore, in the right mechanical environment, bipolar stepper motor systems can provide whatever degree of accuracy and reliability that is required.

Designing a System:
A bipolar stepper motor has several usage benefits over servos, the first being cost. In almost any application, bipolar stepper motor can be used at a fraction of the cost of servo. With servo drives, the problem of feedback loop phase shift and instability is common. However, the bipolar stepper motor is an open-loop system that completely void any potential problem that could arise in this area.

The initial design phase for open-loop systems is similar to that of the servo system. Load characteristics, performance requirements, and mechanical design, including coupling techniques, must be thoroughly considered before a designer can effectively select the best appropriate bipolar stepper motor and driver combination for an application.

Once these factors have been determined, the motor specifications and system motion controller, such as a computer or PLC, can be established. Then the design comes down to selecting the suitable driver and controller to produce the motion necessary for the application.

Defining a Driver Pack:
In order to obtain an optimum solution, the following factors must be considered:
1. Begin with the bipolar stepper motor(s) and controller you have selected for your application.
2. Make use of one driver for each motor. The driver must match the motor current (amps per phase).
3. Include a power supply that supports the driver(s) and motor(s).
4. Select an interface to handle communications between the control device and the indexer (parallel, RS422, RS232C, serial, PLC, or manual switches).
5. Configure the Driver Pack with items 2 through 4 as applicable, or see Driver Packs on our website.


NOTE: When the wiring from a driver to a bipolar stepper motor extends beyond 25 feet, consult Anaheim Automation for additional assistance. Shielded motor cable is available and purchased separately.

The primary question Anaheim Automation needs answered regarding the application of a bipolar stepper motor is, "What is the torque requirement of the mechanism driven?" Accurate measurements of the torque requirements will facilitate in the selection of a bipolar stepper motor and driver/controller. A torque wrench is perhaps the easiest method to determine torque. The wrench's gauge will indicate the torque measurement in units of ounce-inches or pound-inches. A torque watch can also be used; it is an instrument that works similarly to a torque wrench and attaches to the end of a shaft. A torque watch can be purchased at locations where precision instruments are sold.

Another way to measure torque is the old "fish scale method," which involves purchasing a spring scale and a pulley to fit the desired shaft. First mount the pulley onto the shaft, securing a strong string to the pulley. Wind the string around the pulley a few times, attaching the other end to the scale. Continue to pull on the string until the shaft begins to turn. The torque in pound inches is determined by multiplying the force in pounds displayed on the scale, with the radius of the pulley in inches. The radius of the pulley is the distance between the shaft's center and the string wound around the pulley. This crude method can be used to determine both the starting and running torque; depending on how precisely the test is conducted.

The same task can be performed without a spring scale, simply by getting the shaft to turn by adding more weight. Then place the weight on a scale and multiply the pounds or ounces times the radius in inches to determine the torque. If unsure in how to select an appropriate bipolar stepper motor for your application, contact our Applications Department.

Most people do not realize the precision that goes into the manufacturing of products like oil filter rings, small drive and timing belts, and other similar rubber parts; engineers work to ensure they will perform correctly. The necessity to produce a reliable part substantially increases the cost of the good in which the product is installed in. Therefore, manufacturers using these parts need a quick, efficient way of producing them.

A line of automatic rubber cutters ranging all the way from a simple, lathe-like machine up to a four spindle model is manufactured by one of our first customers. The line consists of numerous degrees of automation, one model having the capability to load a machine, cut parts, eject scrap into a waste bin, and place cut parts in a shipping container. Another model can cut double angles to make beveled edges, V-belt configurations, etc.

Raw rubber comes in a tube-like shape that conforms to specified dimensions. The lengths of the tube are placed on mandrels and turned, much like a work piece in a lathe. To make cuts that produce the parts, a cutting mechanism stops at specified intervals as it travels along the tube.

An Anaheim Automation bipolar stepper motor Driver Pack is used to accomplish exact precision when controlling the bipolar stepper motor; it positions the cutter as it travels along the tube. The bipolar stepper motor Driver Pack contains a preset indexer, a high performance bi-level bipolar stepper motor driver, and a matched power supply, all included in a small compact unit that is housed conveniently in the machine's control panel. While the bipolar stepper motor Driver Pack takes care of actual positioning, the operator dials the specified width directly on the thumbwheel switches. The width of the cut can range from a thousandth of an inch to up to the length of the tube. The machines have the ability to index and cut up to 240 times a minute on each spindle.

The control phase of manufacturing becomes significantly easier with the use of bipolar stepper motor Driver Packs, and allows for fast, dependable operation for the customers.

Anaheim Automation's color-coded motor cable is available with aluminum foil shielding and a drain wire. This attribute forces noise to ground, protecting the bipolar stepper motor driver signals against corruption (electrical noise) and possible subsequent system failures.

Shielded, color-coded motor cable is correctly sized (several gauges are offered), available in four, six or eight size conductor types with PVC insulation. The conductors are color-coded to match the leads on many Anaheim Automation standard bipolar stepper motor series, i.e. the D series bipolar stepper motor sequence (red/white, green, green/white, black, white).

Color-coding the bipolar stepper motor cable has significantly reduced mistakes in the field by assuring the use of the correct wire gauges and preventing bipolar stepper motor leads from crossing. Due to the fact that bipolar stepper motor cables have eliminated many complications, we strongly recommend purchasing Anaheim Automated color-coded bipolar stepper motor cable for all motor driver installations. Available in one-foot increments, bipolar stepper motor cable is a small investment that will reap big rewards; it will help you protect your motion system.

Usually, bipolar stepper motor nameplates only indicate the winding current, and on some occasions, the voltage and wind resistance. The rated voltage of a bipolar stepper motor will generate the rated winding current at DC, but this information proves futile; the bipolar stepper motor driver voltages surpass the bipolar stepper motor rated voltage. The current and the low speed torque of a bipolar stepper motor have a direct relationship and need to be considered for optimal systems performance. The winding inductance and drive circuitry, especially the driving voltage, determines how rapid the bipolar stepper motor torque falls off at quicker speeds.

