利盈娱乐(中国)创新平台有限公司

步进电(dian)机控制器

一、步进(jin)电机驱(qu)动电路

在(zai)H桥(qiao)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)的(de)(de)基础上(shang)设计(ji)(ji)步(bu)进(jin)电(dian)(dian)(dian)(dian)(dian)(dian)机驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)。采用分立元件MOS管(guan)搭建(jian)双(shuang)H桥(qiao)驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)是成(cheng)熟的(de)(de)电(dian)(dian)(dian)(dian)(dian)(dian)机控(kong)制(zhi)方案，电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)不(bu)复(fu)杂(za)，性能(neng)(neng)可靠，根据(ju)MOS管(guan)的(de)(de)不(bu)同工(gong)作电(dian)(dian)(dian)(dian)(dian)(dian)流(liu)的(de)(de)上(shang)限甚至(zhi)可以高达数十安(an)培，是理想的(de)(de)步(bu)进(jin)电(dian)(dian)(dian)(dian)(dian)(dian)机驱(qu)(qu)动(dong)(dong)器方案。MOS管(guan)H桥(qiao)驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)有NMOS构型和(he)(he)PMOS+NMOS构型，全(quan)NMOS管(guan)H桥(qiao)导(dao)通电(dian)(dian)(dian)(dian)(dian)(dian)阻(zu)更(geng)小(xiao)，但上(shang)桥(qiao)臂的(de)(de)NMOS管(guan)的(de)(de)导(dao)通电(dian)(dian)(dian)(dian)(dian)(dian)压高于电(dian)(dian)(dian)(dian)(dian)(dian)源电(dian)(dian)(dian)(dian)(dian)(dian)压，需要额外的(de)(de)升压电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)，这样增(zeng)加(jia)了(le)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)的(de)(de)复(fu)杂(za)程度和(he)(he)成(cheng)本，我们采用PMOS+NMOS构型方式搭建(jian)双(shuang)H桥(qiao)步(bu)进(jin)电(dian)(dian)(dian)(dian)(dian)(dian)机驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)，电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)更(geng)简洁，成(cheng)本更(geng)低(di);且在(zai)这样的(de)(de)小(xiao)电(dian)(dian)(dian)(dian)(dian)(dian)流(liu)工(gong)作场(chang)合，PMOS所增(zeng)加(jia)的(de)(de)导(dao)通损耗可以忽略不(bu)计(ji)(ji)。驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)与(yu)MCU之间进(jin)行(xing)(xing)光电(dian)(dian)(dian)(dian)(dian)(dian)隔离，选用广泛使用的(de)(de)低(di)成(cheng)本光耦PC817。加(jia)入双(shuang)输入四通道与(yu)门(74HC08D)，为驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)添(tian)加(jia)使能(neng)(neng)的(de)(de)功能(neng)(neng)，即只有在(zai)使能(neng)(neng)的(de)(de)前提(ti)下，四路(lu)(lu)控(kong)制(zhi)信号才(cai)是有效(xiao)的(de)(de)，使步(bu)进(jin)电(dian)(dian)(dian)(dian)(dian)(dian)机运行(xing)(xing)更(geng)安(an)全(quan)稳(wen)定MOS管(guan)选用IRF5305和(he)(he)IRF1205，其参数为55V、110A，TO252贴片封装。步(bu)进(jin)电(dian)(dian)(dian)(dian)(dian)(dian)机驱(qu)(qu)动(dong)(dong)电(dian)(dian)(dian)(dian)(dian)(dian)路(lu)(lu)原理图(tu)如图(tu)所示。

二(er)、电(dian)机参数测量(liang)电(dian)路

为了实时(shi)监(jian)测(ce)步(bu)进电(dian)机(ji)(ji)的运(yun)(yun)行(xing)状态是否正常，为驱动器设计了电(dian)机(ji)(ji)参数(shu)测(ce)量功能(neng)、通(tong)过实时(shi)监(jian)测(ce)电(dian)机(ji)(ji)的工(gong)作电(dian)压、工(gong)作相电(dian)流和机(ji)(ji)壳温度来实时(shi)获取电(dian)机(ji)(ji)的运(yun)(yun)行(xing)参数(shu)，保证电(dian)机(ji)(ji)运(yun)(yun)行(xing)安全稳定。

电(dian)(dian)(dian)机(ji)(ji)电(dian)(dian)(dian)流采(cai)样(yang)电(dian)(dian)(dian)阻选(xuan)用(yong)康铜电(dian)(dian)(dian)阻，一端连接H桥下方，另一端接GND，其工(gong)作(zuo)温(wen)度范(fan)围宽，温(wen)度系数(shu)仅为-40~40*10-6/℃，是高精(jing)度电(dian)(dian)(dian)流采(cai)样(yang)电(dian)(dian)(dian)阻的理(li)想(xiang)选(xuan)择。电(dian)(dian)(dian)压电(dian)(dian)(dian)流信号调理(li)电(dian)(dian)(dian)路(lu)采(cai)用(yong)LM324运放搭建，电(dian)(dian)(dian)压跟随后送入MCU，由MCU内置10Bit A/D转换器进(jin)行A/D采(cai)样(yang)。机(ji)(ji)壳(qiao)温(wen)度监测(ce)选(xuan)用(yong)数(shu)字(zi)温(wen)芯片DS18B20，将其贴至电(dian)(dian)(dian)机(ji)(ji)外(wai)壳(qiao)表面，实时(shi)监测(ce)温(wen)度参数(shu)并(bing)送入MCU。电(dian)(dian)(dian)机(ji)(ji)参数(shu)检测(ce)电(dian)(dian)(dian)路(lu)原理(li)图(tu)如图(tu)所示。在进(jin)行电(dian)(dian)(dian)路(lu)设计时(shi)，使(shi)用(yong)0欧姆电(dian)(dian)(dian)阻将模拟(ni)地(AGND)和(he)数(shu)字(zi)地(GND)单点连接，以降低相互干扰(rao)，提高电(dian)(dian)(dian)路(lu)性能。

