Stepper motor or Servo Motor - Which is best for your application?
Nowadays it is difficult to pick the best motor for an application in the industrial marketplace. The information available on websites is either very simple or technical. A stepper motor refers to a type of brushless DC motor, which is designed to offer a definite number of definite steps per revolution. Based on the number of pulses received, the stepper motor will move in the forward or reverse direction, every time it is pulsed by the stepper controller.
Pros of Stepper motors
A stepper motor can provide open-loop positioning, one of the biggest advantages as compared to open-loop induction motors, which don't offer "positioning". There is no feedback involved in most of the stepper motors and that's the reason for the lower overall cost of a stepper and control solution.
Also, the stepper motor can be operated with a DC-powered stepper drive which is advantageous for industrial applications. There is no need for larger inverters, which input 230/460VAC or bulky fusing, and cabling as well.
Limits of stepper motors
Stepper motors can ‘lose’ position if it does not offer sufficient torque to move the shaft and load. It can even occur at high speeds where the stepper motor goes very rapidly to lock in at each step.
Steppers do not keep any kind of known positioning when they are powered down. Thus, they have to finish a homing routine each time they are powered up. You can experience this while turning on your printer at home. In brief, stepper motors are perfect for some industries and small power applications that range from adjustable conveyors, 3D printers, and small metering pumps.
What is a servo motor?
While servomotors refer to a motor, which is controlled with feedback. These motors include a stator like an induction motor, but their rotors are made with unusual earth magnets. This cuts down the slip present in induction motors and permits the servo motor to operate at the synchronous speed set by the frequency and number of poles.
Pros of servomotors
AC servo motors use rare earth permanent magnets, so they offer the best-in-class torque density. This is preferred for very dynamic motor applications that must accelerate and decelerate quickly. Servo motors include some sort of feedback, whether it is a resolver or encoder. The shaft feedback is critical because it is used in the servo controller to control rotor position and torque.
Unlike a stepper motor, servomotors can offer momentary peak torque across their speed range. Peak torque of servo motor can be highly significant in particular applications and can cause an optimized motor selection. Also, AC servo motors run at much quicker speeds as compared to stepper motors.
Crucial motion control applications, which include functional safety and the handling of vital or pricey products must utilize servo motors with feedback. The low price advantage of a stepper motor/control can't justify the danger of injury or product breakdown. In packaging machines, robotics, material handling, servo motors are highly used.
Limits of servo motors
The main cons of servo motors as compared to stepper motors is the cost of the motor and the connected drive, which controls it. This is mainly factual for smaller power applications. If there is no need for precision and high torque overload in an application that the servo motor provides, then a stepper motor is possibly the good choice.
Servomotors are best for some industries and applications such as forming machines, packaging machines, powering conveyor systems, metal cutting, and robotics.
Stepper Motor Repair and Servo Motors Repair
CM Industry Supply Automation offers complete Stepper Motor Repair and Servo Motor Repair from a machine tool or an assembly operation.
We have a specialist servo repair department that offers in-house servo motor repairs from different manufacturers such as Lenze, KEB, Siemens, ABB, Allen Bradley, Indramat, Kollmorgen, Rockwell, Mitsubishi, Bosch, Elau, and more.
Contact us now for more details.
Automation systems installed in industry can help a lot because you can perform certain operations by using a robotic or control system. There are various processes that can be used in computers and software to perform such work. Industrial automation has marked as a revolution in the manufacturing industry and the process. There are different types of industrial automation systems available here, you can find a few examples:
You can use sensors in the high traffic area of your industry to monitor the activity of the people. Apart from that, you can find automatic food and beverage packaging system the food industry. It can reduce human contamination and labour to a large extent. Even, 3D printing, and numerical control machines are very common to us, and we can easily use such an automatic system to keep our production faster.
Benefits of an industrial automation system:
You can reduce the cost of the operation by using an industrial operating system. For example, you need to recruit more than a thousand people in your production line, and you need to pay their wages and other benefits. You can simply use some robots to do the same work in less time and you can recruit a few supervisors to monitor the whole process. Initially, you need to invest a lot of money, but it will reduce your production cost in the future. Apart from that, human error is very common, and you need to suffer from the wastage of raw materials and products caused by your operators.
In the case of industrial automation, you can reduce the cost because robots cannot make an error in their operation.