The published torque curve should be used to determine how the bipolar stepper motor should be sized. This is noted by the manufacturer at certain drive voltages, and/or using their own driver circuitry. The two should be carefully chosen due to the fact that here is no guarantee for how adequate the performance will be given different driver circuitry.

Because Bipolar Stepper Motor products fluctuate in the way they perform and the way they are constructed, they are broken down into three basic varieties. Each of these designs of Bipolar Stepper Motor products offers an alternative to an application in a different way. The three basic types of Bipolar Stepper Motor products consist of the Variable Reluctance, Permanent Magnet, and Hybrid.

Variable Reluctance (VR) Bipolar Stepper Motor products:
Variable Reluctance Bipolar Stepper Motor products are recognized for possessing soft iron multiple rotor and a wound stator. The Variable Reluctance Bipolar Stepper Motor products hold no detent torque. They typically operate in step angles from 5 to 15° at fairly high step rates. The four teeth line up with the four stator teeth of phase A by magnetic attraction when phase A is stimulated; as shown in figure 5. The next step is taken when A is switched off and phase B is energized, spinning the rotor clockwise 15°; Continuing the sequence, C is turned on next and then A again. If you change it so that the phase arrangement is reversed, the rotation will rotate counter clockwise.

Permanent Magnet (PM) Bipolar Stepper Motor products:

The second type of Bipolar Stepper Motor products are classified as the Permanent Magnet Stepper motors.These Bipolar Stepper Motor products are diverse from the other two due to the fact that they have permanent magnet rotors and no teeth; the rotors are magnetized perpendicular to the axis. The rotor is attracted to the magnetic poles and as a result it rotates, when the four phases are energized in sequence. The motor will take 90 degree steps as the windings are energized in sequence "ABCD", as shown in Figure 6. Permanent Magnet Bipolar Stepper Motor products generally have step angles of 45 to 90 degrees and have a tendency to step at relatively low rates, but generate high torque and excellent damping characteristics.

Hybrid Bipolar Stepper Motor products:
Hybrid Bipolar Stepper Motor products combine qualities from the permanent magnet as well as variable reluctance Bipolar Stepper Motor products. Here are some likable features of Hybrid Bipolar Stepper Motor products which are from each: These Bipolar Stepper Motor products have an exceptional holding and dynamic torque, a high detent torque, and they'll operate in high Stepper speeds. Step angles of 0.9 to 5.0 degrees are normally seen in Hybrid Bipolar Stepper Motor products. In order for a single power supply to be used to power the motor, Bi-filar windings are supplied to these Bipolar Stepper Motor products. The rotor should rotate in increments of 1.8 degrees if the phases are energized one at a time in the order they are indicated at. These Bipolar Stepper Motor products may be driven in two phases at a time to yield more torque. Hybrid Bipolar Stepper Motor products can be be driven by one then two then one phase to make half steps of 0.9 degree increments.

Anaheim Automation Inc. has developed an extensive line of products over the years; ranging from control units mounted in cabinets, to computer boards and individual components. As the company grew, it broadened its capabilities, and has specialized itself in many different disciplines. As a result, they are now providing custom services to many clients. In 1981, Anaheim Automation released the first bipolar stepper motor Driver Pack. In a rugged metal box, a bi-level bipolar step motor driver and optional controller with a matched power supply were housed. Demand for the product grew rapidly due to its convenience and economic nature. After having problems with box suppliers, the company then decided to open its own sheet-metal shop. Following the establishment of the shop, other companies came to Anaheim Automation for custom sheet-metal work. Today, Anaheim Automation has advanced their sheet metal shop; it allows for automated punching, and a quick turn around on orders for a variety of in-house and custom bipolar step motor driver products. As further development occurred, the requirement for panels did as well, so the company developed an in-house panel building, as well as cable assemblies. These facilities combined with Anaheim Automations research and development capabilities to vertically integrate. They can take a concept, and carry it through graphic arts and photography, to board production and product assembly. This ability allows Anaheim Automation to do what they do best; design a bipolar step motor driver line, and take on turn-key system development projects for special applications. Their usual projects include custom machine-tool controllers, multi-axis control systems, test equipment, custom bipolar stepper motor Driver Packs, and control systems for special effects.

Often customers want plastic extrusion shops to do precision cutting on top of producing extrusions. However until recently, many requests of that nature had to be declined, or the shops had to invest in machines that cost up to $125,000. Recently however, one shop solved this problem by developing an automated Precision Cutter, a machine that holds the close tolerances required, cuts both hard and soft extrusions, also does counterboring and reaming, and costs less than $35,000. With its capability at this price, precision extrusion cutting became a high-return secondary operation for any extrusion shop. The Precision Cutter essentially consisted of a single-axis positioning table, an air-raised-gravity-dropped cutoff saw, and air-operated clamps. An Anaheim Automation Programmable Bipolar Step Motor Driver Pack (which included stepper motor drives and controllers), and an easy-to-use computer program worked together to provide control. In operation, an extrusion was clamped on the Precision Cutters locating table and a stepping motor fastened to the table, so the programmed length extends beyond the cutoff saw. The extrusion and parts that will be cut are secured by clamps on either side of the blade. This clamping ensemble eliminated part movement during the cutting process and made sure the required tolerance-down to the plus or minus 0.002 in.-will be met. The blade completed the cut and then returned to its original position. After this function, the clamps released the cut part and re-positioned the extrusion for the next area to be cut. The computer used for programming was housed in a drawer on the machine. For cutting, the programmer only needs to key in one number. However, if counterboring and reaming were also required, the operator must key in three numbers. Once the operator presses the RESET button, the machine began to cycle through the program until it ran out of material. Computer commands were sent to both the Bipolar Step Motor Driver Pack and the inputs from the sensors on the machine. Anaheim Automation developed an internal program that provided instructions for the stepper motor drives to translate the information into the necessary driver output to operate the stepping motor. The stepping motor positioned the table, and sent the information to output signals that operate the air solenoids that controlled the clamps and the jaw. The bipolar stepper motor Driver Pack chosen contained stepper motor drives, computer interface and the necessary logic it needed to translate machine signals and computer input into pulses. These pulses operated one or more stepper motors and controlled signals for beginning and ending the necessary mechanical processes. High-performance, bi-level stepper motor drives (one for each motor) were the chosen driver(s). A fan-cooled power supply, specifically matched to the requirements of the stepper motor drives and was also included in the bipolar stepper motor Driver Pack. Bipolar Step Motor Driver Packs can operate one, two, three, or four axes of motion, and many other mechanical operations. Precision Cutters were available from machinery manufacturers in single, double, and triple-stepper motor drive models. In this application, the motors were operated by a single Bipolar Step Motor Driver Pack. Due to the control flexibility, the double and triple stepper motor drives models simultaneously processed a single part on one axis, identical parts on all axes, or different parts on each axis. They were capable of handling hard and soft extrusions, in a number of lengths; up to 1 in. in diameter. The selected unit cut steel and other metals, simply by switching the blade on the cutter mechanisim.

