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2022
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Components of the Stepper Motor Used in Computerized Embroidery Machines
The three key elements—step angle (related to the number of phases), holding torque, and current—define the stepper motor used in computerized embroidery machines. These three factors directly determine the specific model of the motor. Typically, computerized embroidery machine stepper motors are designed for wide-range speed control, with their power output varying accordingly.
The three key elements—step angle (related to the number of phases), holding torque, and current—define the stepper motor used in computerized embroidery machines. These three factors directly determine the specific model of the motor. Typically, computerized embroidery machine stepper motors are designed for wide-range speed control applications, with their power output varying accordingly.
A computerized embroidery machine's stepper motor is defined by three key factors: step angle (related to the number of phases), holding torque, and current. Once these three elements are determined, the specific model of the stepper motor for the embroidery machine is finalized.
1. Selection of the step angle: The motor's step angle depends on the precision requirements of the load. First, convert the load's minimum resolution (equivalent unit) to the motor shaft—specifically, determine how many degrees the motor should rotate for each equivalent unit (including any gear reduction). The motor’s step angle should be equal to or smaller than this calculated value. Currently, stepper motors used in computerized embroidery machines available on the market typically come in step angles such as 0.36°/0.72° (for five-phase motors), 0.9°/1.8° (for two- or four-phase motors), and 1.5°/3° (for three-phase motors).
2. Selecting the holding torque. Determining the dynamic torque of a stepper motor in a computerized embroidery machine can be challenging right away, so we often start by first confirming the motor’s holding torque. The selection of the holding torque is based on the load the motor will encounter during operation—this load typically falls into two categories: inertial load and frictional load. However, it’s rare to have either an exclusively inertial or purely frictional load under real-world conditions. When starting directly (usually at low speeds), both types of loads must be considered. During acceleration, the primary focus shifts to the inertial load, while once the motor reaches constant-speed operation, only the frictional load needs attention. As a general guideline, the holding torque should ideally be 2 to 3 times greater than the frictional load. Once the holding torque is chosen, the motor’s frame size and length—its overall geometric dimensions—can then be finalized.
3. Selection of current. For motors with the same holding torque, differences in current parameters can lead to significantly varying operational characteristics. You can determine the appropriate motor current by referring to the torque-frequency characteristic curve (considering the drive power supply and driving voltage). In summary, selecting a motor should follow these steps:
Torque and power conversion. In computerized embroidery machines, stepper motors are typically used for speed control over a wide range, and their power output varies accordingly. Therefore, torque is usually the primary metric used to evaluate performance. The relationship between torque and power can be expressed as follows:
\[ P = \omega \times M \]
where \( \omega \) represents angular velocity in radians per second, and \( M \) is torque measured in Newton-meters.
Additionally, since \( \omega = \frac{2\pi \times n}{60} \), the power equation becomes:
\[ P = \frac{2\pi \times n \times M}{60} \]
Here, \( P \) is the power in watts, \( n \) is the rotational speed in revolutions per minute, and \( M \) is torque in Newton-meters.
For half-step operation, the power formula simplifies to:
\[ P = \frac{2\pi \times f \times M}{400} \]
where \( f \) is the pulse frequency per second, commonly referred to as "PPS" (pulses per second).
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