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IntroductionWhat is the difference between a three-phase AC motor and a single-phase AC motor? If you pay attention to it, you will find that single-phase AC motors have more equipment than three-phase AC motors, which is the start capacitor (starting capacitor). The most common one is in various household appliances. Almost all household appliances with motors are equipped with start capacitors. This article will start with the explanation of the principle of the motor start capacitor, and then describe in detail the failure phenomena, causes and test methods of the start capacitors in the two common home appliances, air conditioners and fans. In addition, the article will also explain some basic questions about start/run capacitors. If you want to learn the related knowledge of motor start capacitors, this article must be worthy of your reading.How to test a RUN or START CAPACITOR the CORRECT wayCatalogIntroductionCatalogI The Principle and Causes of Damage of Start Capacitor 1.1 How Does the Motor Work? 1.2 How Does the Start Capacitor Work? 1.3 Reasons for the Burning of the Start CapacitorII Troubleshooting of Start Capacitor in Air Conditioner 2.1 Functional Characteristics of Start Capacitor 2.2 How to Quickly Figure out Whether the Start Capacitor is Damaged 2.3 Why is the Start Capacitor of the Air Conditioner Outdoor Unit Easy to Damage? 2.4 Symptoms and Test MethodsIII How Test the Motor Start Capacitor of a Fan?IV Relevant Knowledge in the Step of Start Capacitor Test 4.1 How to Choose Start Capacitor? 4.2 Precautions for Replacing the Start CapacitorV How to Test the Motor Start Capacitor without a MultimeterVI Frequently Asked Questions about Start Capacitors 6.1 Which Motors are Served by the Start Capacitor? 6.2 Why Does a Three-phase Motor do not Need a Start Capacitor? 6.3 The Relationship Between Start Capacitors and Motor 6.4 What are the Functions of Start Capacitors, Run Capacitors, and Centrifugal Switches in Single-phase Motors?VII QuizⅧ FAQI The Principle and Causes of Damage of Start Capacitor1.1 How Does the Motor Work?The single-phase current flowing through a single-phase motor cannot generate a rotating magnetic field, and a capacitor is needed to separate the phases. The purpose is to make the current in the two windings produce a phase difference of nearly 90 ゜ to generate a rotating magnetic field. The capacitive induction motor has two windings, namely the starting winding and the running winding. The two windings are 90 degrees apart in space. A large-capacity capacitor is connected in series to the starting winding. When the running winding and the starting winding pass single-phase alternating current, the current in the starting winding is 90 degrees ahead of the current in the running winding due to the action of the capacitor, thus reaching the maximum value first. Two identical pulsed magnetic fields are formed in time and space so that a rotating magnetic field is generated in the air gap between the stator and the rotor. Under the action of the rotating magnetic field, an induced current is generated in the motor rotor, and the current interacts with the rotating magnetic field. The electromagnetic field torque causes the motor to rotate.Figure1. Electric-Motor1.2 How Does the Start Capacitor Work?A single-phase power supply is different from a three-phase power supply in that a three-phase rotating magnetic field is generated in the motor. The principle of capacitor starting of single-phase motor is: using the principle that the current of the capacitor in the circuit is advanced by 90 degrees so that a magnetic field of 90 degrees ahead of the main winding is generated in the starting winding so that there will be an alternating 90-degree angle in the motor. The magnetic field, to put it plainly, uses the phase-shifting principle of the capacitor to transform a single-phase power supply into a two-phase power supply of 90 degrees to each other, and a rotating magnetic field of 90 degrees to each other is generated in the motor. Maybe it is easier to understand to explain from this aspect. The start capacitor is to give the motor a thrust when the motor is started so that the motor can turn from moving to rotating. Without it, when a single-phase AC motor starts, it will shake at the origin instead of rotating; the start capacitor is a two-phase AC motor, so the magnetic field cannot exert force on the rotor without it, and of course, it is impossible to rotate.Figure2. Capacitor Start Run Induction Motor1.3 Reasons for the Burning of the Start CapacitorGenerally, the start capacitor is not easy to burn, because its working time is very short, and it is thrown off by the centrifugal switch at the moment of starting, with no current flowing through the start capacitor. However, not easy to burn does not mean that it will never burn. If the start capacitor burns out, the possible reasons are as follows:① Capacitors have low voltage resistance or poor quality, so it is best to use capacitors with a voltage resistance of 500V. ② The centrifugal switch will often produce an arc when it is turned off. It is possible to burn the switch to the motor. After the switch is started, the switch cannot be turned off. There is always current through the capacitor. It is easy to burn the secondary winding of the motor and the start capacitor within a certain period of time. ③ The capacity of the selected capacitor is too small, and the starting current exceeds the allowable value of the capacitor. ④ The motor is bored or the bearing is damaged. It is difficult for the motor to start the centrifugal switch within a certain period of time and it is difficult to reach the disconnected speed, and the start capacitor is easy to burn.Figure3. Deteriorated CapacitorII Troubleshooting of Start Capacitor in Air Conditioner2.1 Functional Characteristics of Start CapacitorThe start capacitor is an important part of the auxiliary compressor to start. The capacitor is a large-capacity capacitor (1~6uF), which is used to provide starting current for the auxiliary winding of the motor to assist the compressor to start. The start capacitor is generally fixed on the bracket or support plate above the compressor, and the pin is connected to the starting end of the compressor.2.2 How to Quickly Figure out Whether the Start Capacitor is DamagedFirst of all, it depends on what kind of capacitors are used in electrical parts.● If the compressor start/run capacitor is damaged, the compressor cannot start or run intermittently.● If the capacitor of the fan motor is damaged, some malfunctions such as excessive exhaust temperature, excessive exhaust pressure, compressor overload, and small air output will occur during the operation of the air conditioner.2.3 Why is the Start Capacitor of the Air Conditioner Outdoor Unit Easy to Damage?The capacitor of the air conditioner compressor is installed in the outdoor unit. Due to the high temperature of the outdoor unit (ambient temperature + temperature emitted by the condenser), capacitors that have been used for a long time will easily dry up and fail the electrolyte.When replacing capacitors, be sure to use high-quality capacitors. The capacity must be the same, and the withstand voltage must not be lower than the original standard.Figure4. Air Conditioner Outdoor Unit2.4 Symptoms and Test Methods① Smoke.② Cannot operate normally.③ The display cannot be displayed normally.④ The power supply cannot be charged and discharged normally.⑤ Can not heat normally.⑥ The power factor compensates the capacitor damage, resulting in a waste of electricity. Different symptoms of damage to compressor start capacitor and external motor start capacitor:There are two capacitors in the outdoor electromechanical packaging, the larger one is the compressor capacitor, and the smaller one is the external motor capacitor. Different capacitors have different failure phenomena. ① Compressor capacitor damagethe performance phenomenon is that normal compressor startup will be accompanied by loud noise and jitter. If the capacitor is damaged, you will feel a slight jitter in the compressor by pressing the casing above the compressor, and the sound is like the sound of current passing. The compressor will stop running after a period of time. ② The damage of the external motor capacitorAfter the compressor is working normally, the external motor stops working for a period of time. If there is a fault code, there will be high-pressure protection and compressor exhaust pipe temperature protection.Figure5. Basic Electrical Controls of Air-Conditioning UnitsTest methods of air conditioner start capacitor● Method 1:The start capacitor of the air-conditioning compressor is a large-capacity electrolytic capacitor. When testing, using the capacitance setting of the digital multimeter to determine whether there is any abnormality.Under normal circumstances, the capacitance of the capacitor used to detect the capacitance of a multimeter should be the same or very close to the nominal capacitance, otherwise, the start capacitor is mostly deteriorating, such as dry electrolyte, leakage, etc., which should be replaced. ● Method 2:In addition to using a multimeter to test its capacitance, the ohmic setting of a pointer multimeter can also be used to test the charge and discharge performance of the start capacitor.Steps:① Connect the red and black test leads to the two poles of the compressor start capacitor.② The multimeter gear is set in ohm gear.