Anaheim Automation bipolar stepper motor Driver Packs are used in several radiation laboratories throughout the Unites States. These Bipolar Step Motor Driver Packs are packaged bipolar step motor driver(s) containing matched power supplies that are used in radiation laboratories to operate stepper motors. These centers, run by the US Department of Energy, conduct major experiments; one of which is in a two mile long linear electron accelerator. The major use of this accelerator involves moving high energy electrons from the accelerator to a positron electron asymmetric ring. This ring is approximately 230 feet in diameter and contains magnets that keep the electrons traveling at a high speed, close to the speed of light. As a result, radiation is produced. This radiation has broad spectral range, high intensity, small source size, high stability, high polarization, pulsed time structure, and a high vacuum environment. The type of radiation produced by the accelerator makes the ring an incredibly efficient way to conduct experiments. This particular facility is well-known and has attracted a myriad of people from all over the world to use the synchrotron radiation instrument for different fields of biology, chemistry, and physics. This facility has conducted experiments with more than 1,000 researchers who have traveled from hundreds of different locations in the USA, and many foreign countries. Nearby companies also use Anaheim Automations motion control products in the radiation lab for research. As detectors gather data, the storage ring emits X-ray beams toward samples of experimental semiconductor materials. This procedure provides detailed information about materials, including its atomic structure. During one experiment, seven two-axis bipolar step motor Driver Packs were also used in conjunction with detectors; because dual-axis, they operate stepper motors on 14 axes. These motors turn mirrors to position both the X-ray beam, as well as the sample. Typically, computers operate the stepper motor drivers and respond to the data from the detectors as the work progresses, and specify different movements that specialized programs run. The two-axis bipolar step motor Driver Pack saved the laboratory time and money, using matched bipolar step motor driver products, power supplies and fans, in a compact package. Hook-ups were a snap and error-free!

Synchronizing sound and film has been a major challenge facing the entertainment industry, because most motors do not simultaneously start and stop. The problem was amplified with the increase in multi-projector presentations, such as rock shows, amusement parks, and stage shows. The introduction of bipolar step motor driver, motor and controller systems has made this task easier to execute. In many instances, Anaheim Automations stepper motion control products can drive several of the multi-image backgrounds you may see in motion pictures, a sound show, or perhaps in an amusement park. Before stepper motors, sometimes referred to as, stepping motors, motor stepper, and step motors, became available, only mediocre synchronization between sound and image could occur. The systems were expensive and unreliable, especially after they were in transit between events. Drastically different, stepper motors, along with a bipolar step motor driver, provided the ability to program a specific start, run, and stop speed, as well as the rate of speed. This gave the projectors the capacity to operate at different speeds for special applications. With bipolar step motor driver advances, not only are these speeds exact, but with an effortless input to the stepper motor controller system, they are easy and straightforward to change. Along with the customer, Anaheim Automation researched the requirements to drive the required functions, and produced custom bipolar stepper motor Driver Packs that could offer five times the flexibility of their previous systems, cutting their costs in half. With Anaheim Automations vast stepper motor, bipolar step motor driver, and stepper controller product lines, the customer also substantially reduced the bulk of controls and overall weight of their system. Even with improved performance, the projection systems were compact; they are small enough to travel within four road cases and they only take one person to set them up and operate them. These types of advanced stepper motor Driver Packs opened the door for many other opportunities in the filming and projection industry, not just projector synchronization. There is also great potential use for Anaheim Automations step motor, step motor controller and both unipolar stepper motor driver and bipolar step motor driver product lines in the areas of film editing, theater operation, special effects, and more.

Along with the bipolar stepper motor, Anaheim Automation carries a comprehensive line of drivers and controllers, power supplies, gear motors, gearboxes, bipolar stepper motor linear actuators and integrated bipolar stepper motor/driver packages. Additionally, Anaheim Automation offers encoders, brakes, HMI couplings, cables and connectors, linear guides and X-Y tables. If the bipolar stepper motor is not ideal for your application, you might consider brushless DC, brush DC, servo, or AC motors, and their compatible drivers/controllers.

• Cost-effective* • Simple designs • High reliability • Brushless construction • Maintenance-free • If windings are energized at standstill, the motor has full torque • No feedback mechanisms required • High acceleration and power rate • A wide range of rotational speeds can be attained as the speed is proportional to the frequency of the input pulses • Known limit to the dynamic position error *Stepper motor products vary in cost based on the criteria for each application. Some criteria include options of 0.9°, 1.8°, 3.6° and 4.5° step angles, torque ranging from 1 to 5,700 oz-in, and NEMA frame sizes of 08 to 42. Additional attachments such as cables and encoders can be purchased separately for an additional cost. With our friendly customer service and professional application assistance, Anaheim Automation often surpasses customer expectations for fulfilling specific bipolar stepper motor and driver requirements, as well as other motion control needs.