Robotic processes or industrial automation systems mainly mimic human actions, and you can use such automatic resources to increase the productivity of your business. You can also configure an automatic system to complete your administrative work. With an industrial automation system, you can use robotic applications to keep your workspace clean, and they can even handle your high-pressure machinery without any harm. If you use a manual process for manufacturing your products, then there will be a chance of human error. Even, manual handling and packaging of your products can damage your products and you need to bear the loss.
For production growth and reducing wastes, the automatic use of machinery can help in several ways. On-time shutting of the machine operation and restarting of productions are the main features. an If you are dealing with heavy materials, then you need to maintain the best safety protocols. It is an application for hazardous materials too. In this case, you can use an industrial automation system to prevent damages and the risk of an accident.
Apart from that, you can maintain the temperature of your workspace by using some robotic sensors. Even, theautomation system can also save your power consumption cost, and you can use an automation system to connect your electrical devices. You can control all your devices and appliances from a control panel.
There are some machine learning apps available that can be used to build a self-learning control quality system. Skilled workers are specifically trained to use such a system to maintain the best standard. An automation system can consistently deliver the same production level and you can reduce the downtime caused by the human interface.
To know more about industrial automation, you can search such tools online and you can choose the best solutions for your industry. You can customize such apps and software-operated machines or robotic applications as per your needs.
With servomotors normally used in precision manufacturing, its long downtime cost you high. If a servomotor is not working properly, it is important to perform a quick repair. A fast come back to service must be with an assurance of a highly-skilled repair that offers lasting, high-performance movement control.
Sophie Williams, Marketing Manager at CM Industry Supply Automation talks about the key requirements of servo motor repair.
Servomotors are an important component for manufacturing processes starting from printing and packaging to electronic device production. Its downtime costs you high as production rate decreases, project completion deadline misses and reputation gets damaged too. For these concerns, if a servomotor develops a fault, it must be repaired as quickly as possible. A servo motor is capable to offer exact precision at high speed, so any repair must offer it similar performance to a new one.
CM Industry Supply Automation offers 24/7 365 days in-house repair service for servo motors in India and Australia. Our servo motor repair service aims to get a client back up and running within a short time frame.
When the servomotor comes to our workshop, our first job is to diagnose the problem. From the point the fault is determined, the repairing process resume and we try to complete the motor repair within 24 hours. Communication with the client is crucial and they are updated at every step of the repairing process.
Usually, servo motor faults occur due to bearing failure or encoders and brake inaccuracy. In many conditions, these issues occur due to wear and repeated use. Used for accurate position control and maximum-pace acceleration, a servo motor is essentially more complex to repair as compared to an induction motor.
In diagnosing phase, basic electrical tests are performed along with insulation resistance tests. Also, we do alignment tests, analysis of the internal brake, and significantly, encoder count. After that servo motor is stripped and cleaned with the repair or replacement of the encoder as per the requirement, and the brake refurbished.
To achieve the essential precision, a balance test is performed on the rotor to eliminate vibration for better performance and reliability. As normal, the bearings are even checked and replaced as required, as well as the electronic measurement of the housing that can be machined to the correct size to ensure an exact fit for precision and motor long life.
Even the stator is overhauled by removing corrosion on the windings. If essential, rewinds can also be performed in-house, often require eight and 10 hours to complete. Core loss testing even happens in-house to confirm the performance of rewound motors, and expert also checks noise and vibrations.
The servomotor can even be resprayed onsite. Next, with the encoder alignment set, a load test is carried out together with a servo drive, as well as testing the brake. When our experts announce that the servomotor is set to re-enter service, it is despatched to the client's site, prepared for reinstallation.
Our workshop is completely equipped and configured to repair all types and brands of servomotor. If the servo motor is beyond repair, CM Industry Supply Automation offers new servo motors of major brands such as Lenze, KEB, Siemens, Rockwell, Allen-Bradley, ABB, Control Techniques, Mitsubishi, and more at affordable prices.
Call us now for Servo Motor - Servo Motor Repair Services at +918888851242 or +61432112288.
Get all industrial automation products sales & repair services. Call us for Lenze Drive, Keb Drive, Siemens, Allen-Bradley equipment sales and repair services.
CM Industry Supply Automation are supplier and repair services provider of drives, VFD drive (variable frequency drive), VSD (variable speed drive), inverter, frequency converter, ac drive, servo drive, servo motor, industrial drives, industrial drives and controls, industrial drives and applications, high-power servomotor, high torque DC servo motor, high-power servo drives, high frequency drives, of some well-known brands that include:
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