1.

Mathematical Model

1.1. Mathematical Model of the Stepper Motor

1.1.1. Mechanical model of stepper motor

Ft

𝑦, 𝑦,̇ 𝑦̈ mo

Wn 𝜃, 𝜃,̇ 𝜃̈
Wo Wp To
Stepper
Motor
J
Tm

Where:
y is linear displacement, 𝑦̇ is linear velocity and 𝑦̈ is linear acceleration[m].
𝜃 is the angular displacement, 𝜃̇ is the angular velocity and 𝜃̈ is the angular acceleration of the lead
screw[rad].
Wo is the weight of the object, Wp is the weight of the platform and Wn is the weight of the nut[N].
To is the torque required to turn screw and Tm is the torque of the motor[Nm].
Ft is the thrust force of the nut due to the rotation of the screw[N].

Nut, platform and object model:

Assumptions:
1. Screw assumed to handle bending stress caused by moment at screw, hence moment ignored.
2. All masses are taken through the centre of the nut.
3. Air friction is neglected.
 Ft
𝑦, 𝑦,̇ 𝑦̈

Nut

W
𝑚 = 𝑚! + 𝑚" + 𝑚#
𝑊 = 𝑊! + 𝑊" + 𝑊#
𝐹$ − 𝑊 = 𝑚𝑦̈
Where:
𝑚! is the mass of the nut, 𝑚" is the mass of the platform, 𝑚# is the mass of the object and m is the
total equivalent mass of the object, platform and nut [Kg].
W is the total weight of the system [N].

Load screw model:

Relating force to torque
W
W
! = 2$
fN
! Pr
N !

) " #$% &

𝛼
'(!

, 𝐹% = 0

𝑊 − 𝑁 cos 𝜆 cos 𝛼 + 𝑓𝑁 sin 𝜆

, 𝐹& = 0

𝑃' − 𝑁 cos 𝛼 sin 𝜆 − 𝑓𝑁 cos 𝜆 = 0

Where Pr [N] is the force pushing the load W [N] up an incline of angle 𝜆 [rad]. N is the normal
force[N], f is the coefficient of friction between the screw and nut , 𝛽 is the thread angle, 𝛼 is flank
angle [rad], l is the lead [mm] and dm is the mean diameter of the screw[mm].
Equating the above equations and manipulating
(𝐿 + 𝜋𝑑( 𝑓 sec 𝛼)
𝑃' = 𝐹$
𝜋𝑑( − 𝑓𝐿 sec 𝛼
Manufacturers of lead screws seldomly publish the frictional coefficient between the lead screw and
nut. Rather, they publish efficiency at which the lead screw and nut transfers torque to thrust force and
vice versa. The efficiency term is inclusive of friction, hence, if we multiply by the efficiency(e) [%],
the frictional coefficient (f) can be set to 0.
𝐹$ 𝐿
𝑃' =
𝜋𝑑(
𝑑(
𝑇' = 𝑃'
2
𝐹$ 𝐿
𝑇' =
2𝜋
Where 𝑇' is torque required to lift load [Nm]

Introducing efficiency (e)

𝑇'
𝑇# =
𝑒
𝐹$ 𝐿
𝑇# =
2𝜋𝑒
Where 𝑇# is the torque required to turn screw.

Relating angular motion to linear motion:

Assumptions:
1. Assume rigid lead screw
2. Assume no backlash
The lead of the screw is the linear distance the nut travels with one full rotation of the screw. Using
the lead, we can relate angular displacement of the screw to linear displacement of the nut. Integrating
once will relate velocities and integrating a second time will accelerations.
𝐿
𝑦 = 𝜃
2𝜋
𝐿
𝑦̇ = 𝜃̇
2𝜋
𝐿
𝑦̈ = 𝜃̈
2𝜋
Moment of inertia of load
𝐽)* = 𝐽+ + 𝐽, + 𝐽(
𝐽+ is the mass moment of inertia of the load, 𝐽, is that if the screw, 𝐽( is that of the motor and 𝐽)* is
the equivalent mass moment of inertia of the entire system [𝑘𝑔 ∙ 𝑚- ].
Using the definition of kinetic energy in terms of linear and angular velocity to derive a formula for
equivalent mass moment of inertia of the load on the motor.
1 1 1
𝐾𝐸 = 𝑚𝑣 - + 𝐽. 𝑤 - + 𝐽( 𝑤 -
2 2 2
Substituting equation and manipulating…
 𝐿
𝑣 = 𝑤
2𝜋
1 𝑚𝐿-
𝐾𝐸 = L + 𝐽. + 𝐽( N 𝑤 -
2 4𝜋

Compare to kinetic energy equation in terms of inertia and angular velocity only
1
𝐾𝐸 = 𝐽)* 𝑤 -
2
𝑚𝐿-
𝐽)* = + 𝐽. + 𝐽(
4𝜋

1.1.2. Electrical Modelling of the Stepper motor

Assumption: RL circuit with back emf, where phase resistances and inductances are equal.