One of Anaheim Automation Inc.s customers provides services and products for the automobile industry, such as process automation, prototyping, engine test standards, and gauging equipment. At one point, our customer encountered a problem; popular cars were being redesigned, and they needed computer control of a bipolar stepper motor for their project. They had tried several other motion control manufacturers before deciding to have Anaheim Automation help them with their project. The project dealt with the cooling of an engine in a strange area. Anaheim Automations assignment was to construct a prototype that would scoop air from beneath the car and redirect maximum air flow to this area. It was almost impossible to predict an accurate shape that would allow precise airflow, due to the fact that in order to fit in the available space, the duct had to be in an extremely complex configuration. The solution to this problem involved making a flexible duct that, by moving its parts, allowed it to be reshaped. The duct would be mounted in a wind tunnel, and installed in the prototype of the car. Next, engineers experimented with the ducts shape until they discovered what shape allowed for the best air flow. This shape became the basic model to construct in the overall prototype. Anaheim Automation needed to shape the duct without diverting from the project goal, and therefore needed 15 axes of motion and one easy-to-use controller. To meet this necessity, Anaheim Automation assembled five triple-axis bipolar stepper motor drivers, programmable indexers, an interface, and the necessary power supply into a compact package, along with 15 compatible bipolar stepper motor models. When the computer was turned on, the program came up, so the system didnt require any knowledge of the computer operation. In addition, it reduced operation to simply answering three questions (prompting the user). The user could change the speed at any time; however, the operator did not need to know anything about base speed, acceleration, or deceleration, because the parameters for optimal motor speed was preloaded with the system program. While operating, the program prompted the operator with, What axis, how many steps, and which direction? The user only needed to press the F1 function key to produce the desired motion for the bipolar stepper motor to move. With the experiment in full swing, engineers were able to manipulate the air duct in order to achieve maximum air flow underneath the vehicle. The required motion was easily produced at the press of a button, and the positions could be easily repeated. Ultimately, our customers engineering staff was able to determine the exact shape of the duct that provided the car with maximum air flow. Simple, low-cost, and extremely efficient bipolar stepper motor products, and drivers provided the solution the customer required.

The stepper Motor is currently used all around the world for many types of applications. These motors provide as constant power devices. At low rpms a high torque can be achieved the same cannot be said when the speed is increased. A high torque cannot be achieved at higher rpms. These motors are great for positioning objects, such as conveyor belts, assembly lines, lathes, laser cutting, grinding and drilling machines, etc. The bipolar stepper motors is ideal for precise positioning. You may have a fixed speed, variable speed, and position control. These motors are able to handle complex positions or movements. These devices offer power and precision in a compact sizes. These motors can take a great load. A good example to show this would be an escalator. Escalators are constantly worked and carry very heavy loads throughout the day. The step motor has to be able to take up to several hundreds of pounds maybe even thousands. The speed of the escalator is constant and never changes no matter how many people are on it. A different type of application could be an assembly line. This typically requires precise quick and place movements. Most bipolar stepper motor products are open loop systems, meaning there is no feedback info needed about the position. By keeping track of the input step pulses, the position is known. Some of the advantages of a bipolar stepper motor, but not limited to are: • Its input pulse is proportional to angle rotation • If windings are energized at stand sill the motor has full torque • Different rotation speeds are available since the frequency of input pulses are proportional to the speed. • It cost less to have open-loop control that responds to digital input pulses • Precise response time to starting, stopping, and reversing • No brushes within the motor making it more reliable. There are three different types of bipolar stepper motor models to choose from, the variable -reluctance, the permanent-magnet, and last but not least the hybrid step motor. The three all have different qualities for certain applications. The bipolar stepper motor has been around for a long time and are currently and will continue to be used throughout the world. No matter what the application will be the step motor will always rise to the occasion.

One of the best, most flexible, computer-controlled positioning systems is one in which the bipolar stepper motor is integrated. Having more simple and hardy characteristics compared to a closed-loop servo system, bipolar stepper motor and driver systems are digitally controlled, and are a crucial element in the less costly open-loop system. Industrial applications for the bipolar stepper motor are in high-speed pick-and-place equipment and multi-axis CNC machines frequently drive lead screws or ballscrews directly. Usually, a bipolar stepper motor is often used in precision positioning in the fields of lasers and optics, often being used in linear actuators, linear stages, goniometers, mirror mounts, and rotation stages. The bipolar stepper motor is also used for positioning valve pilot stages for fluid control systems, and in packaging machinery. Traditionally, the bipolar stepper motor has been used commercially in floppy disk drives, and continues to be used for flatbed scanners, computer printers, plotters, slot machines, and a myriad of other devices. A bipolar stepper motor can be used to generate power as well, often designed in wind turbines and solar positioning systems.

Time is the centralized theme at the New Mexico Museum of Natural History in Albuquerque. At one point, the museum wanted to convey the idea that traveling through the exhibit is as if one is traveling through time. The museum depicted the conditions of New Mexico during the time periods of the Cretaceous period (75 million years ago) and the Tertiary period (37 million years ago), and how the area has evolved since. However, the museum did so with less than a satisfactory effect on the visitor. The idea they constructed to improve this was known as the Evolator. Derived from a combination of the words EVOLutionary and elevATOR, the evolator was an elevator-like vehicle that allowed visitors to be transported through time as evolution took place. It was designed by Art & Technology, Inc., in California, and is located between two exhibit areas in the museum. Allowing up to twenty people to enter from one exhibit into one door, experience time travel, and exit out the second door into another exhibit, it allows the passengers to experience 30 million years of time travel in six minutes. During time travel, the guests can view the outside world via TV screens, and see the two ports and the evolator traveling through rock strata on both sides of them. They can feel the vehicle moving throughout the tour, as it stops frequently throughout the trip for the computer to evaluate the rocks that are visible through the ports. In order to create the full time travel illusion, five laser disks, special lighting, a sound system, a hydraulic system for rocking the evolator floor and two silicon belts are needed. The 18 foot long silicon belts run as long continuous loops at a high speed during evolator movement, and slow to a stop as the evolator stops. In order for the operation to appear realistic, the belts have to operate in synchronism, a condition that is met by means of using large bipolar stepper motors. Due to the fact that the belts are very heavy, Anaheim Automation needed to develop a high- performance bipolar stepper motor Driver Pack (known as DPK Series) for the job. A computer was selected to coordinate the bipolar stepper motor, driver and controller system that makes the evolator work. The computer provides the DPK with clock and direction signals that trigger the bipolar stepper motor Driver Pack to operate the bipolar stepper motors, according to the required movements of the silicon belts. Time travel visitors were as thrilled with the success of the Evolator as were!