三(san)、电源及MCU控制电路

系统(tong)中，驱(qu)动电(dian)(dian)路用(yong)输入(ru)电(dian)(dian)压(ya)供(gong)电(dian)(dian)，MCU和(he)蓝(lan)牙(ya)模块(kuai)需要额(e)外的(de)(de)3.3V电(dian)(dian)压(ya)供(gong)电(dian)(dian)，传统(tong)的(de)(de)线性稳(wen)压(ya)器效率(lv)低(di)、尺寸大且(qie)发热(re)严重，因此使用(yong)DC-DC开关(guan)电(dian)(dian)源方式提供(gong)3.3V电(dian)(dian)压(ya)。开关(guan)稳(wen)压(ya)芯片(pian)(pian)选用(yong)MPS公司(si)MP2359方案，其(qi)(qi)效率(lv)可(ke)高(gao)(gao)至92%、工(gong)(gong)作频(pin)率(lv)高(gao)(gao)达1.4MHZ，极(ji)高(gao)(gao)的(de)(de)工(gong)(gong)作频(pin)率(lv)决定其(qi)(qi)只需要小容(rong)量的(de)(de)输入(ru)电(dian)(dian)容(rong)、输出(chu)电(dian)(dian)容(rong)和(he)功率(lv)电(dian)(dian)感(gan)即可(ke)正(zheng)常工(gong)(gong)作。蓝(lan)牙(ya)选用(yong)HC- 05模块(kuai) ，串口自(zi)动发送。主(zhu)控芯片(pian)(pian)为PIC24FJ64GA004，电(dian)(dian)源及(ji)主(zhu)控芯片(pian)(pian)外围电(dian)(dian)路如图(tu)。

四、应(ying)用设置(zhi)

1、设置(zhi)步进(jin)(jin)驱动器(qi)的(de)细(xi)分(fen)数(shu)，通常细(xi)分(fen)数(shu)越高，控制分(fen)辨率越高。但(dan)细(xi)分(fen)数(shu)太高则影响到最大进(jin)(jin)给速(su)(su)度(du)(du)。一(yi)般来说(shuo)，对于模具机用户可考虑脉(mai)冲当(dang)量为0.001mm/P(此(ci)(ci)时(shi)最大进(jin)(jin)给速(su)(su)度(du)(du)为9600mm/min)或者0.0005mm/P(此(ci)(ci)时(shi)最大进(jin)(jin)给速(su)(su)度(du)(du)为4800mm/min);对于精度(du)(du)要求(qiu)不(bu)高的(de)用户，脉(mai)冲当(dang)量可设置(zhi)的(de)大一(yi)些，如0.002mm/P(此(ci)(ci)时(shi)最大进(jin)(jin)给速(su)(su)度(du)(du)为19200mm/min)或0.005mm/P(此(ci)(ci)时(shi)最大进(jin)(jin)给速(su)(su)度(du)(du)为48000mm/min)。对于两相步进(jin)(jin)电机，脉(mai)冲当(dang)量计算方(fang)法如下(xia):脉(mai)冲当(dang)量=丝杠(gang)螺距÷细(xi)分(fen)数(shu)÷200。

2、起跳(tiao)速(su)度:该(gai)(gai)参数(shu)(shu)对应(ying)步(bu)进(jin)(jin)电机(ji)(ji)的起跳(tiao)频率。所(suo)谓起跳(tiao)频率是(shi)(shi)步(bu)进(jin)(jin)电机(ji)(ji)不经(jing)过加速(su)，能(neng)(neng)够直接启(qi)动(dong)工作的最(zui)高频率。合理(li)地(di)选取该(gai)(gai)参数(shu)(shu)能(neng)(neng)够提高加工效率，并且(qie)能(neng)(neng)避开步(bu)进(jin)(jin)电机(ji)(ji)运动(dong)特性不好的低速(su)段;但是(shi)(shi)如果该(gai)(gai)参数(shu)(shu)选取大(da)了(le)，就会造成闷车(che)，所(suo)以(yi)一(yi)定(ding)要留有余(yu)量。在(zai)电机(ji)(ji)的出(chu)厂(chang)参数(shu)(shu)中，一(yi)般包含起跳(tiao)频率参数(shu)(shu)。但是(shi)(shi)在(zai)机(ji)(ji)床装配好后，该(gai)(gai)值可能(neng)(neng)发(fa)生变化(hua)，一(yi)般要下降，特别是(shi)(shi)在(zai)做带(dai)负载(zai)运动(dong)时(shi)。所(suo)以(yi)，该(gai)(gai)设定(ding)参数(shu)(shu)最(zui)好是(shi)(shi)在(zai)参考(kao)电机(ji)(ji)出(chu)厂(chang)参数(shu)(shu)后，再实际测量决定(ding)。

3、单轴加速(su)度:用(yong)以描(miao)述单个进给(ji)轴的加减速(su)能力，单位是(shi)毫米/秒平方(fang)。这(zhei)个指标由机(ji)床的物理特(te)性决定，如(ru)运动部分的质量、进给(ji)电(dian)机(ji)的扭矩(ju)、阻力、切削负载等(deng)。这(zhei)个值(zhi)越大，在(zai)(zai)(zai)(zai)运动过程(cheng)中花(hua)在(zai)(zai)(zai)(zai)加减速(su)过程(cheng)中的时间越小(xiao)，效率越高。通(tong)常，对(dui)于步进电(dian)机(ji)，该值(zhi)在(zai)(zai)(zai)(zai)100 ~ 500之间，对(dui)于伺服电(dian)机(ji)系统，可以设置(zhi)在(zai)(zai)(zai)(zai)400 ~ 1200之间。在(zai)(zai)(zai)(zai)设置(zhi)过程(cheng)中，开始设置(zhi)小(xiao)一点，运行(xing)一段时间，重复做各种典型运动，注(zhu)意观察，如(ru)果没有异常情(qing)况，然后(hou)逐步增加。如(ru)果发现异常情(qing)况，则降(jiang)低该值(zhi)，并留50%~100%的保险余量。