𝑅/ 𝐿/

𝑢/
𝑒/

Figure 3.1: Phase A RL circuit

According to KVL:
01! ($)
𝐿/ 0$
= −𝑅/ 𝑖/ (𝑡) − 𝑒/ (𝑡) + 𝑢/ (𝑡)……………………………….(1)

Where:
𝑒/ = 𝐾( 𝜔( cos 𝑝𝜃( ……………………………………….(2)
Where 𝐿/ is the inductance[H], 𝑖/ (𝑡) is the electric current flowing through circuit[A], 𝑅/ is the
resistance in the circuit[Ω], 𝑒/ (𝑡) and 𝑒4 (𝑡) are the back emf in the circuit[V], 𝑢/ (𝑡) is the applied
voltage to the circuit[V], 𝐾( is the motor constant, 𝜔( is the rotor angular speed[rad/s], p is the number
of motor pole pairs.
 𝑅4 𝐿4

𝑢4
𝑒4

Figure 3.2: Phase B RL circuit

01" ($)
𝐿4 0$
= −𝑅4 𝑖4 (𝑡) − 𝑒4 (𝑡) + 𝑢4 (𝑡)……………………………….(3)

Where:
𝑒4 = 𝐾( 𝜔( sin 𝑝𝜃( ………………………………………..(4)
Where 𝐿4 are inductance[H],𝑖4 (𝑡) is the electric current flowing through the circuit [A], 𝑅4 is the
resistance in the circuit[Ω], 𝑒4 (𝑡) is the back emf in the circuit[V] and 𝑢4 (𝑡) is the applied voltage to
the circuit[V].
∴

1.2. Mechanical Model of the Stepper Motor

Assumption: Shaft is modelled as a rigid body subjected to different torques

𝜏)(
𝜃(

𝜏5 , 𝜏0( , 𝐵𝜔( , 𝐽𝜃(̈

Figure 3.3: Stepper Motor

∑ 𝑀67 = 𝐽( 𝜃(̈ …………………………………………… (5)

𝐽( 𝜃(̈ = 𝜏)( − 𝐵𝜃(̇ − 𝜏0( − 𝜏5
𝐽𝑚 𝜃𝑚̈ + 𝐵𝜃𝑚̇ + 𝑘𝑡 𝜃𝑚 = 𝜏𝑒𝑚 − 𝜏𝑑𝑚 − 𝜏𝑙
Where:
𝜏)( = 𝐾( (−𝑖/ sin(𝑝𝜃( ) + 𝑖4 cos(𝑝𝜃( ))………………………… (6)
𝜏0( = 𝑇0( sin(2𝑝𝜃( + 𝛼)…………………………………. (7)
Where 𝐽( is the mass moment of inertia[𝑘𝑔⁄𝑚- ], 𝜃(̈ is the angular acceleration[𝑟𝑎𝑑⁄𝑠 - ], 𝜏)( is the
electromotive torque[N.m], B is the viscous friction constant [𝑘𝑔⁄𝑠𝑚], 𝜃(̇ is the rotor angular
speed[rad/s], 𝜏0( is the detent torque applied[N.m], 𝜏5 is the applied load torque [N.m] and 𝑇0( is
detent torque [N.m] and 𝑘$ [N.m/rad] is the torsional stiffness and 𝜃( is the rotor angular position .

1.3. Mathematical Model of the Lead screw

𝜃.
𝐾. (𝜃̇ . − 𝜃(̇ )

𝜏(

Figure 3.4: FBD of led screw

Assumption: experiences torsional spring stiffness
∑ 𝑀67 = 𝐽. 𝜃.̈ …………………………………………….(8)
𝜏( − 𝐾. (𝜃.̇ − 𝜃(̇ ) = 𝐽. 𝜃.̈ = 𝜏.
𝐽. 𝜃.̈ + 𝐾. ( 𝜃(̇ − 𝜃!̇ ) = 𝜏.

Where 𝜏( is the resultant torque applied to the lead screw by the stepper motor[N.m], 𝐽! is the moment
of inertia of the lead screw[𝑘𝑔⁄𝑚- ], 𝜃!̈ is the angular acceleration of lead screw[rad/s], 𝐾. is torsional
spring constant[Nms/ras] and 𝜃!̇ is the angular velocity of lead screw[𝑟𝑎𝑑⁄𝑠 - ].