③ Under normal circumstances, the pointer of the multimeter first swings to the right to a position, then slowly swings to the left, and finally stops at a fixed position.④If the pointer does not swing or the swing range is small, it indicates that the performance of the compressor start capacitor is poor.Suggested Reading: 5 Ways to Test Capacitors How to replace the start capacitor?If it is ensured that the air conditioner failure is caused by the damage of the compressor start capacitor itself, the damaged compressor start capacitor needs to be replaced. Replacing the start capacitor can generally be divided into three steps: removing the start capacitor, finding a replaceable start capacitor, and replacing the start capacitor. ①Remove the start capacitorThe compressor start capacitor is located on the circuit support board above the compressor. When disassembling, unplug the connecting wire and use a screwdriver to remove the fixing screw of the snap ring. ② Looking for replaceable capacitorsAfter removing the damaged compressor start capacitor, then select a suitable new start capacitor to replace it according to the specifications and volume of the damaged start capacitor.The specific content of how to select the start capacitor will be explained in detail below. ③Replace the start capacitorAfter selecting the compressor start capacitor, install the new compressor start capacitor in the outdoor unit, fix the metal fixing ring, reconnect the connecting cable, and then power on and test the machine to complete the replacement.Figure6. Motor Start CapacitorIII How Test the Motor Start Capacitor of a Fan?①Connect all parts on the circuit board of the air conditioner completely.②Turn on the power supply.③Use the remote control to adjust the temperature to make the fan motor rotate.④Connect the ground terminal of the oscilloscope probe to the ground terminal of the circuit board.⑤Use an oscilloscope probe to detect the white lead on the Hall element plug.⑥The oscilloscope shows signal waveform. When testing the start capacitor of the fan motor, a multimeter should be used to measure the resistance of the capacitor. Due to the large size of the capacitor, it is impossible to use the capacitor input jack for testing. At this time, you can use the multimeter pen to test and judge the quality of the capacitor by the change of the value displayed by the multimeter. If the resistance value displayed by the multimeter changes from small to large and then changes to infinity, it means that this is a good capacitor with charging and discharging functions. Check again after changing the test leads, the displayed value still changes from small to large, and changes to infinity. After measuring the capacitor, if the test leads are not replaced when the test is performed again, and the resistance value is displayed as infinite, it means that charging and discharging are not performed, but it does not mean that the capacitor is damaged. Therefore, when testing the capacitance, the test leads must be replaced no matter which multimeter is used.Figure7. Fan MotorRelated recommendation: How to Test Ceramic Disc Capacitor IV Relevant Knowledge in the Step of Start Capacitor Test4.1 How to Choose Start Capacitor?● How to calculate the starting and running capacitance of a single motorrun capacitance C=120000*I/2.4*f*U*cosφWhere: I is current; f is the frequency; U is the voltage; cosφ is the power factor, taking 0.5 to 0.7. The run voltage of the run capacitor is greater than or equal to (2～2.3) U.Start capacitor capacity = (1.5 ~ 2.5) run capacitor capacity.The run voltage of the start capacitor is greater than or equal to 1.42 U.(It is best when the voltage across the capacitor is 311V during operation) The working capacitor is 1-4UF per 100W, and the start capacitor is 4-10 times the working capacitor (the motor requires a larger starting torque). Empirical data, if your motor does not exceed 200W, the start capacitor will not exceed 100uF. If you run the capacitor, you can choose several values for the power-on test, and see which capacitor has the smallest current in the whole machine, then the capacity of the capacitor is the most Good value.) The capacity of the single-phase split-phase motor capacitor can be calculated by the empirical formula C=35000I/2PUfcos&Such as I=250W/220V=1.2AC=35000x1.2/2x1x50x220X0.8=24ufCan choose 350V30uf capacitance.Figure8. Starting Capacitor Table ● How to calculate the voltage across the run capacitor of a single-phase motor?① First of all, you must know the impedance value of the secondary winding. You can measure the resistance value by measuring the DC resistance with a multimeter. Then, the secondary winding is connected to a 12V AC voltage and the current value is measured. According to the winding impedance equal to the resistance and reactance in series, it can be calculated by phasor Out the winding inductance value. ② In normal operation, the capacitor is connected in series on the secondary winding, that is, the three equivalent parameters of winding resistance, winding reactance, and capacitance are connected in series and then connected to 220V voltage. It is easy to calculate the phasor according to the formula of the series circuit. Calculate the voltage on the capacitor. ③ When a single-phase motor is running, the voltage at both ends of the capacitor is generally above 300VAC, so the capacitor voltage is generally selected for a capacitor with a withstand voltage of 400V or more, and a capacitor with a voltage of more than 450V is better. ④ For the calculation of the capacitance withstand voltage, please refer to Article 2. First, measure the resistance R and reactance XL of the secondary winding, and then select the capacitance C according to the power of the motor to calculate the capacitive reactance Xc.The actual voltage across the capacitor during operation: Uc= Xc*220/(R+jXL-jXc); the withstand voltage value of the capacitor: Uce=1.3~1.5Uc.Figure9. Single Phase Motor Starting ● Detailed selection guide of start capacitor and run capacitorSingle-phase motor capacitor selection.Withstand voltage formula: U (capacitance) is greater than or equal to 1.5*USingle-phase run capacitor formula: C=1950×I/U×cosφ (using a capacitor, which is both a start capacitor and a run capacitor, is commonly used for small-capacity motors such as electric fans and washing machines)Start capacitor capacity formula: C=3500*I/U*cosφ (a capacitor is only used when starting, disconnected during normal operation, and switched with a transfer switch or a centrifugal switch.Dual-value capacitor run capacitor capacity formula: C=1200*I/U*cosφ (use 2 capacitors, one for operation and one for startup)Dual-value capacitor start capacitor capacity formula: C=(2～3)*C (run capacitor) C: Capacitor capacity: I: motor rated current, U: motor rated voltage, cosφ: power factor 0.7.Generally, there is no need to calculate. The run capacitor is 2~3μF per 100W, and the start capacitor is 2~3 times the run capacitor. The capacitor selection of the motor has strict requirements on the voltage, and it must be equal to or greater than 1.5 times the rated voltage of the motor. For a power supply with a rated voltage of 220V, the rated voltage of the capacitor cannot be lower than 400V. The capacitance value has a certain broadness, it doesn't matter if it is larger or smaller, especially the start capacitor, which can be selected at 2-6 times the working capacitor. ● How to choose the capacitor of single-phase asynchronous capacitor start the motorWe can calculate according to the following formulaPhase start capacitor capacity:C=350000*I/2p*f*U*cosφIn the formula: I---current;f-frequency;U---voltage;2p-the larger power factor is 2, and the smaller power factor is 4; cosφ---power factor (0.4～0.8).Split-phase start capacitor withstand voltage:The capacitor withstand voltage is greater than or equal to 1.42*U. Run capacitor capacity:C=120000*I/2p*f*U*cosφIn the formula: I---current;f-frequency;U---voltage;2p-take 2.4;cosφ---power factor (0.4～0.8). Run capacitor withstand voltage:The withstand voltage of the capacitor is greater than or equal to (2～2.3)*U.start capacitor capacity of double-value capacitor motor:C=(1.5～2.5)*operating capacitor capacity.Withstand voltage of start capacitor:The capacitor withstand voltage is greater than or equal to 1.42*U.4.2 Precautions for Replacing the Start CapacitorThe start capacitor is an important part of the electronic circuit. Once the start capacitor is broken, the motor cannot be started. The damaged start capacitor will only make a buzzing sound when it is energized for a short time, causing the current to surge, and long-time energization will cause severe overheating and even burn the motor, so it should be replaced immediately. And it is not difficult to judge that the start capacitor is broken. Most of the damaged start capacitors are bulging, and the surface will be burnt due to excessive current, and the rotor speed will be slow and weak. Of course, the most intuitive and accurate way is to use the capacitance setting of a multimeter to measure the quality. Once we have confirmed that the start capacitor has failed, the things that should be noted when replacing the start capacitor:① After the start capacitor is discharged, there will still be part of the residual charge that cannot be discharged for a while, and an artificial discharge should be performed again. ② Since the failed start capacitor may have poor lead contact, internal disconnection or fuse blown, etc., part of the charge may not be discharged. Therefore, the maintenance personnel should wear insulating gloves before touching the failed start