Automation and Material Handling specialists create products for a broad range of businesses, including automotive, pharmaceutical, packaging and electronics companies. Anaheim Automation, Inc. has been a supplier to these companies for over 40 years. When it comes to automating equipment, machinery and processes, some methods are efficient, while others are not. Anaheim Automation has an outstanding record for choosing sensible methods and cost-effective designs, but when we recommend multi-axis bipolar stepper motor Driver Packs and boards for moderately straightforward machines, they maximize their cost effectiveness even further. For single-axis applications that are redundant and require accurate positioning, the economical DPD72451 Preset Indexer Driver Pack is ideal, and has been a long-time favorite. Each compact bipolar stepper motor Driver Pack contains a preset indexer, a bi-level bipolar stepper motor driver, a power supply, and a cooling fan. The preset indexer has such abilities as Home, Hard and Soft Limit inputs, two Homing modes, Jog/Run, Fast Jog, and switch selectable Base Speed, Maximum Seed, and Acceleration/Deceleration. The DPF72452 Bipolar Stepper Motor Driver Pack offers the same performance for two axes. It is a larger unit with twice the capacity. The companion Quad Board is consists of four banks of digital pots mounted on a PC board, along with the supplementary circuitry. According to what the user desires, the board has the capacity to dial in up to four different move lengths. Anaheim Automation simplifies installation by offering the Quad Board connected to and mounted on the bipolar stepper motor Driver Pack. A classic example of this inventive production is a machine that rivets stiffeners on the edge of up to 800 circuit boards per hour. In this practical application, wherein bipolar stepper motor products are used, Anaheim Automation, Inc. helped a machinery manufacturer build equipment for a telephone company. This particular machine had the requirement of automatically installing stiffeners along the edge of circuit boards. A stiffener is added from a magazine, to each board that is positioned on a linear table. The bipolar stepper motor, operated by the Driver Pack, positions a table so the rivets can be inserted through the stiffener and the board in three different areas: a distance of 1-1/2 in. from the first hole, 4-1/2 in. to the second hole, and 4-1/2 in. to the third hole, and return to home. The Quad Board settings were used in order to keep two additional settings available to handle any prospective complex arrangements. Despite how simple the machine was, it was also capable of extraordinary tasks; one example being its ability to turn out 800 boards in one hour. Anaheim Automation used the same idea for other, very different machines. In the case of a pharmaceutical company; they used a flutter valve maker. For this machine, a roll of vinyl was advanced to a dimension, heat sealed, and cut along the seal. Each of the two rolls provide two valve sizes. In this case, the bipolar stepper motor controlled a drive-roller against a pinch roller, and the Quad Board settings controlled the length of the material. This left two settings for further expansion. Just like our other machines, efficiency coincides with simplicity. In this example, we can turn out 15 flutter valves a minute. This approach not only provided the benefits of simple and efficient productivity, but it only required a simple interface with a machines PLC. There was no need for high level software; therefore Anaheim Automation was able to maintain lower costs, and simplify service considerations.

Stepper motor products are versatile motion control components that can be applied to several different industries, from entertainment and film, to the business world, to science and medicine. Aircraft: A bipolar stepper motor is frequently used in aircraft instruments, scanning equipment, and sensing devices, such as antennas. Automotive: SUVs and RVs, as well as some high-end automobiles, use the bipolar stepper motor to receive telecommunication signals. A bipolar stepper motor is also used for cruise control, automated dashboards gauges and electronic window equipment, as well as in automobile factories on their production lines. Cameras - Filming and Projection: Not only does the bipolar stepper motor operate filming cameras and projectors, in the entertainment industry, but automatic digital cameras and mobile phone camera modules utilize tiny bipolar stepper motor for focusing and zooming functions as well. The security industry also uses a bipolar stepper motor for zooming, tilting and scanning operations in surveillance and security cameras. Entertainment and Gaming: Slot machines, lottery machines, raffles, card shufflers, and wheel spinners can all be operated by cost-effective and reliable bipolar stepper motor. You can also find the bipolar stepper motor in stage productions to control curtains and lighting functions, for plays and concerts, as well as seminars and rallies. Laboratory and Factory Improvements and Upgrades: A bipolar stepper motor is employed to perform tedious movements pertaining to mixing chemicals in laboratories, and operating equipment for controlled environmental testing. The bipolar stepper motor is used in retrofit kits (bipolar stepper motor, drivers, controllers and power supplies) for CNC machine control, factory automation and assembly processes. The bipolar stepper motor can also be found in scientific study, used to position observatory telescopes, and in many different types of scientific equipment, i.e. spectrographs, analyzers, and diagnostic machines. Medical: The bipolar stepper motor provides a wide variety of functions for the medical and dental world. The bipolar stepper motor is used within medical scanners, multi-axis bipolar stepper motor microscopic or nanoscopic motion control of automated devices, auto-injectors, samplers, dispensing pumps, respirators, blood analysis machinery and chromatographs. In the dental industry, a bipolar stepper motor operates fluid pumps, and are often found inside digital dental photography equipment. Office Equipment: PC based scanning equipment, optical disk drive head driving mechanisms, bar-code printers, label and box printers, scanners, and data storage drives all utilize the bipolar stepper motor for their motion control operation.

Anaheim Automations tremendous versatility of control systems is evident in their new program titled, Musical Motors. They have utilized bipolar stepper motor, stepper drivers, and stepper controllers to operate at speeds that coincide with musical notes and pitches to produce a number of different tunes. Each tune is performed by simply running the program that converts each music note into a certain step-per-second. All of the different bipolar stepper motor are programmed to produce an appropriate pitch based on how many steps-per-second they run, and for how long. Typically played at a trade show, the program provides the element of surprise; most people do not expect to hear music that is being played by bipolar stepper motor!

Employees were hired at a local packaging plant, for the sole purpose of making sure bottles were packaged with their labels facing outward in their packages. They were employed to manually adjust the positioning of the bottles and send them to the blister pack machine. Anaheim Automation helped expedite that process using bipolar stepper motor and drivers. With the new automated design, bottles were sensed with a photo-electric sensor that stops the belt and notifies the pulse generator in an Anaheim Automation Driver Pack. The bipolar stepper motor Driver Pack controls a bipolar stepper motor, which rotates the bottle by turning a rubber drive wheel. An orientation indicator is placed on the bottle that, when sensed, prompts the pulse generator and activates a discharge solenoid, which then places the bottle into the awaiting package. The packaged bottle then allows the photo sensor to trigger the next bottle to come into position to repeat the process. Implementing this process using a bipolar stepper motor Driver Pack resulted in quicker packaging with viewable bottles, at a considerably lower cost! Both the customer and its intended end-users were quite pleased with this development.