4、弯道加(jia)速(su)度:用以(yi)描(miao)述多个(ge)进给轴联动时(shi)的(de)(de)加(jia)减速(su)能(neng)力，单位是毫米/秒平方。它决定了(le)机(ji)床(chuang)在(zai)(zai)做圆弧(hu)运(yun)动时(shi)的(de)(de)最高速(su)度。这个(ge)值越(yue)(yue)大，机(ji)床(chuang)在(zai)(zai)做圆弧(hu)运(yun)动时(shi)的(de)(de)最大允(yun)许(xu)速(su)度越(yue)(yue)大。通常(chang)，对(dui)于(yu)步(bu)进电机(ji)系(xi)(xi)统组(zu)成的(de)(de)机(ji)床(chuang)，该值在(zai)(zai)400~1000之间(jian)，对(dui)于(yu)伺服电机(ji)系(xi)(xi)统，可以(yi)设(she)置(zhi)在(zai)(zai)1000 ~ 5000之间(jian)。如果(guo)(guo)是重(zhong)型机(ji)床(chuang)，该值要小一(yi)些。在(zai)(zai)设(she)置(zhi)过程中，开始设(she)置(zhi)小一(yi)点，运(yun)行一(yi)段时(shi)间(jian)，重(zhong)复做各种典型联动运(yun)动，注意观察，如果(guo)(guo)没有(you)异(yi)常(chang)情(qing)况，然后逐步(bu)增加(jia)。如果(guo)(guo)发现(xian)异(yi)常(chang)情(qing)况，则降低该值，并留50%~100%的(de)(de)保险余量。

通常考虑到步(bu)进电机的(de)驱动能(neng)力、机械装配的(de)摩擦(ca)、机械部件的(de)承受能(neng)力，可以在厂商参数中(zhong)修改各个轴的(de)最(zui)大速(su)度(du)，对机床用(yong)户实际使(shi)用(yong)时(shi)的(de)三个轴最(zui)大速(su)度(du)予以限(xian)制，。

5、根(gen)据三个轴(zhou)零点传感器(qi)的(de)安(an)装(zhuang)位置(zhi)，设置(zhi)厂商(shang)(shang)参(can)(can)数中的(de)回机械原(yuan)(yuan)点参(can)(can)数。当设置(zhi)正确后(hou)，可运行(xing)"操作"菜(cai)单(dan)中的(de)"回机械原(yuan)(yuan)点"。先(xian)单(dan)轴(zhou)回，如果运动方(fang)向正确则继续回，否则需(xu)停止，重新设置(zhi)设置(zhi)厂商(shang)(shang)参(can)(can)数中的(de)回机械原(yuan)(yuan)点方(fang)向，直至所有轴(zhou)都可回机械原(yuan)(yuan)点。

6、设(she)置(zhi)自(zi)(zi)动(dong)(dong)加(jia)(jia)油参(can)(can)数(shu)(设(she)置(zhi)得(de)小一些(xie)，如5秒加(jia)(jia)一次油)，观察自(zi)(zi)动(dong)(dong)加(jia)(jia)油是否正确(que)，如果正确(que)，则将自(zi)(zi)动(dong)(dong)加(jia)(jia)油参(can)(can)数(shu)设(she)置(zhi)到实际需要的参(can)(can)数(shu)。

7、校(xiao)验(yan)电子(zi)齿轮和脉冲(chong)当(dang)量的设(she)定值(zhi)是否匹(pi)配。可以(yi)在(zai)机床的任意一根轴(zhou)上做个标(biao)记，在(zai)软件中(zhong)把该点(dian)坐标(biao)设(she)为工作零(ling)点(dian)，用(yong)直接输入指令、点(dian)动或手轮等工作方(fang)式使该轴(zhou)走固定距(ju)离(li)，用(yong)游(you)标(biao)卡尺测量实际距(ju)离(li)与(yu)软件中(zhong)坐标(biao)显示距(ju)离(li)是否相附(fu)。

8、测定有(you)无(wu)丢(diu)脉冲。您可(ke)(ke)以用直(zhi)观的(de)(de)方(fang)法:用一把尖(jian)刀(dao)在(zai)工(gong)件(jian)毛坯(pi)上(shang)点(dian)一个(ge)点(dian)，把该点(dian)设(she)为工(gong)作原(yuan)(yuan)点(dian)，抬(tai)高Z轴，然(ran)后把Z轴坐标设(she)为0;反复使机床运动，比如空刀(dao)跑(pao)一个(ge)典(dian)型的(de)(de)加(jia)工(gong)程序(xu)(最好包含三轴联动)，可(ke)(ke)在(zai)加(jia)工(gong)中(zhong)暂停(ting)(ting)或停(ting)(ting)止，然(ran)后回工(gong)件(jian)原(yuan)(yuan)点(dian)，缓(huan)慢(man)下降Z轴，看刀(dao)尖(jian)与(yu)毛坯(pi)上(shang)的(de)(de)点(dian)是(shi)否吻合。如有(you)偏(pian)差，请检查(cha)步进驱(qu)动器接收脉冲信号的(de)(de)类型，检查(cha)端(duan)子板与(yu)驱(qu)动器间接线是(shi)否有(you)误。如果还出现闷车或丢(diu)步，按10、11、12步调整加(jia)速度等参数(shu)。

五、步进电机(ji)概述

步(bu)进电机(ji)(ji)(ji)是一种(zhong)感应电机(ji)(ji)(ji)，它的工作原理(li)是利用(yong)电子电路，将直流电变成分时供电的，多相(xiang)时序(xu)控制(zhi)电流，用(yong)这种(zhong)电流为(wei)步(bu)进电机(ji)(ji)(ji)供电，步(bu)进电机(ji)(ji)(ji)才能正常工作，驱动(dong)器(qi)就(jiu)是为(wei)步(bu)进电机(ji)(ji)(ji)分时供电的，多相(xiang)时序(xu)控制(zhi)器(qi)