capacitor. Using the short-circuit wire to short the two poles of the faulty capacitor first, and then it can be removed and replaced by hand. ③ If multiple start capacitors are used in series, they should be discharged separately.Figure10. Replace the Start Capacitor④ When handling or replacing a malfunctioning start capacitor, disconnect the power supply of the start capacitor, disconnect the switch or unplug the plug, and discharge the start capacitor. ⑤ When discharging, first connect the grounding terminal of the grounding wire, and then use the grounding rod to discharge the start capacitor several times until there is no discharge spark or discharge sound, and then fix the grounding terminal. ⑥ It should also be noted that general users often ignore the instruction manual, and the precautions for use must be carefully understood and followed during installation. As we all know, the impedance of a capacitor is inversely proportional to frequency. As the frequency increases, the loss also increases. Measures should be taken to limit the harmonics and inrush current in the circuit. Capacitors always generate heat, so pay special attention to ventilation and cooling. After the reactive power compensation device is installed, during the trial operation, the system should be tested, and measures should be taken in time if over-voltage, over-current, oscillation, and harmonics are found, which is very necessary for the normal operation of the capacitor. V How to Test the Motor Start Capacitor without a MultimeterA DC voltmeter can be connected to the capacitor in parallel, and an insulating shaker can be used to charge the capacitor (note the + and-poles)(1) See if the voltage can rise to the rated voltage of the capacitor:① 0V, the capacitor is short-circuited.② Slowly rise to the rated voltage of the capacitor, it proves that the capacitor is good.③ Raised quickly to the rated voltage of the capacitor, and the insulation resistance is about the internal resistance of the DC voltmeter, then the capacitor is open.(2) When it is stable at the rated voltage value of the capacitor, look at the insulation resistance of the capacitor:①The insulation resistance is close to the internal resistance of the DC voltmeter, so the capacitance is good.②If the insulation resistance is less than the internal resistance of the DC voltmeter, it means that the leakage of the capacitor is large, and it is easy to generate heat and cannot be used.VI Frequently Asked Questions about Start Capacitors6.1 Which Motors are Served by the Start Capacitor?Although some electrical appliances seem to have similar principles, they are different in the selection of motors, such as electric fans and air conditioners. Most electric fans use single-phase motors. Single-phase motors have only one 220v live wire and one neutral wire, while air conditioners often uses the three-phase motor, which has three wires, 220v live wire, neutral wire, and 380v live wire. The most obvious difference between a single-phase motor and a three-phase motor is that the number of start capacitors is different. A single-phase motor is equipped with a start capacitor, while a three-phase motor has no start capacitor.6.2 Why Does a Three-phase Motor do not Need a Start Capacitor?Because the three-phase motor itself has three running windings and can generate a magnetic field by itself, the appearance of the magnetic field can effectively replace the start capacitor, so the three-phase motor is generally not equipped with a start capacitor. However, the start capacitor still plays an irreplaceable role in a single-phase motor, because there is only one running winding in a single-phase motor, which cannot form a rotating magnetic field, and the operation of electrical appliances can only rely on the start capacitor. In addition to the start capacitor in a single-phase motor, there is also a run capacitor. Although these two capacitors work together, the function of the start capacitor is much greater than that of the run capacitor, so once they start capacitor is damaged, the fan will make a lot of noise, The blade speed is reduced. If this happens to your electric fan, you might as well try to replace a start capacitor, the problem should be solved.6.3 The Relationship Between Start Capacitors and MotorAt present, in single-phase motors with low-power motors, the start capacitor is connected in series with the starting coil and then connected in parallel with the running coil to work at the same time. In order to speed up the start-up time of the high-power motor, a large capacitor to help start is added. After the motor is started, the additional large start capacitor is disconnected by the centrifugal switch. The smaller capacitor connected in series with the starting coil is responsible for the phase shift required during normal operation. Electric current, the power supply machine is operating normally. Is there a single-phase motor that is connected to the starting coil and connected in parallel with the running coil in the circuit from start to run and does not require other large capacitors to help start? Low-power motors are always used in the circuit. High-power motors have to add additional capacitors due to their large power and large starting distance.Figure11. Torque-speed characteristic6.4 What are the Functions of Start Capacitors, Run Capacitors, and Centrifugal Switches in Single-phase Motors?The start capacitor is used for phase separation, and the purpose is to make the current in the two windings produce a phase difference close to 90 ゜ to generate a rotating magnetic field, allowing the motor to run quickly in a static state. There is an automatic clutch switch in the motor. When the motor is started, the motor will continue to run due to inertia. When the speed reaches a certain speed, the start capacitor will be separated by centrifugal action and automatically connected to the run capacitor, and the motor will enter the normal working state. The function of the run capacitor is to keep the current in the two windings with a phase difference of 90° to generate a continuous rotating magnetic field. For motors with start capacitors, the rotational torque generated by the start capacitors is larger than that of the run capacitors, which is more suitable for starting with a load. Motors without start capacitors are not suitable for starting with a larger load.VII QuizThe starting capacitor of a single phase motor is(A) Electrolytic capacitor(B) Ceramic capacitor(C) Paper capacitor(D) None of the above.Answer: AⅧ FAQ1. What happens when a start capacitor goes bad?A motor connected to a run and start capacitor may still attempt to start if one or both of the capacitors has failed, and this will result in a motor that hums and will not remain running for long. ... In most cases of capacitor problems, such as damage or a loss of charge, the capacitor will need to be replaced. 2. What's the difference between a run capacitor and a start capacitor?The start capacitor creates a current to voltage lag in the separate start windings of the motor. The current builds up slowly, and the armature has an opportunity to begin rotating with the field of current. A run capacitor uses the charge in the dielectric to boost the current which provides power to the motor. 3. How do you test a start capacitor with an ohmmeter?To test the capacitor with a multimeter, set the meter to read in the high ohms range, somewhere above 10k and 1m ohms. Touch the meter leads to the corresponding leads on the capacitor, red to positive and black to negative. The meter should start at zero and then moving slowly toward infinity. 4. How to test a motor start capacitor?Motor run capacitor failure symptoms include warm air flowing from the vents inside the home, the air conditioner taking more time than usual to kick on or it turns off before it is programmed to, or there is a constant low hum emitting from the machine that isn't typical. 5. How do I test a capacitor with a multimeter?To test the capacitor with a multimeter, set the meter to read in the high ohms range, somewhere above 10k and 1m ohms. Touch the meter leads to the corresponding leads on the capacitor, red to positive and black to negative. The meter should start at zero and then moving slowly toward infinity. 6. How do you check if a capacitor is bad with a multimeter?If the capacitance value is within the measurement range, the multimeter will display the capacitor's value. It will display OL if a) the capacitance value is higher than the measurement range or b) the capacitor is faulty. 7. How do I test a capacitor without a multimeter?Just connect those two ends of the capacitor to a single-phase supply and switch it ON for a few seconds. Then take that two-terminal and short it, you will get a spark. 8. How can I check a capacitor?Put the Analog Multimeter in the Ohmmeter position and if there are multiple ranges, choose a higher range. Connect the leads of the capacitor to the multimeter probes and observe the readings on the multimeter. For a good capacitor, the resistance will be low in the beginning and will gradually increase. 9. Can I replace a start capacitor with a run capacitor?Start capacitors give a large capacitance value necessary for motor starting for a very short period of time (usually seconds long). A start capacitor can never be used as a run capacitor because it cannot handle current continuously. 10. Which is bigger, start or run capacitor?A lot of torque is necessary to start up an AC system, so a start capacitor will have greater capacitance than a run capacitor. 