The new DPD72451 Driver Pack is an individual preset indexer module, complete with Control Link (Indexer), BLD75 bi-level driver, and matched power supply. In order to handle all aspects of positioning on a single axis, it is ready to connect between an input device such as a thumbwheel switch counter, with a bipolar stepper motor. The preset indexer board was originally built around the capabilities of a single-chip indexer. The chip is derived from the SMC 20BC, a programmable bipolar stepper motor controller chip. It features hard and soft limit outputs, three homing modules, jog/run, fast jog, and programmable base speed, maximum speed, and acceleration/deceleration. The Driver Pack therefore provides extended capabilities that make it applicable to a broad range of functions, the most popular being cut-to-length. The necessary buffering and other circuitry required to support the chip is also included. However because the units are mounted separately in most installations, a thumbwheel switch is not included on the indexer. Anaheim Automation offers numerous different input devices for use with the DPD72451, including three-, four-, five-, and six-decade thumbwheel switch encounters; two-, four-, and six-decade rotary switches; and two-, four-, and six-quad rotary switches. The high-performance bi-level driver BLD75 operates four-, six- or eight-lead bipolar stepper motors. Due to its characteristic of being a bi-level driver, it provides high torque (power) output and high start-stop speed. The power supply in the DPD72451 is fan-cooled and matched to the requirements of the PCL451 and the BLD75 bi-level driver. Together, the indexer, bi-level driver, and matched power supply provide a complete, concise package with exceptional price and performance for a myriad of different applications. When two axes are required, two PCL451s can be housed in a larger Driver Pack, along with dual bi-level drivers and the appropriate power supply.

Although the bipolar stepper motor has been overshadowed in the past by servo systems for motion control, it has emerged as the preferred technology in more and more areas. The major factor in this trend towards the bipolar stepper motor is the prevalence of digital control, the emergence of the microprocessor, improved designed (i.e. high?torque models), and lower cost. Today, bipolar stepper motor applications are all around us: they are used in printers (paper feed, print wheel), disk drives, clocks and watches, as well as used in factory automation and machinery. A bipolar stepper motor is most often found in motion systems requiring position control. Anaheim Automation’s cost?effective bipolar stepper motor product line is the wise choice for both OEM and user accounts. Anaheim Automations customers for the bipolar stepper motor product line is diverse: industrial companies operating or designing automated machinery or processes involving food, cosmetics or medical packaging, labeling or tamper?evident requirements, cut?to?length applications, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, camera tracking, inspection and security devices, aircraft controls, pump flow control, metal fabrication (CNC machinery), and equipment upgrades. Anaheim Automation, Inc. bipolar stepper motor product line integrates a matched bipolar stepper motor, driver and controller in one unit. This design concept makes selection easy, thus reducing errors and wiring time. With friendly customer service and professional application assistance, Anaheim Automation often surpasses the customers expectations for fulfilling specific bipolar stepper motor and driver requirements, as well as other motion control needs. Bipolar Stepper Motors are Used in Many Industries Stepper motors have become an essential component to applications in many different industries. The following is a list of industries making use of bipolar stepper motors: • Aircraft – In the aircraft industry, bipolar stepper motors are used in aircraft instrumentations, antenna and sensing applications, and equipment scanning • Automotive – The automotive industry implements bipolar stepper motors for applications concerning cruise control, sensing devices, and cameras. The military also utilizes bipolar stepper motors in their application of positioning antennas • Chemical – The chemical industry makes use of bipolar stepper motors for mixing and sampling of materials. They also utilize bipolar stepper motor controllers with single and multi-axis bipolar stepper motors for equipment testing • Consumer Electronics and Office Equipment – In the consumer electronics industry, bipolar stepper motors are widely used in digital cameras for focus and zoom functionality features. In office equipment, bipolar stepper motors are implemented in PC-based scanning equipment, data storage drives, optical disk drive driving mechanisms, printers, and scanners • Gaming – In the gaming industry, bipolar stepper motors are widely used in applications like slot and lottery machines, wheel spinners, and even card shufflers • Industrial – In the industrial industry, bipolar stepper motors are used in automotive gauges, machine tooling with single and multi-axis bipolar stepper motor controllers, and retrofit kits which make use of bipolar stepper motor controllers as well. Stepper motors can also be found in CNC machine control • Medical – In the medical industry, bipolar stepper motors are utilized in medical scanners, microscopic or nanoscopic motion control of automated devices, dispensing pumps, and chromatograph auto-injectors. Stepper motors are also found inside digital dental photography (X-RAY), fluid pumps, respirators, and blood analysis machinery, centrifuge • Scientific Instruments –Scientific equipment implement bipolar stepper motors in the positioning of an observatory telescope, spectrographs, and centrifuge • Surveillance Systems – Stepper motors are used in camera surveillance

