When designing and optimizing a stepping motor, accurately predicting its performance is crucial. However, due to the unique structure and operating conditions of these motors, engineers often make simplifying assumptions during calculations—such as neglecting magnetic saturation or assuming that the core’s magnetic pressure drop is independent of the rotor position. These approximations can introduce some degree of error into the results. To address this, this paper focuses on the BF36 magnetoresistive stepping motor, using finite element analysis to simulate the entire motor field with mesh auto-splitting technology. This approach allows for a more accurate assessment of the motor's magnetic field energy and static torque, considering real-world factors like magnetic saturation.
The BF36 is a three-phase reluctance stepping motor with 6 stator poles, each having 3 rectangular teeth, and a rotor with 20 evenly spaced teeth, spaced at 18 degrees. The rated voltage is 24V, and the rated current is 0.15A. It can be energized in either single-phase or two-phase modes. By applying a current to the stator coils and analyzing the resulting magnetic field distribution, we can calculate the static torque characteristics of the motor. Using numerical methods such as the Simpson integral, we determine the magnetic co-energy at different rotor positions, which is then used to compute the static torque.
By varying the rotor angle from 0° to 9°, and repeating the calculations, we obtain the relationship between current and flux linkage for each position. This helps us understand how the motor behaves under different conditions. The results show that when the motor is energized at its rated current, the calculated static torque values are close to the measured ones, confirming the accuracy of the method. For example, the maximum static torque error was found to be around 5.41% for single-phase operation and 7.34% for dual-phase operation.
In addition, the shape of the stator and rotor teeth significantly affects the motor’s performance. Through various simulations, it was found that the optimal tooth height should be close to the pitch, while the tooth width should be approximately 37.5% of the pitch. This configuration maximizes the static torque, providing a practical guideline for manufacturers during the design process.
In conclusion, this study demonstrates that by incorporating finite element analysis and accounting for magnetic saturation, we can achieve more accurate predictions of stepping motor performance. The findings not only validate the theoretical model but also offer valuable insights for improving motor design in industrial applications.
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