Ⅰ IntroductionFlyback Diodes, which are also known as freewheeling diodes, generally refer to diodes that are inversely paralleled across the ends of energy storage elements such as inductors, relays, and thyristors. When a voltage or current changes suddenly in a circuit, it protects other components in the circuit. When using a flyback diode, the circuit current can be changed more gently to avoid the occurrence of voltage spike. This article will introduce in detail what is flyback diode, how freewheeling diode works, flyback diode selection and the flyback diode function.How Freewheeling Diode WorksCatalogⅠ IntroductionⅡ DesignⅢ How It Works?Ⅳ SelectionⅤ Applications5.1 Summary5.2 In Forward Switching Power Supply5.3 In Converter Technology5.4 In Unidirectional Half Wave Silicon Control Rectifier Circuit5.5 In BUCK CircuitⅥ Something Has to CareIn electronics, a flyback voltage or an inductive flyback is a voltage spike created by an Inductor when its power supply is removed abruptly. The reason for this voltage spike is the fact that there cannot be an instant change to the current flowing through an Inductor.In addition, time constant of the inductor determines the rate at which the current can change through an inductor. This is similar to the time constant of a capacitor, which determines the rate at which its voltage can change.The freewheeling diode is named because it plays the role of freewheeling in the circuit. It is generally used in the circuit to protect components from being damaged or burned out by voltage breakdown, connected in parallel to both ends of the elements that generate the induced electromotive force(EMF), and form a loop with them, so that the high electromotive force generated in the loop is consumed by the continuous current method, thereby protecting the components in the circuits.Flyback diodes are connected in parallel at both ends of the coil. When the current passes through the coil, it will generate induced electromotive force at both ends. When the current disappears, its induced electromotive force generates a reverse voltage to the components in the circuit. When the reverse voltage is higher than the reverse breakdown voltage of the elements, it will cause damage to the elements such as triode and thyristor. When the current flowing through the coil disappears, the induced electromotive force generated by the coil is consumed by the work formed by the diode and the coil, thereby protecting the other elements in the circuit.Ⅱ DesignIn the following figure, it is showed that a flyback diode is placed across the inductor. An ideal flyback diode will have a very large peak forward current; capacity which helps in handling the voltage transients from damaging the diode, and inductor’s power supply is suited for reverse breakdown voltage and low forward voltage drop. Voltage spike can be 10times to the voltage of power supply which depends on the equipment involved and the application. So it is understood that not to underestimate the energy which contain within an energized inductor. Figure 1. Flyback DiodeFor an ideal flyback diode selection, a diode which has very large peak forward current capacity (to handle voltage transients without burning out the diode) should be selected, moreover, low forward voltage drop, and a reverse breakdown voltage fitted the inductor's power supply. Depending on the application and equipment in real requirement, some voltage surges can be upwards of 10 times the voltage of the power source, so it is critical not to underestimate the energy contained within an energized inductor.Flyback Diode Selection Note You Should KnowWhen used with a DC coil relay, a flyback diode can cause delayed drop-out of the contacts when power is turned off, due to the continued circulation of current in the relay coil and diode. When rapid opening of the contacts is important, a small value resistor can be placed in series with the diode to help dissipate the coil energy faster, at the expense of higher voltage at the switch.Schottky diodes are preferred in flyback diode applications as switching power converters, because they have the lowest forward drop (~0.2V rather than >0.7V for low currents) and are able to quickly respond to reverse bias (when the inductor is being re-energized). They therefore dissipate less energy while transferring energy from the inductor to a capacitor.When the flyback diode is used to simply dissipate the inductive energy, as with a solenoid or electric motor, cheap 1N540x and 1N400x general-purpose diodes are used instead. Ⅲ How It Works?Flyback diodes are often used with energy storage elements to prevent sudden changes in voltage and current to provide a pathway. The inductor can provide continuous current to the load through it to avoid sudden changes in load current and smooth the current. In the switching power supply, you can see a freewheeling circuit composed of a diode and a resistor connected in series, which is connected in parallel with the primary side of the transformer. When the switch is turned off, the freewheeling circuit can release the energy stored in the transformer coil to prevent the induced voltage from being too large and breakdown the switch. Generally, it is often to choose the fast recovery diode or the Schottky diode as flyback diode.Circuit Expressions Figure 2. Flyback Diode in Switching Power Supply CircuitIn Figure 2(c), when KR is turned on, the upper is positive voltage and the lower is negative voltage,  and the current direction is from top to bottom. When the VT is turned off, the current in the KR is suddenly interrupted and an induced potential is generated. The current direction is kept constant, that is, keeping the KR current direction from the top to bottom, which based on the Lenz's law. The induced potential and the power supply voltage are superimposed and applied across the VT, making it easy for the VT to breakdown. To avoid it, VD is used to short-circuit the induced potential generated by KR, that is, The current flows clockwise in the small circuits of the diodes and relays to protect the VT. R and C in Figure 2(b) also use the principle that the voltage on C cannot be abruptly changed to absorb the induced potential.In short, the flyback diode is connected in parallel to the relay or the inductor at both ends of the circuit. When the inductor is powered off, the electromotive force at both ends does not disappear immediately. At this time, the residual electromotive force is released through a freewheeling diode to reverse the reverse generated by the coil (the EMF is consumed in the form of current). It can be seen that the freewheeling diode is not a substantial component, but plays a "freewheeling" role in the circuit.For example, reversely connect a flyback diode at both ends of a relay coil or at both ends of a unidirectional thyristor. In practice, electromagnetic relays are usually controlled by triodes or MOS tubes to achieve automatic control of electrical loads (such as through a single-chip microcomputer), and the coil of the relay is a large inductance, which can store electrical energy in the form of a magnetic field. So when it pulls in, it stores a lot of magnetic field. When the triode controlling the relay changes from on to off, the coil is powered off, but there is a magnetic field in the coil. At this time, the back electromotive voltage can be as high as 1000v to destroy other circuit components. This is because the access of the diode is exactly the same as the direction of the reverse electromotive force. So that the reverse potential is neutralized by the freewheeling diode in the form of current to protect other circuit components. In addition, it is generally a diode with a fast switching speed.  Figure 3. Freewheeling Diode CircuitBecause the relay coil exists inductive load, which will absorb the self-inductive voltage of the relay coil when the triode is turned off. According to Lenz's law, when the current on the inductor decreases, a self-inductive voltage is generated. The direction of this voltage is that the forward terminal is negative and the collector of the driving tube is positive. This voltage will break through the triode, so an freewheeling diode is connected in parallel with the relay to absorb this self-inductive voltage.1) The influence of the time parameter of the circuit below the ms level on the mechanical contact is ignored.2) Even the 1N4000 reverse recovery time is far below the ms level, and the forward conduction time is shorter.3) Capacitance between the driving tubes and parasitic capacitance of the relay is enough to disable the high-speed diode.4) The consumption of inductive energy storage mainly depends on the winding resistance, which is generally in an overdamped state.It is general to use transistors as switches. As shown in Figure, a transistor TR1 is used to control the conduction of the relay coil, and the relay contact is used to control the load circuit.In a thyristor circuit, the thyristor is generally used as a contact switch, if a large inductive load is controlled, a high-voltage back electromotive force will be generated, and the principle is the same as that of a relay.Flyback diode also used on displays coils commonly used in relays. It is often used with energy storage elements to prevent sudden changes in voltage and current and provide a path. The inductor can provide continuous current to the load to avoid sudden changes in load current and smooth the current. In the switching power supply, it is common to see a freewheeling circuit composed of a diode and a resistor connected in series. The following circuit is connected in parallel with the primary side of the transformer. Figure 4. Flyback Diode in Relay CircuitThe freewheeling diode is added to both ends of the inductive load, and the inductive here is to have an inductive characteristic. The characteristic of the inductive load is that the current cannot be abruptly changed, in other words, it can't be all of a sudden. Common inductive loads include relay coils and solenoid valves.Figure 5.  