If you suspect that the stepper motor of the machine is out of step, you can perform a simple test to identify the issue.
First, let's clarify what "out of step" means. Stepper motors typically come in three-phase or five-phase configurations. A three-phase motor usually has three LEDs on its controller, while a five-phase one has five. These LEDs indicate the motor’s movement sequence.
A three-phase motor has three sets of windings, meaning it uses three wires. The term "six-step" refers to the fact that the motor cycles through six steps before returning to the starting position. Each LED corresponds to one step, and the motor moves by 0.1 wire per step. When it completes two full rotations, it moves 0.6 wire in total.
If the motor is out of step, it often means that one or more phases are missing. This could be due to a broken wire in the motor or the controller. To check, you can manually move the motor step by step, advancing it by 0.1 wire each time. While doing this, feel if the motor is locked or not. If the LED is on but the motor isn’t locked, there may be an issue with that particular wire.
To begin, turn off all power and disconnect the motor from the controller. Identify the three main wires and locate the 24V power line. Use a multimeter to measure the resistance between the 24V line and the other two wires. Under normal conditions, the resistance should be around 8.5 ohms. If the reading differs significantly, there might be a problem with that wire.
If the motor passes the test, repeat the same process for the controller. If the issue is with the motor, trace back along the detected wire to find the fault. If the wire is simply broken, you may be able to repair it. However, if the damage is severe, replacing the motor might be necessary.
If the controller is at fault, continue checking the wiring connected to it. By following this methodical approach, you can isolate the problem and take appropriate action to fix it.
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