虽然步(bu)(bu)进电(dian)(dian)(dian)机(ji)已(yi)被广泛地应用(yong)，但步(bu)(bu)进电(dian)(dian)(dian)机(ji)并不能像普通的直流电(dian)(dian)(dian)机(ji)，交(jiao)流电(dian)(dian)(dian)机(ji)在常规下(xia)使用(yong)。它必(bi)须由双环形脉冲(chong)信号、功率驱动电(dian)(dian)(dian)路等组成控制系统方可使用(yong)。因(yin)此(ci)用(yong)好步(bu)(bu)进电(dian)(dian)(dian)机(ji)却(que)非易(yi)事，它涉(she)及(ji)到机(ji)械、电(dian)(dian)(dian)机(ji)、电(dian)(dian)(dian)子及(ji)计(ji)算机(ji)等许多(duo)专业知(zhi)识。

步(bu)进(jin)电(dian)机作为(wei)执行元件，是机电(dian)一(yi)体化(hua)的(de)关键(jian)产品之一(yi), 广泛应用在(zai)各种自动化(hua)控制系统中(zhong)。随着微(wei)电(dian)子和计算机技(ji)术的(de)发展，步(bu)进(jin)电(dian)机的(de)需(xu)求量与(yu)日俱(ju)增，在(zai)各个国民经济领域都有应用。

步(bu)进(jin)电(dian)(dian)机(ji)是一种将(jiang)电(dian)(dian)脉(mai)冲(chong)(chong)转化(hua)为角位(wei)移(yi)的执行机(ji)构(gou)。通(tong)俗一点讲：当步(bu)进(jin)驱动(dong)器(qi)接收(shou)到(dao)一个脉(mai)冲(chong)(chong)信(xin)号，它(ta)就驱 动(dong)步(bu)进(jin)电(dian)(dian)机(ji)按设定的方向转动(dong)一个固定的角度(du)（即步(bu)进(jin)角）。您(nin)可(ke)以通(tong)过控制(zhi)脉(mai)冲(chong)(chong)个数来控制(zhi)角位(wei)移(yi)量，从而达到(dao)准确(que)定位(wei)的目的；同时您(nin)可(ke)以通(tong)过控制(zhi)脉(mai)冲(chong)(chong)频率来 控制(zhi)电(dian)(dian)机(ji)转动(dong)的速度(du)和加速度(du)，从而达到(dao)调速的目的。

六、步(bu)进电机的主要(yao)特点

1)一般步进(jin)电机的精度为步进(jin)角的3-5%，且(qie)不累积。

2)步(bu)进(jin)电(dian)机外表允许的最(zui)高温度。

步进电(dian)机(ji)温度(du)过高首先(xian)会使电(dian)机(ji)的(de)磁性材料退磁，从而导致力矩下降乃至 于失步，因此电(dian)机(ji)外表允许的(de)最高温度(du)应取决于不同(tong)电(dian)机(ji)磁性材料的(de)退磁点(dian)；一般来讲(jiang)，磁性材料的(de)退磁点(dian)都在(zai)摄氏130度(du)以(yi)上(shang)，有(you)的(de)甚至高达摄氏200度(du)以(yi) 上(shang)，所以(yi)步进电(dian)机(ji)外表温度(du)在(zai)摄氏80-90度(du)完全正常。

3)步进电机的力矩会随转(zhuan)速的升高而下(xia)降(jiang)。

步进(jin)电(dian)机转动时(shi)，电(dian)机各相绕组的电(dian)感将(jiang)形成一个反(fan)向(xiang)电(dian)动势；频率越高，反(fan)向(xiang)电(dian)动势越大。在它的作用下，电(dian)机随频率（或(huo)速度）的增(zeng)大而(er)相电(dian)流减(jian)小，从(cong)而(er)导致(zhi)力(li)矩下降。

4)步进(jin)电机(ji)低(di)速(su)时可以(yi)正常运转,但(dan)若高于一定速(su)度就无法启动(dong),并伴有啸叫声。

步(bu)进电机(ji)有一个技术(shu)参数(shu)：空载(zai)启(qi)动(dong)频(pin)率(lv)，即(ji)步(bu)进电机(ji)在(zai)空载(zai)情况下能够 正常启(qi)动(dong)的(de)脉冲频(pin)率(lv)，如果脉冲频(pin)率(lv)高(gao)于该(gai)值，电机(ji)不能正常启(qi)动(dong)，可能发生丢步(bu)或堵转(zhuan)。在(zai)有负载(zai)的(de)情况下，启(qi)动(dong)频(pin)率(lv)应(ying)更(geng)低。如果要使电机(ji)达到高(gao)速(su)转(zhuan)动(dong)，脉冲 频(pin)率(lv)应(ying)该(gai)有加(jia)速(su)过程，即(ji)启(qi)动(dong)频(pin)率(lv)较低，然后按一定加(jia)速(su)度升(sheng)到所希望的(de)高(gao)频(pin)（电机(ji)转(zhuan)速(su)从低速(su)升(sheng)到高(gao)速(su)）。

5 )步(bu)进(jin)电机必须加驱(qu)动才可以运转， 驱(qu)动信(xin)号必须为脉(mai)冲信(xin)号，没有脉(mai)冲的(de)(de)(de)时候(hou)， 步(bu)进(jin)电机静止， 如果加入适当的(de)(de)(de)脉(mai)冲信(xin)号，就会以一定的(de)(de)(de)角度（称(cheng)为步(bu)角）转动。转动的(de)(de)(de)速度和脉(mai)冲的(de)(de)(de)频率成正比。