Typical Freewheeling CircuitThe Figure 5 shows the typical application circuit of the flyback diode, where the resistor R determined whether it is needed or not. When the energy storage element VT is turned on, the upper voltage is positive, and the lower voltage is negative, and the current direction is from top to bottom. When the VT is turned off, the current in the energy storage element is suddenly interrupted, and an induced potential is generated at this time. This induced potential and the power supply voltage are superimposed and applied to both ends of the VT, which can easily cause VT to break down. VD can be added for this purpose, so that the induced potential generated by the energy storage element can be short-circuited to achieve the purpose of protecting the VT. Ⅳ Selection1) Based on working voltage2) Based on working current1N4007 is a not bad choice but not the best, because the PLC may be damaged before the diodes have time to play the freewheeling effect. Therefore, it is best to use FR107 to protect the freewheeling circuit, which can better protect the PLC output interface, and the cost will not rise too much. It is also possible to choose IN5819 or IN5817, which has better performance than FR107, but the cost is a little higher. Ⅴ Applications5.1 SummaryFlyback diodes are usually used with energy storage elements, and their role is to prevent sudden changes in voltage and current in the circuit and provide a power-consuming path for reverse electromotive force. The inductive coil can provide continuous current to the load through EMF, so as not to change the load current and smooth the current. In the switching power supply, a freewheeling circuit always composed of a diode and a resistor connected in series. This circuit is connected in parallel with the primary side of the transformer. When the switch is turned off, the freewheeling circuit can release the energy stored in the transformer coil to prevent the induced voltage from being too large and breakdown the switch.5.2 In Forward Switching Power SupplyIn the forward switching power supply, when the MOS is turned off, the secondary side of the transformer provides current to the outside by the energy stored in the inductor. In order to make the inductor play this role under load, a freewheeling diode is added on the secondary side of the transformer. The inductor, load, and freewheeling diodes create paths to transfer the energy in the inductor to the outside.5.3 In Converter TechnologyIn the electronic converter circuit, the single-phase bridge rectifier in the rectification section is the single-phase rectifier circuit with the most practical applications. And three-phase bridge rectification is the most widely used method for power systems, especially generator excitation systems. Both of these circuits must be connected to a flyback diode. Its function is almost the same. Take a single-phase bridge circuit as an example: When the rectifier bridge is connected to an inductive load, because the inductor current cannot be abruptly changed, during the thyristor off time, it must connect freewheeling diode at both ends of the load to provide a smoothing path  to prevent dangerous overvoltages across the inductive load, and also the thyristor can be commutated to conduct.The three-phase bridge rectifier circuits used in generator excitation systems are divided into three-phase half-control bridges and three-phase full-control bridge circuits. Therefore, in order to ensure reliable commutation of the rectifier components, the half-control bridge needs to connect flyback diodes in parallel at both ends of the inductive load, while the full-control bridge does not need to do so. In addition, when the conduction angle is changed, the average voltage and line current of the half-controlled bridge change more slowly than the full-controlled bridge.At present, current converters such as rectifiers and inverters are now used in a large number of devices, in which flyback diodes are typically added to the internal DC bus of the converter. Because if the load is an inductive element, when a large-capacity inverter on the bus fails, the DC bus will generate huge reverse surge energy. At this time, it is necessary to provide a discharge channel for this energy, otherwise it will break down or burn the converter. This channel needs a diode to form, that is a flyback diode.5.4 In Unidirectional Half Wave Silicon Control Rectifier CircuitFor unidirectional half-wave silicon control rectifier circuit with large inductive load, when the  silicon control is turned off in the negative half cycle, the inductive load will generate a high reverse induced electromotive force. This reverse electromotive force is sufficient to cause the silicon control to break down and burn. After that, the reverse electromotive force can be discharged into the forward voltage drop of the diode (about 0.7V), thereby effectively protecting the circuit components. 5.5 In BUCK Circuit Figure 6. BUCK CircuitIn the BUCK circuit, fast recovery diodes or Schottky diodes are generally selected as freewheeling diodes. It is generally used in the circuit to protect components from being broken down or burned by induced voltage. The two ends of the element form a loop with it, so that the high electromotive force generated in the loop is consumed in a continuous current manner, thereby protecting the elements in the circuit.In theory, the diode is selected at least 2 times the maximum current. In actual use, due to the strong transient overload resistance of the diode, an ultra-fast diode with a maximum current of 50A can also be used. In addition, a reasonable heat sink generally has little damage in actual use. The total impedance when conducting is the internal resistance of the motor plus the equivalent internal resistance of the drive tube. And the total impedance during freewheeling is the internal resistance of the motor plus the equivalent internal resistance of the freewheeling diode. In general, the AC equivalent internal resistance of the freewheeling diode is smaller than the AC equivalent internal resistance of the driving transistor. Therefore, in conventional design, the maximum current of the freewheeling diode is generally doubled to the maximum current of the motor.The transient current is only a moment, and the anti-overload capability of the surface-contact diode is enough, as long as it is not used in overvoltage, if necessary, a small resistor can be connected in series to limit the current. The flyback diode is to protect the switching device. The transient current during freewheeling is related to the working voltage of the motor and the internal resistance of the winding, and has nothing to do with the power of the motor. If necessary, the peak value of the transient current is the reverse self-inductance voltage minus diode junction voltage drop and then divided by the loop resistance. The reason why a diode with a certain current used is because the internal resistance of the winding of the low-voltage high-power motor is low, so the transient current will be relatively large. A series of small resistors can suppress the peak current, the transient voltage of the switch tube rises slightly because the operating voltage is not high, and now the current withstand voltage of transistors is at least 50V or more. Ⅵ Something Has to CareFreewheeling diodes are commonly used in switching power supplies, relay circuits, thyristor circuits, IGBTs, and other circuits. They are widely used, so it is necessary to pay attention to the following points when using them: 1) Fylback diode is an effective method to prevent the high voltage generated by self-inductive potential from causing damage to related components when the DC coil is powered off.2) The polarity of the flyback diode must not be connected wrongly, otherwise a short circuit situation will be caused.3) The flyback diode is always reversed to the DC voltage, that is, the negative pole of the diode is connected to the positive pole of the DC power supply.4) The flyback diode works in the forward conduction state, not in the breakdown state or the high-speed switching state, that is, the flyback diode does not used in electrical breakdown, recoverable situation, but its unidirectional conduction effect is the key point.5) Zener diodes can't be regarded as flyback diode. Because the zener diodes use reverse characteristics, and the flyback diodes use forward characteristics. Frequently Asked Questions about Flyback Diode or Freewheeling Diode1. What is a flyback diode?A flyback diode is a diode connected across an inductor used to eliminate flyback, which is the sudden voltage spike seen across an inductive load when its supply current is suddenly reduced or interrupted. 2. What is the role of freewheeling diode?A Flyback diode is also called as freewheeling diode. ... Here catch diode is used to eliminate flyback, when the abrupt voltage spike is witnessed across the inductive load when the supply current abruptly reduced. It helps the circuit from damaging. 