What is the difference betwwen a 3-phase stepper motor with encoder and a dc-brushless motor?
What is the difference between a 3 phase 16step/rev stepper motor in comparision to a DC-brushless motor with encoder but without hall effect sensors? Please help?
In some configurations there is very little difference. Reasons follow:
Stepper motors by continuous encodings or a stopped (addressing) code provide a rotating field or even a stopped field by converting digital BCD counts into a code that by a planned coincidence causes the fields’ electromagnetic poles to N and S positions to attract the S and N armature poles to a desired orientation, whether still or rotating in real time. When the computer causes the armature to rotate, the field normally does not slip, because stepmotors are chiefly used for precise positioning, in which the number of revolutions will determine how far a mail or female thread will travel.
Stepper motors can be four-pole, 8-pole … even 2 exp x pole. Stepper motors can be 6 pole, 12 pole, … even 3 exp x pole. More poles make the positioning more focused in final addressed position. The fact that 6-pole 3-pole motors can run as a 3-phase motor, in, like Y connection to 3 phase and neutral AC power may have an interesting crossover as an application of stepping motor engineered system. Most 3-phase motors are used for grunt labor applications, e.g., assembly line belt drives. If such a three-phase motor were driving an elevator by a cogs and chain, it would be possible to drive the elevator and stop and start the elevator at exact positions with no brakes. (But there would be no precision whatever if the armature were a typical squirrel cage armature. Precision motoring requires an armature that has steady-state N & S poles–so that it would remain synchronous with each movement of each change in field. (Squirrel cage motors armatures receive their field strength by magnetic induction from the rotating control field (a rotating magnetic field caused by the peripheral electromagnets as the magnetic fields of each electromagnet vector-sum in the empty hollow cylindrical space between the armatur and the peripheral electromagnet poles, and armatures like that inherently slip a little bit all the time, which doesn’t hurt much in a refrigerator motor of a washer motor or in a 3-phase coal conveyor belt drive. Who cares if the coal is delayed 3% if the motor doesn’t have to have a DC field supply and sliprings to make the armature synchronous? Hence the 3-phase elevator motor running from a computer-controlled stepmotor power supply would also need a synchronous 3-phase motor, which would either have permanent magnets to energize the armature field in steady state; or it would have to have 3 pairs of 2 electromagnets forming a six points of an asterisk crosssection of the armature. The steady state armature field also would help a stopped motor field grab the armature while the elevator is at a station. Typical 3-phase synchronous motors have slip rings to bridge DC current to the rotating armature. Stepmotors for many precision robot jobs need dozens of poles to obtain more shaft angle addressing precision. However, stepmotors can also have more addressing precision than a simple count of poles can provide, because there is a way to have some of the extra poles reversed, so that the motor can stop with the armature having some of its fields distorted as the armature. This compromises the resulting field. This arrangement can be happening in real time travel, which reduces the steps that a milling machine might leave on a finished product.
A DC brushless motor operates like a DC motor with brushes, except that the DC power routes current to the armature poles according to semiconductors that receive their steering signals from photocells that tell the semiconductors in series with each opposite electromagnet when to turn on and when to turn off. Nearly all garden-variety dc motors have a 2-pole distributed d-c energized N-S field on the outside, the stator windings.
(irrelevant but interesting, these motors need to have a way to deal with back emf voltage produces as any given field collapses. A varactor is one way to protect the switching transistors from these high voltage. The varactor’s resistance goes up sharply with voltage that is above the normal operating voltage that the armature receives.)
It is also possible to put all the stuff that is in the outside of the dc motor on the inside, and put all the stuff that is on the inside onto the outside. Because after all, the business end of the poles positions are all relative, right?
Dc motors change their speed when under load. They normally draw more current when they slow down. For some applications, you could just energize the DC motor which has a permanent-magnet armature by means of encoded stepped fields on the stator winding area providing on the outside tha same number of N-S field pairs that would have been on the inside, the rotor.
If the load increased beyond the torque that would hold the armature, the windings would draw a lot of extra power and the armature would probably almost stall. To mitagate against stall, then all currents need to run at or near peak required currents yet no winding should be allowed to burn out. This doesn’t sound efficient.
So if you install a digital position code reader on on the outside and install digital position code positions on the armature, any time that the armature position slips backwards beyond tolerable specifications, the motor can receive more current in all outside rotating field coils. If the field slips regardless, the motor can be put in reset by computer control to protect the power supply and the field coils.
When a traditional dc motor has been engineered with “reverse inside-out configuraton,” digital encoding, and these measures of field control, there is very little difference between a stepmotor and a brushless dc motor.
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