6)三(san)相步(bu)进电机的步(bu)进角度(du)为(wei)7.5 度(du)，一圈360度(du)， 需要48个脉冲完成。

7)步进(jin)电机具(ju)有(you)瞬间启动和(he)急(ji)速(su)停止的(de)优越特(te)性。

8)改变(bian)脉冲的(de)(de)顺(shun)序，可以方(fang)便的(de)(de)改变(bian)转动(dong)的(de)(de)方(fang)向。因(yin)此，目前打印机(ji)，绘(hui)图仪(yi)，机(ji)器人，等(deng)等(deng)设备都以步进(jin)电机(ji)为动(dong)力核(he)心。

七、步进电机驱动(dong)器的特(te)点(dian)

1）构成步进电机(ji)驱动(dong)器系统(tong)的专用集成电路：

A、脉冲分配器集成电路：如三洋公司的PMM8713、PMM8723、PMM8714等。

B、包含脉(mai)冲分(fen)配器(qi)和电(dian)(dian)流斩波的控制器(qi)集成电(dian)(dian)路：如SGS公司(si)的L297、L6506等。

C、只含功率驱动(dong)（或包含电(dian)流控制、保护(hu)电(dian)路）的(de)驱动(dong)器集(ji)成(cheng)电(dian)路：如日本新电(dian)元工(gong)业公司的(de)MTD1110（四相斩(zhan)(zhan)波(bo)驱动(dong)）和MTD2001（两相、H桥、斩(zhan)(zhan)波(bo)驱动(dong)）。

D、将(jiang)脉冲分配器(qi)、功(gong)率驱动、电流控制和保护电路(lu)都(dou)包括在内的(de)驱动控制器(qi)集(ji)成电路(lu)，如东芝公(gong)司(si)的(de)TB6560AHQ、MOTOROLA公(gong)司(si)的(de)SAA1042（四相(xiang)）和ALLEGRO公(gong)司(si)的(de)UCN5804（四相(xiang)）等。

2）“细分驱(qu)动(dong)(dong)(dong)”概述：将“电(dian)(dian)机(ji)固有(you)步距角(jiao)(jiao)”细分成若(ruo)干小步的驱(qu)动(dong)(dong)(dong)方(fang)法，称为细分驱(qu)动(dong)(dong)(dong)，细分是通过驱(qu)动(dong)(dong)(dong)器精确控(kong)制步进电(dian)(dian)机(ji)的相电(dian)(dian)流(liu)实现的，与电(dian)(dian)机(ji)本 身无关。其(qi)原理是，让(rang)定子(zi)通电(dian)(dian)相电(dian)(dian)流(liu)并不一次升到(dao)位，而(er)断(duan)电(dian)(dian)相电(dian)(dian)流(liu)并不一次降为0（绕组电(dian)(dian)流(liu)波形不再是近似方(fang)波，而(er)是N级近似阶(jie)梯波），则定子(zi)绕组电(dian)(dian)流(liu)所 产生的磁场合力，会使转子(zi)有(you)N个新(xin)的平衡位置（形成N个步距角(jiao)(jiao)）。

八、步进(jin)电机分类

步(bu)(bu)(bu)进(jin)(jin)(jin)电(dian)机(ji)分三(san)种：永(yong)磁式(shi)(shi)（PM） 、反(fan)应(ying)(ying)式(shi)(shi)（VR）和(he)混合(he)式(shi)(shi)（HB）。永(yong)磁式(shi)(shi)步(bu)(bu)(bu)进(jin)(jin)(jin)一(yi)般(ban)(ban)(ban)为两相(xiang)，转矩(ju)和(he)体积(ji)较小，步(bu)(bu)(bu)进(jin)(jin)(jin)角(jiao)一(yi)般(ban)(ban)(ban)为7.5度(du)或(huo)15度(du)；反(fan)应(ying)(ying)式(shi)(shi)步(bu)(bu)(bu)进(jin)(jin)(jin)一(yi)般(ban)(ban)(ban)为三(san)相(xiang)，可实现大转矩(ju)输出，步(bu)(bu)(bu)进(jin)(jin)(jin)角(jiao)一(yi)般(ban)(ban)(ban)为1.5度(du)，但噪声和(he)振(zhen)动都很大，在(zai)欧美等发达国家(jia)80年代(dai)已(yi)被淘汰；混合(he)式(shi)(shi)步(bu)(bu)(bu)进(jin)(jin)(jin)是(shi)指混合(he)了永(yong)磁式(shi)(shi)和(he)反(fan)应(ying)(ying)式(shi)(shi)的优点，分为两相(xiang)和(he)五相(xiang)，两相(xiang)步(bu)(bu)(bu)进(jin)(jin)(jin)角(jiao)一(yi) 般(ban)(ban)(ban)为1.8度(du)而(er)五相(xiang)步(bu)(bu)(bu)进(jin)(jin)(jin)角(jiao)一(yi)般(ban)(ban)(ban)为 0.72度(du)，这种步(bu)(bu)(bu)进(jin)(jin)(jin)电(dian)机(ji)的应(ying)(ying)用最为广泛。

1）、步进电机的(de)优(you)缺点

1． 电机旋转的(de)角度(du)正比于脉(mai)冲数(shu)；

2． 电机停(ting)转的时候具有最大的转矩（当(dang)绕组激磁时）；

3． 由于(yu)每步(bu)(bu)的精(jing)度在百分之三到百分之五(wu)，而且不会(hui)将一步(bu)(bu)的误差积累(lei)到下一步(bu)(bu)因(yin)而有较好(hao)的位置精(jing)度和运动的重(zhong)复(fu)性(xing)；

4． 优秀(xiu)的起停和反转响应；

5． 由(you)于没有电(dian)刷，可靠性(xing)较高，因此电(dian)机(ji)的(de)寿(shou)命仅仅取决于轴承的(de)寿(shou)命；