3. What is a flyback diode used for?A flyback diode is a diode connected across an inductor used to eliminate flyback, which is the sudden voltage spike seen across an inductive load when its supply current is suddenly reduced or interrupted. 4. How does a flyback diode work?The Flyback diode makes inductor to draw current from itself in a loop until the energy is dissipated in diode and wires. When the current flow to an AC induction motor is suddenly interrupted, then the inductor tries to maintain increasing the voltage and the current by reversing polarity. 5. How do you choose a freewheeling diode?The diode reverse voltage rating should be at least the voltage applied to the relay coil. Normally a designer puts in plenty of reserve in the reverse rating. A diode in your application having 50 volts would be more than adequate. Again 1N4001 will do the job. 6. How do I choose a flyback diode for a relay?Specify a diode for at least 79.4 mA current. In your case, a 1N4001 current rating far exceeds the requirement. The diode reverse voltage rating should be at least the voltage applied to the relay coil. Normally a designer puts in plenty of reserve in the reverse rating. 7. What are the advantages of freewheeling diode?What are the advantage of free wheeling diode in a Full Wave rectifier? It reduces the harmonics and it also reduces sparking and arching across the mechanical switch so that it reduces the voltage spike seen in a inductive load. 8. Why freewheeling diode is used in controlled rectifier?When the inductive circuit is switched off, this diode gives a short circuit path for the flow of inductor decay current and hence dissipation of stored energy in the inductor. This diode is also called Flywheel or Fly-back diode. circuits, inverter circuits, and chopper circuits by making it continuous. 9. What is the effect of adding free wheeling diode?It reduces the harmonics and it also reduces sparking and arching across the mechanical switch so that it reduces the voltage spike seen in a inductive load. 10. What is the use of freewheeling diode in converter circuit?A free wheeling diode is used in converter circuits . It is connected across the load. During positive cycle of input it is reverse biased. During negative cycle of input the diode conducts and the energy stored in the circuit inductor during the previous half cycle is delivered to the load itself.

 This article is a brief introduction to contactor.  Catalog  I. What is a Contactor?II. Differences Between Contactor and RelaysIII. Contactor Working PrincipleIV. About Arc SuppressionFAQ I. What is a Contactor? As an essential part of the motor control gear, the most widespread switching device used in a starter is the a,c. airbrake contactor which consists of contact assemblies actuated by electromagnetic action. An operating coil is enclosed by the magnetic yoke, as well as when energized attracts an armature to which is attached a set of moving contacts which make with a set of stationary contacts. Modern contractors use a silver alloy contact tip, normally silver–cadmium oxide or silver–tin oxide alloy attached to a brass or copper backing strip. The choice of tip material is critical and is normally established after many types of tests.  Note: The rating of the contactor depends on the size, shape, and material of the contacts and on the efficiency of the arc extinction method used. An electrical contactor is an electromagnetic switch similar to a relay. It is a switch that can be controlled with the current/pulse to switch over an electrically powered circuit. II. Differences Between Contactor and Relays Let me put forward a basic question firstly:If you see in industrial control panels, both relays and contractors are used for the same purpose, so why different names? Both of them perform the same task. The relay is usually used in low voltage paths such as switching tube-light or small LEDs. The contactor is used in electrical circuits of industrial motors or other heavy applications. So, the difference is from an application point of view. The basic working principle is the same for both. The relay behaves similarly to how a contractor works. If you want to switch circuits with high voltages, use contactors and if you want to switch light voltages then the relay is ready for you.  It is important to note here the difference between protection and switching. A relay is a protection device whereas a contactor cannot assure you about protection. The relay can differentiate between normal & abnormal conditions and give command accordingly which contactor cannot. Switching means to break and make a circuit and a contactor is mainly used for that purpose. III. Contactor Working Principle When the contactor coil is de-energized, gravity or a spring returns the electromagnet core to its initial position and opens the contacts. For contactors energized with alternating current, a small part of the core is surrounded by a shading coil, which slightly delays the magnetic flux in the core. The following video will help you understand the working principle of contactor more intuitively:  IV. About Arc Suppression Most motor control contactors at low voltages (600 volts and less) are air brake contactors; air at atmospheric pressure surrounds the contacts and extinguishes the arc when interrupting the circuit. Modern medium-voltage AC motor controllers use vacuum contactors. High voltage AC contactors (greater than 1,000 volts) may use a vacuum or an inert gas around the contacts. High voltage DC contactors (greater than 600V) still rely on air within specially designed arc-chutes to break the arc energy. High-voltage electric locomotives may be isolated from their overhead supply by roof-mounted circuit breakers actuated by compressed air; the same air supply may be used to "blow out" any arc that forms.Without adequate contact protection, the occurrence of electric current arcing causes significant degradation of the contacts, which suffer significant damage. An electrical arc occurs between the two contact points (electrodes) when they transition from a closed to an open (break arc) or from an open to a closed (make arc). The break arc is typically more energetic and thus more destructive. Without adequate contact protection, the occurrence of electric current arcing causes significant degradation of the contacts, which suffer significant damage. An electrical arc occurs between the two contact points (electrodes) when they transition from a closed to an open (break arc) or from an open to a closed (make arc). The break arc is typically more energetic and thus more destructive.FAQ 1. What is the main function of contactor?Function of contactor, generally used for connected and disconnected of electric current supply. Usually in use for applications: motors, heater, lighting or electric power distribution. 2. Why do we need contactors?Contactors are used for high power applications. They allow a lower voltage and current to switch a much higher power circuit, so they are generally larger and more heavy-duty than control relays, enabling them to switch higher power loads on and off for many thousands of cycles. 3. How a contactor is wired?Break your circuit, L N E through your contactor. Link a permanent live and a neutral from your supply to your coil (Al + A2) then use your switch feed to your photocell from A1, and switch the wire to the switched phase of your contactor load. This should now open when light, close when dark. 4. What is NO and NC In Contactor?Normally Open (NO) and Normally Closed (NC) terms refer to type of dry contact or wet contact. Put very simply, a Normally Open sensor will have no current when in a normal state but when it enters an alarm state it will have +5V applied to the circuit. 5. How many types of contactors are there?The contacts are classified as power contact, auxiliary contact, and contact spring. There are two types of power contact; stationary contact and movable contact. The material used for the contacts has stable arc resistance and high welding resistance. 6. Why contactor is used?Contactors are used for high power applications. They allow a lower voltage and current to switch a much higher power circuit, so they are generally larger and more heavy-duty than control relays, enabling them to switch higher power loads on and off for many thousands of cycles 7. What is the difference between a relay and a contactor?A contactor joins 2 poles together, without a common circuit between them, while a relay has a common contact that connects to a neutral position. Additionally, contactors are commonly rated for up to 1000V, while relays are usually rated to only 250V. 8. What are the types of contactors?There are different types of contacts in a contactor, and they are; auxiliary contact, power contact, and contact spring. The power contact has two types that are; stationary and movable contact. Material for making contacts must have a high welding resistance and stable arc resistance. 9. What are the three major parts of a contactor or relay?There are three major parts of a contactor or relay: the coil, mechanical linkage and contacts. The coil is used to create a magnetic field and is rated based on voltage (24 V, 120 V, 208/204 V, 480 V). The mechanical linkage connects the armature to the contacts when the coil is energized, completing the circuit. 10. How contactor is connected?A contactor is typically controlled by a circuit which has a much lower power level than the switched circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch. Unlike general-purpose relays, contactors are designed to be directly connected to high-current load devices. 