Each type of bipolar stepper motor varies per application by its construction and functionality. The three most common bipolar stepper motor types are Variable Reluctance, Permanent Magnet, and Hybrid Bipolar Stepper Motors. Variable Reluctance (VR) Bipolar Stepper Motor VR bipolar stepper motors are characterized as having multiple soft iron rotors and a wound stator. VR bipolar stepper motors generally operate on the basic principle of the magnetic flux finding the lowest reluctance pathway through a magnetic circuit. In general operation, VR bipolar stepper motors have relatively high step rates of 5 to 15 degrees and have no detent torque. The step angles taken in VR bipolar stepper motors are related to the number of teeth the stator and rotor have. The equation relating these two variables can be found in the formula section of this guide. How Does a Variable Reluctance Bipolar Stepper Motor Work? Referring to Figure 1 on Page 2, the poles become magnetized when the stator windings are energized with DC current. With the poles becoming magnetized, the rotor teeth are now attracted to the energized stator poles and rotate to line up. With the windings around stator A becoming energized the rotor teeth become attracted allowing the poles to line up. When A’s windings become de-energized and B’s windings become energized, the rotor rotates to line its teeth with the stator teeth. This process continues in sequence with C, followed by D being energized allowing for the rotor to rotate. Brief Summary of Variable Reluctance Bipolar Stepper Motors: • The rotor has multiple soft iron rotors with a wound stator • Least complex and expensive bipolar stepper motor • Large step angles • No detent torque detected in hand rotation of a de-energized motor shaft Permanent Magnet (PM) Bipolar Stepper Motor PM bipolar stepper motors are comprised of permanent magnet rotors with no teeth, which are magnetized perpendicular to the axis of rotation. By energizing the four phases in sequence, the rotor rotates due to the attraction of magnetic poles. The bipolar stepper motor shown in Figure 2 on page 3 will take 90 degree steps as the windings are energized in clockwise sequence: ABAB. PM bipolar stepper motors generally have step angles of 45 or 90 degrees and step at relatively low rates. However, they exhibit high torque and good damping characteristics. Anaheim Automation carries a wide selection of PM bipolar stepper motors, ranging from 15 to 57mm in diameter. Brief Summary of Permanent Magnet (PM) Bipolar Stepper Motors: • The rotor is a permanent magnet • Large to moderate step angle • Often utilized in computer printers as a paper feeder Hybrid Bipolar Stepper Motors Hybrid bipolar stepper motors incorporate the qualities of both the VR and PM bipolar stepper motor designs. With the Hybrid bipolar stepper motor’s multi-toothed rotor resemblance of the VR, and an axially magnetized concentric magnet around its shaft, the Hybrid bipolar stepper motor provides an increase in detent, holding and dynamic torque. In comparison to the PM bipolar stepper motor, the Hybrid bipolar stepper motor provides performance enhancement with respect to step resolution, torque, and speed. In addition, the Hybrid bipolar stepper motor is capable of operating at high stepping speeds. Typical Hybrid bipolar stepper motors are designed with step angles of 0.9°, 1.8°, 3.6° and 4.5°; 1.8° being the most common step angle. Hybrid bipolar stepper motors are ideally suited for applications having stable loads with speeds under 1,000 rpm. There are key components which are influential of the running torque of a Hybrid bipolar stepper motor which are laminations, teeth and magnetic materials. Increasing the amount of laminations on the rotor, precision and sharpness of the rotor and stator teeth, and strength of magnetic material are all factors taken into account in providing optimal torque output for Hybrid bipolar stepper motors. Brief Summary of Hybrid Bipolar Stepper Motors: • Smaller step angles in comparison to VR and PM bipolar stepper motors • Rotor is made of a permanent magnet with fine teeth • Increase in detent, holding and dynamic torque • 1.8° is the most common step angle NOTE: At Anaheim Automation, the 1.8 degree Hybrid bipolar stepper motor is the most widely stocked bipolar stepper motor type, ranging in NEMA frame sizes, 08 to 42. The Hybrid bipolar stepper motor can also be driven two phases at a time to yield more torque, or alternately one then two then one phase, to produce half-steps or 0.9 degree increments.

A bipolar stepper motor (also referred to as a step or stepping motor) is an electromechanical device achieving mechanical movements through conversion of electrical pulses. Stepper motors are driven by digital pulses rather than by a continuous applied voltage. Unlike conventional electric motors which rotate continuously, bipolar stepper motors rotate or step in fixed angular increments. A bipolar stepper motor is most commonly used for position control. With a bipolar stepper motor/driver/controller system design, it is assumed the bipolar stepper motor will follow digital instructions. One important aspect of bipolar stepper motors is their lack of feedback to maintain control of position. It is this lack of feedback which classifies bipolar stepper motors as open-loop systems.

Bipolar Stepper Motor products are a type of digital device. Digital information is processed through the Bipolar Stepper Motor products to accomplish an end result, in this instance, controlled motion.You can assume that Bipolar Stepper Motor products will dependably follow digital instructions just as a computer is anticipated to. This is the unique feature for Stepper motors. Bipolar Stepper Motor products are an electric power motor that is driven by digital pulses as opposed to a continuously applied voltage. Inherent in this concept is open-loop control, where a train of pulses converts into so many shaft revolutions, with each revolution requiring a given number of pulses. Each pulse equals one rotary increment, or step (hence, Stepper motors), which is only a portion of one finished rotation. As a result, counting pulses can be applied in Bipolar Stepper Motor products to accomplish a ideal amount of shaft rotation. The count automatically represents how much movement has been achieved, without the demand for feedback information, as would be the instance in servo systems.

NOTE: Always read the specification sheet/user’s guide accompanying each product. Problem: Stepper motor wires were disconnected while the driver was powered up. Solution: Avoid performing any service to the bipolar stepper motor, driver or controller while the power is on, especially in regard to the motor connections. This precaution is imperative for both the driver and the technician/installer. Problem: The bipolar stepper motor has a shorted winding or a short to the motor case. Solution: It is likely you have a defective bipolar stepper motor. Do not attempt to repair motors. Opening the bipolar stepper motor may cause the motor to lose its magnetism, causing poor performance. Opening of the bipolar stepper motor case will also void your warranty. The motor windings can be tested with an ohmmeter. As a rule of thumb, if the bipolar stepper motor is a frame size of NEMA 08, 11, 14, 15, 17, 23, or 34 and the warranty period has expired, it is not cost-effective to return these bipolar stepper motors for repair. Contact the factory if you suspect a defective bipolar stepper motor that is still under warranty, or if the bipolar stepper motor is a NEMA frame size 42 or a K?series motor. Problem: Environmental factors are less than ideal. Solution: Environmental factors such as welding, chemical vapors, moisture, humidity, dust, metal debris, etc., can damage the electronic components and the bipolar stepper motor. Protect drivers, controllers and bipolar stepper motors from environments that are corrosive, contain voltage spikes, or prevent good ventilation. Anaheim Automation offers products in several line voltage ranges, as well as splash?proof, IP65 rated bipolar stepper motors. For wash?down or explosion?proof motors, contact the factory directly. For AC lines containing voltage spikes, a line regulator (filter) will likely be required. NOTE: If your application requires welding, or if welding is done in the same work environment, contact the factory for advice on how to protect the bipolar stepper motor driver and controller. Problem: The bipolar stepper motor is back?driving the stepper driver. Solution: A bipolar stepper motor being turned by a load creates a back EMF voltage on the driver. Higher speeds will produce higher voltage levels. If the rotational speed gets excessively high, this voltage may cause damage to the driver. This is especially dangerous when the motor is back?driven while the driver is still on. Place a mechanical stop or brake in applications which may be subject to these phenomena.