6． 电机的响(xiang)应仅由数字输入脉(mai)冲确定(ding)，因而可以(yi)采用开环控制(zhi)，这使得电机的结构(gou)可以(yi)比较简单而且控制(zhi)成本(ben)；

7． 仅(jin)(jin)仅(jin)(jin)将负载(zai)直接连接到电机的(de)转轴上也可以极低(di)速(su)的(de)同(tong)步旋转。

8． 由于速度正(zheng)比(bi)于脉(mai)冲频率，因(yin)而有比(bi)较宽的(de)转速范围(wei)。

九、步进(jin)电机的(de)故障诊断与分析处理

（1）常见故障原因(yin)

1)驱动步(bu)(bu)进电机的脉冲频(pin)率太高，使(shi)步(bu)(bu)进电动机不(bu)能响应，发生失步(bu)(bu)或(huo)堵转。

2)驱(qu)动(dong)电源不佳而造(zao)成步进电机失步。

3)步(bu)进电(dian)机控制及驱(qu)动电(dian)路(lu)常见(jian)的故障有(you)停转、摆(bai)动和不能紧锁。

4)工(gong)作(zuo)台负载过重能造成步(bu)进电(dian)机失步(bu)甚(shen)至停转。

5)步(bu)进电机(ji)本身问题或绕组烧(shao)坏(huai)造(zao)成失步(bu)或停(ting)转。

（2）典型(xing)故障分析与处(chu)理

起动和运行速度慢,影响(xiang)系统同步(bu)

1)步进(jin)(jin)(jin)电(dian)(dian)动(dong)机(ji)检修(xiu)时(shi),常要(yao)将(jiang)定子各相控制(zhi)绕(rao)(rao)组中串联(lian)的小(xiao)电(dian)(dian)阻(zu)摘下(xia),进(jin)(jin)(jin)行(xing)绕(rao)(rao)组检测(ce)和修(xiu)理,检修(xiu)后未(wei)再接入(ru)串联(lian)电(dian)(dian)阻(zu),有时(shi)小(xiao)电(dian)(dian)阻(zu)损坏或(huo)失(shi)效(xiao)未(wei)更换,造成难起动(dong),运(yun)行(xing)速度减慢。小(xiao)电(dian)(dian)阻(zu)失(shi)效(xiao)或(huo)未(wei)接入(ru),则回(hui)路时(shi)间(jian)常数(shu)加(jia)(jia)大(da),使(shi)脉(mai)冲电(dian)(dian)流上(shang)升沿(yan)(yan)和下(xia)降沿(yan)(yan)由(you)陡变为平坦,恶化了(le)频率(lv)特性(xing)(xing),也即恶化了(le)步进(jin)(jin)(jin)电(dian)(dian)动(dong)机(ji)运(yun)行(xing)特性(xing)(xing)。所(suo)以,当步进(jin)(jin)(jin)电(dian)(dian)动(dong)机(ji)修(xiu)完后,一定要(yao)接入(ru)小(xiao)电(dian)(dian)阻(zu);检修(xiu)过程也必须用万用表检测(ce)小(xiao)电(dian)(dian)阻(zu)有无断路、短(duan)路或(huo)击穿故(gu)障,如有则应同(tong)(tong)时(shi)更换合(he)格的同(tong)(tong)规(gui)格小(xiao)电(dian)(dian)阻(zu),不(bu)要(yao)使(shi)之(zhi)失(shi)效(xiao)仍接入(ru)线路,不(bu)然(ran)影响抑制(zhi)绕(rao)(rao)组中电(dian)(dian)感,使(shi)系统不(bu)同(tong)(tong)步,又为查找故(gu)障增加(jia)(jia)麻烦。

2)定转(zhuan)子(zi)气(qi)隙不均,使(shi)定转(zhuan)子(zi)相(xiang)擦(ca),造成(cheng)起动(dong)(dong)困(kun)难或运(yun)行(xing)速(su)度减慢。由于气(qi)隙不均造成(cheng)定转(zhuan)子(zi)相(xiang)擦(ca),加大了步(bu)进电动(dong)(dong)机静态力矩(ju),阻力加大使(shi)动(dong)(dong)态特性变坏,导(dao)致起动(dong)(dong)和运(yun)行(xing)速(su)度减慢。当发生(sheng)此(ci)类故障(zhang)时,应(ying)仔细检查定转(zhuan)子(zi)相(xiang)擦(ca)的原因。根据造成(cheng)的具体(ti)原因,采取有效措施,排除故障(zhang),使(shi)气(qi)隙均匀。

①检查中如(ru)发现(xian)因轴承(cheng)损(sun)坏或端(duan)盖止口(kou)与定(ding)子外(wai)壳不同心所至,应更换新(xin)的(de)合格轴承(cheng),及新(xin)配(pei)端(duan)盖,新(xin)端(duan)盖止口(kou)车削要按外(wai)壳止口(kou)公差尺寸配(pei)车。

②如检查出属转轴(zhou)变(bian)弯(wan),可采取调直方法(fa)调直弯(wan)曲(qu)端或(huo)更(geng)换新(xin)轴(zhou)。

③测量转子(zi)外径如(ru)发(fa)现椭(tuo)圆度(du)超差,将(jiang)转子(zi)进(jin)行精(jing)车一刀或磨(mo)削(xue)(xue)加工,消除不(bu)圆度(du)。应(ying)注意车削(xue)(xue)或磨(mo)削(xue)(xue)加工时,加工量不(bu)宜(yi)过大(da),仅(jin)需将(jiang)椭(tuo)圆大(da)直径车去或磨(mo)去,否则气隙加大(da),会导致(zhi)电机其它性(xing)能变坏。

