Analysis and Solution of Stepper Motor Heating

During the use of stepper motors, serious heating problems are often encountered. When the motor heats up beyond its range of use, it will shorten the lifespan and control accuracy of the motor. In severe cases, it can also disrupt the overall running rhythm of the machine, causing various quality and safety accidents.

The heating phenomenon of stepper motors is an inherent characteristic that cannot be eliminated in all models. Within the temperature range of the motor, this heating phenomenon will not affect the performance of the motor and does not require deliberate intervention. However, when the motor heats up beyond the operating temperature range, it may cause a series of problems, such as demagnetization of the magnetic steel inside the motor, resulting in a decrease in output torque, an increase in motor inductance, and a decrease in the maximum speed of the motor.

Severe heating of stepper motors may be caused by various factors. Here are some common reasons and corresponding solutions:

1. Excessive current setting leads to severe motor heating:

The main reason for this situation is that the output current exceeds the rated current of the motor, causing the coil to overheat.

2. Improper driving method of the motor leads to severe heating:

The main reason for this situation is that the motor drive mode (full step, half step, micro step) affects the efficiency of the current waveform, or the pulse frequency setting is unreasonable, resulting in increased high-frequency losses.

3. Overloading or jamming of mechanical loads can cause severe heating of stepper motors

The main reason for this situation is that the mechanical structure friction increases or gets stuck, and the load exceeds the motor's carrying capacity, resulting in an increase in motor current.

4. Poor heat dissipation leads to severe motor heating

The main reason for this situation is that the motor is installed in a closed environment and lacks heat dissipation measures.

5. Driver or motor malfunction causing severe motor heating

The main reason for this situation is abnormal output of the driver and short circuit or insulation aging inside the motor winding.

Summarize the steps for checking the heating of stepper motors during operation:

1. Check the current setting: Prioritize confirming whether the driver current matches the motor parameters.

2. Optimize driving parameters: adjust driving mode, chopping frequency, etc.

3. Check mechanical loads: Ensure smooth operation of the mechanical system without additional resistance.

4. Improve heat dissipation: Increase heat dissipation measures or force cooling.

5. Fault diagnosis: Test whether the driver and motor are damaged.

By gradually investigating, the root cause of the fever can usually be located and the problem can be solved. If the issue still cannot be resolved, it is recommended to contact the manufacturer for professional technical support.

The stepper motor produced by Shenzhen Power Motor Industrial Co.,Ltd, compared to other companies' products, effectively reduces the heat generation of the motor by about 10% by optimizing the tooth shape size of the stator and rotor chips, optimizing the structure and material of the main components such as magnetic steel and silicon steel sheets, and improving the reliability of the product, while achieving the same performance. In addition, the company can develop matching motor drive solutions based on the actual working conditions of customers, providing protection for our customers.