Common Causes for Bipolar Stepper Motor and/or Stepper Driver Failure NOTE: Make sure to look over the specification sheet/users guide that accompanies each product Problem: Irregular or erratic bipolar stepper motor or drivers function. Solution: In terms of failures, this is the most common, and the hardest to detect. Start by checking to make sure that all connections are secured between bipolar stepper motors and drivers. Evidence like discoloration at the terminals/connections, may reveal a loose connection. Make certain to inspect all terminal blocks and connectors when exchanging a bipolar stepper motor, driver, or Driver Pack in a motion control system. Check cabling/wiring for precision. Stress bipolar stepper motor wiring and connections for worse problems and check with an ohmmeter. Problem: Stepper motor wires had been disconnected while the driver was powered up. Solution: Refrain from performing any service to the bipolar stepper motors or drivers as the power is on, especially in regard to motor connectors. This safety measure is not only to protect the specialist or installer, but will also to protect the driver. Problem: Bad system performance. Solution: Check to discover if the wire/cables are too long. Keep wire/cable to the bipolar stepper motors below 25 feet in length. For applications where the wiring from the bipolar stepper motors to the stepper drivers is higher than 25 feet, please contact the factory for instructions, as chances are that transient voltage protection devices are going to be required. Another likelihood is that the bipolar stepper motor lead wires are of a gauge that is far too small. Never match your cable wires to the gauge size of the bipolar stepper motor lead wires. Anaheim Automation advises using a shielded cable for such wiring (purchased separately). Because most bipolar stepper motors start to lose their magnetism over time of use, you should keep reports of how old each one is; as this can affect performance. Typically its possible to expect 10,000 operating hours for bipolar stepper motors (roughly 4.8 years, running one eight-hour shift every work day). Also, make certain that your bipolar stepper motor and driver combo is a beneficial match for your application. Contact the factory, should you have any worries. Problem: The bipolar stepper motor has a shorted winding or a short to the motor case. Solution: It is likely that you have a defective bipolar stepper motor. Do not attempt to repair motors. Opening the bipolar stepper motor case may de-magnetize the motor, leading to poor performance. Opening of the bipolar stepper motor case will also void your warranty. As an alternative, use an ohmmeter to test the motor windings. As a general guideline, if the bipolar stepper motor is a frame size of NEMA 08, 11, 14, 15, 17, 23, or 34 and the warranty period has expired, it is not cost-effective to return these bipolar stepper motors for service. Call the factory if you believe you have a defective bipolar stepper motor that is still under warranty, or if it is a NEMA size 42 or a K-series motor. Problem: The bipolar stepper motor driver or Driver Pack is over-heating. Solution: Air flow and cooling accommodations are vital : inability to provide adequate air flow will affect the bipolar stepper motor drivers overall performance and will shorten the life of the driver. Maintain driver temperatures below 60 degrees Celsius. To preserve good airflow: use fans, heat sink material, and base plates, so as not to exceed the optimum temperature rating of the bipolar stepper motors, drivers or controllers. Be mindful of temperatures inside cabinets and enclosures where stepper drivers may be attached. Problem: Environmental factors are less than ideal. Solution: Environmental factors, such as welding, chemical vapors, moisture, humidity, dust, etc., can damage both the electronics and the bipolar stepper motors. Protect drivers, controllers and bipolar stepper motors from environments that are corrosive, contain voltage spikes, orreduce good ventilation. Anaheim Automation offers products in a number of line voltage ranges. A line filtration system/regulator will probably be desired for AC lines that contain voltage spikes. Problem: Pulse rates (Clock or Step) to the driver are too high. Solution: The typical half-step driver can drive bipolar stepper motors at a top rate of 20,000 pulse per second. Pulse rates of above 60,000 pulses per second can impair the driver. The best combination of the motor and driver for the greatest performance is more clear in the individual specification sheets for each product. Problem: The bipolar stepper motor is stalling. Solution: Watch out for motors that stall, as it has the potential to damage the phase transistors on the driverby large voltage spikes. Some drivers are created to protect itself from such an event. If not, Transient Suppression Devices can be added externally. Seek advice from the factory for further information. Problem: The bipolar stepper motor is back-driving the driver. Solution: A bipolar stepper motor that is being turned with a load creates a back EMF current on the driver. Higher speeds will produce higher voltage levels. If the rotational speed should get very high, this voltage could potentially cause damage to the driver. This is especially dangerous when the motor is back-driven while the driver is on. Put a mechanical stop or brake in applications that might be subject to these phenomena. General Safety Considerations for Bipolar Stepper Motor Applications The up coming safety considerations are required to be observed during all phases of operation, service and repair. Failure to comply with these safety measures violates protection standards of design, manufacture, and intended use of a Unipolar Bipolar Stepper Motor, drivers and controllers. Anaheim Automation, Inc. takes on no responsibility for the customers failure to comply with thesespecifications. Even well built products, operated or installed inaccurately, can be hazardous. Safety measures must be observed by the user with caution to the load and operating environment. The customer is responsible for proper selection, installation and operation of the products purchased from Anaheim Automation, Inc. • Use care when handling, testing, and adjusting during installation, set-up and operation • Anytime power is applied, service should not be conducted • Be sure that the motor/driver has enough heat dissipation and air flow • Exposed circuitry should be effectively guarded or enclosed to counteract unauthorized human contact with live circuitry • It is important that all products be properly grounded and securely mounted • Elements including flammable gases, vapors, liquids or dust should not interact with motors in operation

Several choices for customization options for Bipolar Stepper Motor products are accessible through Anaheim Automation. The variety of modifications includes, but is not confined to: shaft, brake, oil seal for an IP65 rating, mounting dimensions, speed, torque, and voltage. Contact Anaheim Automation today to set up an order for utilities with Bipolar Stepper Motor products that require customization: 1-714-992-6990.