（2）步进(jin)电动(dong)机(ji)运行中(zhong)失步

当步(bu)进(jin)(jin)电(dian)动机(ji)改变负(fu)载(zai)运(yun)(yun)行(xing)时,如(ru)带大惯(guan)量负(fu)载(zai)则产生(sheng)振荡,造成(cheng)电(dian)机(ji)在某一(yi)运(yun)(yun)行(xing)频率下(xia),起动丢(diu)步(bu)或停转滑步(bu)。造成(cheng)步(bu)进(jin)(jin)电(dian)动机(ji)运(yun)(yun)行(xing)中失(shi)步(bu)。为了消(xiao)(xiao)除(chu)大惯(guan)性负(fu)载(zai)引起失(shi)步(bu),可(ke)以采(cai)用(yong)机(ji)械阻尼(ni)的方法,用(yong)以消(xiao)(xiao)除(chu)或吸收振荡能量;也(ye)可(ke)以通(tong)过加(jia)大负(fu)载(zai)的摩擦力矩(ju)的方法,从而改善运(yun)(yun)行(xing)特(te)性,消(xiao)(xiao)除(chu)失(shi)步(bu)。因为步(bu)进(jin)(jin)电(dian)动机(ji)受控(kong)于(yu)电(dian)脉(mai)冲而产生(sheng)步(bu)进(jin)(jin)运(yun)(yun)动,采(cai)取(qu)如(ru)上措施能使电(dian)脉(mai)冲正常(chang),不受干扰,从而消(xiao)(xiao)除(chu)电(dian)机(ji)运(yun)(yun)行(xing)中失(shi)步(bu)。

另一种(zhong)失(shi)(shi)步可能是(shi)原采用(yong)双(shuang)(shuang)电(dian)(dian)(dian)源供电(dian)(dian)(dian)的而(er)改(gai)为单(dan)电(dian)(dian)(dian)源供电(dian)(dian)(dian),又未采取相(xiang)应(ying)补救措施(shi),使起动(dong)(dong)(dong)频(pin)(pin)(pin)(pin)率(lv)和运(yun)(yun)(yun)行(xing)频(pin)(pin)(pin)(pin)率(lv)降低(di),矩(ju)(ju)频(pin)(pin)(pin)(pin)特(te)性恶化而(er)失(shi)(shi)步。当是(shi)此(ci)种(zhong)原因(yin)所至(zhi),应(ying)重新恢(hui)复(fu)双(shuang)(shuang)电(dian)(dian)(dian)源供电(dian)(dian)(dian)。有些(xie)使用(yong)单(dan)位或部门,为简化电(dian)(dian)(dian)路(lu)采用(yong)单(dan)电(dian)(dian)(dian)源供电(dian)(dian)(dian)造(zao)成(cheng)电(dian)(dian)(dian)动(dong)(dong)(dong)机(ji)运(yun)(yun)(yun)行(xing)失(shi)(shi)步,这(zhei)种(zhong)做法(fa)不当,要知(zhi)道采用(yong)双(shuang)(shuang)电(dian)(dian)(dian)源是(shi)为了提高(gao)起动(dong)(dong)(dong)和运(yun)(yun)(yun)行(xing)两种(zhong)频(pin)(pin)(pin)(pin)率(lv),改(gai)善矩(ju)(ju)频(pin)(pin)(pin)(pin)特(te)性,从(cong)而(er)改(gai)善了输入(ru)步进电(dian)(dian)(dian)动(dong)(dong)(dong)机(ji)绕组中脉冲电(dian)(dian)(dian)流(liu)(liu)(liu)的上升(sheng)沿和下降沿。用(yong)单(dan)电(dian)(dian)(dian)源供电(dian)(dian)(dian),脉冲稳定电(dian)(dian)(dian)流(liu)(liu)(liu)得不到(dao)维(wei)持,步进电(dian)(dian)(dian)动(dong)(dong)(dong)机(ji)功(gong)率(lv)相(xiang)应(ying)减小,所以在(zai)驱动(dong)(dong)(dong)中相(xiang)当于(yu)容(rong)量减小而(er)过(guo)载(zai),效(xiao)率(lv)降低(di)而(er)失(shi)(shi)步。采用(yong)双(shuang)(shuang)电(dian)(dian)(dian)源,用(yong)高(gao)低(di)两套电(dian)(dian)(dian)路(lu),即在(zai)步进电(dian)(dian)(dian)动(dong)(dong)(dong)机(ji)绕组脉冲电(dian)(dian)(dian)流(liu)(liu)(liu)通入(ru)瞬间,对其施(shi)以高(gao)压(ya),强迫电(dian)(dian)(dian)流(liu)(liu)(liu)上升(sheng)加速;池电(dian)(dian)(dian)流(liu)(liu)(liu)达到(dao)一定值后,再改(gai)施(shi)以低(di)压(ya),使电(dian)(dian)(dian)机(ji)正常运(yun)(yun)(yun)行(xing)。这(zhei)种(zhong)措施(shi)不仅使驱动(dong)(dong)(dong)电(dian)(dian)(dian)源容(rong)量大(da)(da)大(da)(da)减小,同时也提高(gao)了运(yun)(yun)(yun)行(xing)效(xiao)率(lv),改(gai)善运(yun)(yun)(yun)行(xing)特(te)性,电(dian)(dian)(dian)动(dong)(dong)(dong)机(ji)不会失(shi)(shi)步运(yun)(yun)(yun)行(xing)。