This article introduces stepper motor at full length.There are five parts of this article--the definition of stepper motor; types of steppers; how a stepper motor work; how to select and the basic wiring.  CatalogI. What is a Stepper Motor?II. Types of Stepper MotorsIII. How Does a Stepper Motor WorkIV. How to Select a Stepper motorV. Basic Wiring of Stepper MotorFAQI. What is a Stepper Motor? A Stepper Motor or a step motor is a brushless, synchronous motor which divides a full rotation into a number of steps. Unlike a brushless DC motor which rotates continuously when a fixed DC voltage is applied to it, a step motor rotates in discrete step angles. The Stepper Motors therefore are manufactured with steps per revolution of 12, 24, 72, 144, 180, and 200, resulting in stepping angles of 30, 15, 5, 2.5, 2, and 1.8 degrees per step. The stepper motor can be controlled with or without feedback.   II. Types of Stepper MotorThere are a wide variety of stepper types, some of which require very specialized drivers. By construction the step motors come into three broad classes: 1.Permanent Magnet StepperPermanent magnet motors tend to "cog" as you twist the rotor with your fingers, while variable reluctance motors almost spin freely (although they may cog slightly because of residual magnetization in the rotor). You can also distinguish between the two varieties with an ohmmeter. Variable reluctance motors usually have three (sometimes four) windings, with a common return, while permanent magnet motors usually have two independent windings, with or without center taps. Center-tapped windings are used in unipolar permanent magnet motors. 2.Variable Reluctance StepperJust as resistance determines the flow of electric current, reluctance determines the flow of magnetic flux. In a variable reluctance (VR) stepper, the rotor turns at a specific angle to minimize the reluctance between opposite windings in the stator. The primary advantage of VR steppers is that they have an excellent angular resolution. The primary disadvantage is low torque. 3. Hybrid Step MotorHybrid stepper motors provide excellent performance in areas of torque, speed, and step resolution. This type of motor provides a combination of the best features available on both the PM and VR types of stepper motors. Permanent magnet and hybrid stepper motors are two types of the most commonly used stepper motors. Permanent magnet and hybrid stepper motors are two types of the most commonly used stepper motors. III. How Does a Stepper Motor Work Stepper motors consist of a permanent magnetic rotating shaft, called the rotor, and electromagnets on the stationary portion that surrounds the motor called the stator. Figure above illustrates one complete rotation of a stepper motor. At position 1, we can see that the rotor is beginning at the upper electromagnet, which is currently active (has voltage applied to it). To move the rotor clockwise (CW), the upper electromagnet is deactivated and the right electromagnet is activated, causing the rotor to move 90 degrees CW, aligning itself with the active magnet. This process is repeated in the same manner at the south and west electromagnets until we once again reach the starting position.  In the above example, we used a motor with a resolution of 90 degrees for demonstration purposes. In reality, this would not be a very practical motor for most applications. The average stepper motor's resolution -- the number of degrees rotated per pulse -- is much higher than this. For example, a motor with a resolution of 5 degrees would move its rotor 5 degrees per step, thereby requiring 72 pulses (steps) to complete a full 360-degree rotation. You may double the resolution of some motors by a process known as "half-stepping". Instead of switching the next electromagnet in the rotation on one at a time, with half-stepping you turn on both electromagnets, causing an equal attraction between, thereby doubling the resolution. As you can see in Figure 2, in the first position only the upper electromagnet is active, and the rotor is drawn completely to it. In position 2, both the top and right electromagnets are active, causing the rotor to position itself between the two active poles. Finally, in position 3, the top magnet is deactivated and the rotor is drawn all the way right. This process can then be repeated for the entire rotation.  IV. How to Select a Stepper Motor Selecting between a servo motor and a stepper motor can be quite a challenge involving the balancing of several design factors. Cost considerations, torque, speed, acceleration, and drive circuitry all play a role in selecting the best motor for your application.  At first, we need to know the basic differences between stepper and servo motors.   Stepper and servo motors differ in two key ways, in their basic construction and how they are controlled.  Stepper motors have a large number of poles, magnetic pairs of north and south poles generated either by a permanent magnet or an electric current, typically 50 to 100 poles. In comparison, servo motors have very few poles, often 4 to 12 in total. Each pole offers a natural stopping point for the motor shaft.  Driving a stepper motor to a precise position is much simpler than driving a servo motor. With a stepper motor, a single drive pulse will move the motor shaft one step, from one pole to the next. Since the step size of a given motor is fixed at a certain amount of rotation, moving to a precise position is simply a matter of sending the right number of pulses. In contrast servo motors read the difference between the current encoder position and the position they were commanded to and just the current required to move to the correct position.The greater number of poles allows a stepper motor to move accurately and precisely between each pole and allows a stepper to be operated without any position feedback for many applications. Servo motors often require a position encoder to keep track of the position of the motor shaft, especially if precise movements are required. Note that with today's digital electronics, stepper motors are much easier to control than servo motors. All in all, Selecting the best motor for your application depends on a few key design criteria for your system including cost, positional accuracy requirements, torque requirements, drive power availability, and acceleration requirements. Overall, servo motors are best for high speed, high torque applications while stepper motors are better suited for lower acceleration, high holding torque applications. V. Basic Wiring of Stepper Motor  Stepper motors are available in two basic wiring configurations, bipolar and unipolar. Unipolar motors have one winding with a center tap for each phase. This allows the motor direction to be reversed easily by changing which section of the phase is powered rather than reversing the flow of current. This allows the control circuitry to be very simple. Unipolar motors typically have six leads, three for each phase, but can also be found with five leads, with the center tap of both phases internally connected. Unipolar motors can be easily controlled with a microcontroller or stepper motor controller and are very affordable.  Bipolar motors have one or two windings without a center tap for each phase. In order for the direction of rotation to be reversed on a bipolar motor, the current direction needs to be reversed. This requirement makes the driving circuitry more complicated and is generally implemented with an H-bridge control arrangement or an H-bridge motor driver. While more complicated to drive, bipolar motors are much stronger for the same weight and size. Bipolar motors can be configured with series or parallel windings, allowing them to be driven with the lower current in series or higher inductance and greater torque in parallel. Bipolar motors generally have four or eight leads, two or four per phase, allowing them to be distinguished from the five and six-lead unipolar motors. FAQ 1. What is a stepper motor used for?The stepper motor is used for precise positioning with a motor, such as hard disk drives, robotics, antennas, telescopes, and some toys. Stepper motors cannot run at high speeds, but have a high holding torque. 