27 differences between stepper motor and servo motor - News - Global IC Trade Starts Here.

1. How to choose a stepper motor or a servo motor? The choice depends on the specific application. Consider factors such as load type (horizontal or vertical), torque, inertia, speed, accuracy, acceleration/deceleration requirements, control method (position, torque, or speed mode), power supply type (DC/AC/battery), and voltage range. These factors help determine the right motor and drive/controller for your system.

2. Should I use a stepper or a servo motor system? It depends on the application. Stepper motors are cost-effective and suitable for simpler tasks, while servo motors offer higher precision and performance for more complex motion control needs.

3. How to use a stepper motor driver? Choose a driver with current rating equal to or greater than the motor’s rated current. Use a subdivided driver for reduced vibration or high precision. For high-torque motors, use a high-voltage driver to improve high-speed performance.

4. What is the difference between 2-phase and 5-phase stepper motors? 2-phase motors are low-cost but can have higher vibration at low speeds and lower high-speed torque. 5-phase motors offer smoother operation, less vibration, and up to 30–50% higher high-speed performance. They can even replace servos in some applications.

5. When to choose DC servo vs AC servo systems? DC brushed motors are cost-effective, simple to control, and ideal for general industrial or residential use. Brushless DC motors are compact, efficient, and suitable for high-performance applications. AC servo motors are brushless and typically used in precise motion control with high torque and stability, though they may have lower maximum speeds compared to DC systems.

6. What to consider when using a motor? Before powering on: - Ensure the power supply voltage is appropriate (avoid overvoltage). - Check the polarity of DC input. - Confirm the motor model and current settings match the drive/controller. - Secure all control signal connections, especially in industrial environments where shielding is important. - Start with the minimal setup and gradually add components after testing. - Ensure proper grounding and monitor the motor for unusual sounds, vibrations, or temperature changes during initial operation.

7. Why does a stepping motor sometimes not move or lose steps? Check: - Motor torque is sufficient to handle the load (choose a motor with 50–100% more torque than required). - Input pulse current is adequate (at least 10mA) to activate the optocoupler. - Starting frequency is set correctly and acceleration is properly programmed. - Motor must be fixed to avoid resonance issues. - For 5-phase motors, check phase wiring for errors.

8. Can I control a servo motor via communication? Yes, it's possible, but for fast response applications, a dedicated motion control card with DSP is recommended for advanced features like S-curve acceleration and multi-axis interpolation.

9. Is it safe to use a switching power supply for stepping or DC motors? Avoid using switching power supplies for high-torque motors unless the supply has double the required power. Motors act as inductive loads and can cause voltage spikes that damage the power supply or driver. A conventional transformer-based DC power supply is safer.

10. Can I control a stepper motor with ±10V or 4–20mA signals? Yes, but you’ll need additional signal conversion modules to interface with the motor driver.

11. Can I control a servo motor with only a tachometer port? Yes, if you have an encoder-to-tachometer signal module.

12. Can the encoder of a servo motor be disassembled? No, disassembling can damage the quartz disc and introduce dust, which affects accuracy and lifespan. Professional maintenance is required.

13. Can I repair or modify a stepper or servo motor myself? Not recommended. Disassembling without proper tools and expertise can damage internal components, reduce performance, and make reassembly difficult. Always consult the manufacturer.

14. Can a servo controller detect external load changes? Yes, it can stop, return, or maintain thrust when encountering resistance.

15. Can I mix domestic and foreign components? In principle, yes, but ensure compatibility by checking technical parameters. Mismatched components may reduce performance or cause long-term issues. Consult the supplier before installation.

16. Is it safe to run a motor above its rated voltage? Generally, it’s safe as long as the motor operates within speed and current limits. However, exceeding the rated voltage could lead to driver failure. Also, ensure the motor meets the drive’s minimum inductance requirement and that current limits don’t exceed the motor’s rated current.

17. How to select the right power supply for my application? Choose a supply voltage 10–50% higher than the maximum required. Calculate the total power needed and add 5%. Use the formula I = P/V to determine the current. Ensure the driver can provide enough energy for your application.

18. What working modes are available for a servo drive? Available modes vary by drive model. Not all drives support all control modes.

19. How to ground the drive and system? - Avoid grounding non-isolated DC bus ports if connected to AC power. - In most systems, all grounds are connected at the signal end to minimize noise. - Connect the driver’s signal ground to the controller’s ground. - Shield grounding should be done at a single reference point to prevent ground loops.

20. Why can’t a gearbox perfectly match the motor’s standard torque? Many gear ratios exceed the reducer’s torque capacity. Manufacturing each reducer to match full torque would increase complexity, cost, and size, which goes against product design principles.

21. Which reducer to choose: planetary or spur gear? Planetary reducers are ideal for high torque in small spaces, offering better reliability and longer life. Spur gear reducers are more cost-effective and efficient for low-noise, low-current applications.

22. What is duty cycle? Duty cycle is the ratio of working time to total cycle time (working + non-working). If the load is light, the motor can operate at three times its continuous current for short periods, providing more force than normal continuous operation.

23. Can a standard rotary motor circuit be used for linear motors? Yes, many linear motor types can function similarly to rotating motors. Consult the supplier for details on compatibility.

24. Can a linear motor be installed vertically? Yes, but additional components like balancing devices or brakes may be needed to ensure smooth vertical movement.

25. Can multiple movers be installed on the same platform? Yes, as long as they do not interfere with each other.

26. Can multiple brushless motor movers share the same magnetic track? Yes, provided they are positioned to avoid interference.

27. What are the advantages of using a linear motor over a ball screw? Linear motors eliminate mechanical backlash, wear, and jamming, resulting in smoother motion, higher precision, speed, and acceleration. They also offer better control, reliability, compactness, and long service life. When designing a system, consider the trade-offs between push-pull force, speed, and positioning accuracy. A well-integrated solution involving the right motor, driver, and feedback system will deliver optimal performance. For demanding applications, custom solutions may be required, though they will increase costs.