Stepper motor phase loss reason and phenomenon analysis - Database & Sql Blog Articles

Stepping motors used in wire cutting machines are typically either a five-phase ten-step or a three-phase six-step system. These systems operate by sequentially energizing specific phases in a particular order to achieve precise stepping motion. A missing phase or an incorrect phase sequence can lead to the motor either losing steps or rotating in place. The key difference between these two issues is that a missing phase results in the motor having no active phase, which means it loses its holding torque and can be manually rotated. On the other hand, a phase sequence error causes the motor to step incorrectly—either skipping steps or not moving at all.

Machines that have been functioning properly usually do not experience phase sequence errors mid-operation. More commonly, the issue arises from a missing phase. Several factors can contribute to this problem:

1. The feed signal sent from the control board
2. The 24V power supply provided by the drive unit
3. The power output from the motor driver transistor
4. The current limiting of the resistor and the protection of the bypass diode
5. The cable and connectors that transmit the drive current to the motor
6. The windings and leads within the motor itself

There are multiple possible reasons for a missing phase, so it's important to start by checking the LED display, which shows the working condition of the driver transistor. If the transistor is intact but the LED still indicates a missing phase, you should systematically check the connectors on both ends of the cable. Also, verify the 24V power supply and the resistance value of the current-limiting resistor. It’s crucial to avoid disassembling or soldering parts blindly during the troubleshooting process.

Before proceeding with repairs, there are two situations where you should contact the manufacturer first:

1. If the feed signal from the board is out of phase
2. If there is an internal break in the stepper motor

If the issue lies with the driver transistor, there are two main possibilities: if the LED is not lit, it may indicate that the transistor is open; if the LED remains on, it could suggest a shorted transistor. When replacing the driver transistor, make sure there is good contact between the transistor and the heat sink. Apply thermal grease to the surface to ensure proper heat dissipation and prevent overheating and potential damage in the future.

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