2. What is a stepper motor and how does it work?Stepper motors are DC motors that move in discrete steps. They have multiple coils that are organized in groups called "phases". By energizing each phase in sequence, the motor will rotate, one step at a time. With a computer controlled stepping you can achieve very precise positioning and/or speed control. 3. What is the working principle of stepper motor?The basic working principle of the stepper motor is the following: By energizing one or more of the stator phases, a magnetic field is generated by the current flowing in the coil and the rotor aligns with this field. 4. Are stepper motors AC or DC?Stepper motors are DC motors that move in discrete steps. They have multiple coils that are organized in groups called "phases". By energizing each phase in sequence, the motor will rotate, one step at a time. With a computer controlled stepping you can achieve very precise positioning and/or speed control. 5. How long do stepper motors last?4.8 yearsThe typical lifetime for a stepper motor is 10,000 operating hours. This approximates to 4.8 years; given the stepper motor operates one eight-hour shift per day. The lifetime of a stepper motor may vary in regards to user application and how rigorous the stepper motor is run. 6. Do stepper motors need drivers?Stepper motors require a driver. There are usually 200 steps per revolution or 1.8 degrees per step (but they also can be “micro-stepped”). In general, you use an H-driver to reverse a DC motor, but it can also be done with a DPDT relay. 7. Do stepper motors go bad?Stepper motors very rarely go bad. It's possible, like a bearing fails. More often the wiring goes bad, or the stepper driver, or the driver overheats. 8. Why is it called stepper motor?Stepper motors are so named because each pulse of electricity turns the motor one step. Stepper motors are controlled by a driver, which sends the pulses into the motor causing it to turn. 9. What are the three types of stepper motor?There are three main types of stepper motors:Permanent Magnet Stepper. Variable Reluctance Stepper.Hybrid Syncronous Stepper. 10. How is stepper motor different from DC motor?The stepper motor operates in open loop whereas Direct current motor operates in closed loop. Stepper are are easy to control with the help of microprocessors and other controlling devices. Control of DC motor is not easy. ... DC motor has a continuous displacement and can be controlled accurately and positioned exactly.  11. Do stepper motors have brushes?Stepper motors are different from ordinary DC motors in at least four important ways. The first difference you notice is that they have no brushes or commutator (the parts of a DC motor that reverse the electrical current and keep the rotor—the rotating part of a motor—constantly turning in the same direction). 12. What voltage is a stepper motor?Stepper motors have a rated voltage and current. A typical stepper motor like our NEMA 17 might have a rated voltage of 2.8 Volts and a maximum current of 1.68 Amps. This basically means if you hook it up to 2.8 Volts it will draw 1.68 Amps. 13. Why do stepper motors fail?One of the major problems with a stepper motor is complete motor failure. This problem is caused by excessive current being sent to the device by the power supply. A short circuit in the wiring from the power supply to the motor cause this problem with the stepper motor. Some application will cause this short circuit. 14. Can stepper motors run continuously?Stepper motors fall somewhere in between a regular DC motor and a servo motor. They have the advantage that they can be positioned accurately, moved forward or backwards one 'step' at a time, but they can also rotate continuously. 15. How do I choose a stepper motor driver?A simple way to choose a stepper drive is to look for four things — voltage, current, microstepping, and maximum step pulse rate. Ensure that the drive can handle a wide range of current so that you can test the system at different voltage levels to fit your application.  

Texas Instruments (TI) (NASDAQ:TXN) today introduced two new device families that help reduce size and weight in motor drive applications. When used together, DRV832x brushless DC (BLDC) gate drivers and CSD88584/99 NexFET™ Power Blocks require as little as 511 mm2, half the board space of competing solutions.The DRV832x BLDC gate drivers feature a smart gate-drive architecture that eliminates up to 24 components traditionally used to set the gate drive current while enabling designers to easily adjust field-effect transistor (FET) switching to optimize power loss and electromagnetic compliance. The CSD88584Q5DC and CSD88599Q5DC power blocks leverage two FETs in a unique stacked-die configuration, which doubles power density and minimizes the FET resistance and parasitic inductances typically found in side-by-side FET configurations.An 18-volt compact BLDC motor reference design demonstrates how the DRV8323 gate driver and CSD88584Q5DC power block can drive 11 W/cm3 power and enable engineers to jump-start their designs for smaller, lighter-weight power tools, integrated motor modules, drones and more. Benefits of using a CSD88584/99 and DRV832x device togetherMaximum power density: The combined solution delivers 700 W of motor power without a heat sink, providing 50 percent higher current than conventional solutions without increasing the footprint.High peak current: As demonstrated by the 18-volt BLDC reference design, the smart gate driver and power block are capable of driving a peak current of up to 160 A for more than 1 second.Optimal system protection: The combination enables shorter trace lengths and actively prevents unintended FET turn-on, while also providing undervoltage, overcurrent and thermal protection.Superior thermal performance: The CSD88584Q5DC and CSD88599Q5DC power blocks come in TI's DualCool™ thermally enhanced package, which enables designers to apply a heat sink to the top of the device to decrease thermal impedance and increase the amount of power dissipated to maintain safe operating temperatures for the board and end application.Clean switching: The power blocks' switch-node clip helps eliminate parasitic inductance between high- and low-side FETs. Additionally, the DRV832x gate driver's passive component integration minimizes board traces.Tools and support to jump-start designIn addition to the 18-volt BLDC motor reference design, engineers can search for other motor reference designs that use the power blocks and gate drivers to help solve their system design challenges. The three-phase smart gate-driver evaluation module (EVM) allows designers to drive a 15-A, three-phase BLDC motor using the DRV8323R gate driver, CSD88599Q5DC power block and MSP430F5529microcontroller LaunchPad™ development kit. The EVM is available from the TI store for US$99.00.Package, availability and pricingThe new DRV832x BLDC smart gate drivers offer peripheral and interface options for engineers to select the best device for their design: with or without an integrated buck regulator or three integrated current-shunt amplifiers. Each device option is available in a hardware or serial interface and comes in quad flat no-lead (QFN) packaging. The CSD88584/99 power blocks come in DualCool small outline no-lead (SON) packaging, with 40- or 60-V breakdown voltage (BVDSS) choices.   Ref:KY32-MSP430F5529IPNKY362-DRV8301-69M-KITKY32-DRV8301DCAR