（3）、控(kong)制(zhi)绕组一相反绕,影响正常运(yun)行

当步(bu)进电(dian)(dian)(dian)(dian)(dian)动机不(bu)能(neng)正(zheng)常(chang)运(yun)行(xing)(xing)时,除上述两种原因(yin)影响速度或(huo)失(shi)步(bu)外,可能(neng)是(shi)定(ding)了控制绕(rao)组(zu)(zu)有一相(xiang)(xiang)反接(jie)(jie)。当一相(xiang)(xiang)绕(rao)组(zu)(zu)反接(jie)(jie),相(xiang)(xiang)当于(yu)通(tong)电(dian)(dian)(dian)(dian)(dian)电(dian)(dian)(dian)(dian)(dian)流(liu)方向相(xiang)(xiang)反,电(dian)(dian)(dian)(dian)(dian)流(liu)相(xiang)(xiang)互抵(di)消,电(dian)(dian)(dian)(dian)(dian)动机在此相(xiang)(xiang)内无脉冲电(dian)(dian)(dian)(dian)(dian)流(liu),运(yun)行(xing)(xing)失(shi)常(chang)或(huo)根本(ben)不(bu)能(neng)运(yun)行(xing)(xing)。在通(tong)电(dian)(dian)(dian)(dian)(dian)情况下,检测(ce)三相(xiang)(xiang)电(dian)(dian)(dian)(dian)(dian)流(liu)就能(neng)发现。检测(ce)出反接(jie)(jie)相(xiang)(xiang)后,将该相(xiang)(xiang)绕(rao)组(zu)(zu)首(shou)末引出线(xian)对调,按正(zheng)确接(jie)(jie)法接(jie)(jie)好,再通(tong)电(dian)(dian)(dian)(dian)(dian)运(yun)行(xing)(xing)进行(xing)(xing)电(dian)(dian)(dian)(dian)(dian)流(liu)的检测(ce)。

（4）、开(kai)路故障

定子控制绕组开路故障,表现为一种是引线接(jie)头(tou)处(chu)(chu)断或(huo)焊接(jie)处(chu)(chu)全脱焊,或(huo)从某一匝中导线折断;另(ling)一种情(qing)况(kuang)是导线将断未断,如假焊、虚焊,或(huo)有裂纹。

此故(gu)障可采用(yong)检(jian)(jian)测(ce)普(pu)通(tong)三(san)相电动机断路方法来(lai)检(jian)(jian)测(ce),较(jiao)方便的是用(yong)万用(yong)表(biao)电阻档来(lai)检(jian)(jian)测(ce),当指针(zhen)不动或电阻很(hen)大,说明所检(jian)(jian)测(ce)一相绕组(zu)为(wei)开路。

修(xiu)理方法是找到故障处,将断开两头漆皮刮掉后拧紧再焊牢,包(bao)上绝缘。

（5）、短路故障

步(bu)进电动机定子控制绕组(zu)一般为单(dan)根导线(xian)绕制的多匝绕组(zu),短(duan)(duan)路也是匝间短(duan)(duan)路。检(jian)测方(fang)法(fa)主要分(fen)以下两步(bu):

目测法:凡短路(lu)的(de)(de)绕组因短路(lu)电流大而过热(re),绕组导(dao)线绝(jue)缘层有(you)发黑变脆(cui)的(de)(de)糊焦(jiao)状,凡有(you)此种(zhong)情况的(de)(de)为故障相(xiang);

用在通电(dian)运行状况下,测(ce)量(liang)各相(xiang)电(dian)流,凡电(dian)流大的相(xiang)为(wei)故障(zhang)相(xiang)。

故障相找到后(hou)(hou),如果短路在端部外层,采用加热绕组后(hou)(hou),轻轻撬起(qi)短路匝,用薄绝缘(yuan)(yuan)纸垫好,再(zai)压(ya)实,线(xian)圈局部加热,再(zai)刷上(shang)1032号绝缘(yuan)(yuan)漆后(hou)(hou)烘于即可;如短路严重(zhong)不(bu)能局部修理,只有重(zhong)绕线(xian)圈换上(shang)。

（6）、击穿故(gu)障

击穿故障(zhang)的(de)绕组可目(mu)测出,也可用兆欧表摇(yao)测其绝(jue)缘(yuan)(yuan)电阻,一(yi)般击穿后绕组将接地,检测相绝(jue)缘(yuan)(yuan)电阻为零者,说明即(ji)击穿又(you)接地。

（7）、电源装置故障使步进电动机不能运行

功率放大失(shi)(shi)灵(ling),门电路(lu)中电子开关损(sun)坏及计数(shu)(shu)器失(shi)(shi)灵(ling)是(shi)常发(fa)生的(de)。可采用万用表(biao)及示波器等仪表(biao),对(dui)(dui)照线路(lu)逐(zhu)段检(jian)测(ce)(ce)。如测(ce)(ce)出(chu)放大程(cheng)序逻辑部分无信(xin)(xin)号(hao)或(huo)信(xin)(xin)号(hao)弱,说明(ming)功率驱动(dong)(dong)器有(you)毛病,对(dui)(dui)其(qi)应进一步检(jian)测(ce)(ce)和排除故障(zhang)至有(you)正常信(xin)(xin)号(hao);当(dang)电子开关未在起(qi)动(dong)(dong)位(wei)置,门电路(lu)就开通,说明(ming)起(qi)动(dong)(dong)开关已经(jing)(jing)损(sun)坏,只有(you)更换合格的(de)开关;如反(fan)馈(kui)信(xin)(xin)号(hao)没有(you),即反(fan)馈(kui)没有(you)电压值,说明(ming)反(fan)馈(kui)环(huan)节有(you)故障(zhang),应检(jian)测(ce)(ce)脉冲数(shu)(shu)选器及整形反(fan)相(xiang)环(huan)节等,找出(chu)毛病调整至有(you)正常反(fan)馈(kui)电压为止。当(dang)发(fa)现(xian)电动(dong)(dong)机通电顺序不对(dui)(dui),不符(fu)合设定顺序,说明(ming)环(huan)形分配器失(shi)(shi)灵(ling),因(yin)它(ta)(ta)的(de)级(ji)数(shu)(shu)应等于电动(dong)(dong)机的(de)相(xiang)数(shu)(shu),在此情况下,它(ta)(ta)才按规定逻辑给电动(dong)(dong)机各相(xiang)绕组依次通电,使之(zhi)顺序转或(huo)逆转。总之(zhi),对(dui)(dui)电源装置应经(jing)(jing)常检(jian)测(ce)(ce)和调试,防止故障(zhang)出(chu)现(xian),影响电动(dong)(dong)机正常运(yun)行。

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