On Mon, 2011-02-07 at 13:01 -0800, Michael Jones wrote:

> I am running a set of KL23H276-28-4B on a little Shereline CNC mill with EMC
> running to a Geck G540 controller.  

> I've noticed that after a while (even just sitting still with the machine
> powered) that the steppers are very warm (I haven't checked actual temp
> yet).  They're not so warm you can't touch them, but not comfortable to hold
> on tight for long (imagine the temp of a fresh cup of coffee in a paper
> cup). 

> Is this "normal" should I be concerned.   They don't seem to get any hotter
> than that, running or standing still with power on doesn't seem to make a
> difference.  

A stepper is full on all of the time, even at rest (unless your drive
has a park current feature). What makes the motor move is a change in
which coil is full on. The heat is a waste product and is similar to the
heat given off from a resistor. The heat from a resistor is Watts =
Volts x Amps = Amps^2 x Resistance. 
http://en.wikipedia.org/wiki/Watt 

As long as there is current going through the stepper motor, it will be
giving off heat. I found on my test bench that the motor I was playing
with actually gave off a lot more heat at rest. I believe this is
because one coil is on full time, where as when the stepper is in
motion, back EMF lowers the effective voltage, the steps have current
gaps between steps, and the heat is spread over more area (two or four
coils instead of one).

I believe to keep from skipping steps, you want to drive the stepper as
hard as you can. Usually, the limiting factor is heat. How much heat
depends on the quality of the motor materials. The manufacturer may have
a specification for the motor in question. If so, drive your motor so
that it comes close to this temperature, but not over it for an extended
period. A fan could be useful too, but you should have a temperature
activated cut-out in case the fan fails.
-- 
Kirk Wallace
http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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