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Stepper motor heating problem and solution

       Any motor will heat up, but the degree is different. For all kinds of motors, the inside is composed of iron core and winding coil. The winding has resistance, and the power will generate loss. The loss is proportional to the square of the resistance and current. This is what we often call copper loss. Assuming that the current is not a standard DC or sine wave, it will also produce harmonic losses. The core has a hysteresis eddy current effect, which also produces losses in the alternating magnetic field. Its size is related to the material, current, frequency, and voltage, which is called iron loss. Both copper loss and iron loss are manifested in a hot way, which affects the efficiency of the motor.


       Stepper motors generally pursue positioning accuracy and torque output, the efficiency is relatively low, the current is generally large, and the harmonic components are high, and the frequency of the alternating current also varies with the rotational speed. Therefore, the stepping motor generally has a fever condition, and the situation is more common, and more serious than AC motor.


       Stepper motor heating does not affect the life of the stepper motor, and it is not necessary for most customers. However, severe fever can have some negative effects. For example, if the heat shrinkage coefficient of each part inside the stepping motor is different, the structural stress changes and the small change of the internal air gap will affect the dynamic response of the stepping motor, and the high speed will easily lose the step. For example, some places do not allow excessive heating of the stepper motor, such as medical equipment and high-precision test equipment. Therefore, the necessary control should be discontinued for the heating of the stepper motor. Our stepper motor is used on steel robots, the ambient temperature is more than 100 degrees, and it has been working normally.


  The measures that can be taken to reduce the heating of the stepper motor are as follows: assume that the stepper motor driver has an automatic semi-flow mode, and try to make it work in a semi-flow state because the stepper motor has the largest total heat generation work. Assuming that the load torque range allows, the rated current of the stepper motor can be reduced such as 5A stepper motor, let it work in 4A state, choose low resistance, low current, reduce copper loss and iron loss, retrofit Fan, and force cooling.

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