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Please read the instructions in all the other parts of this HTML documentation (Web site) before trying to hook-up any R/C Booster to your stepper motors. Using a R/C Booster on some circuit you have purchased ready made, or one that you built from parts, may damage the circuit. You should not connect a booster to a circuit unless you are sure that doing so will not cause damage to the circuit or damage to the motor being used. This information is intended only for use by technically knowledgeable persons in testing my CAM programs DANCAM.EXE (tm) and DANPLOT.EXE (tm) and is not recommended to be used with or incorporated into commercial products.
Steps to hook-up to a R/C Booster:
Make a stepper motor coil drive amplifier that will pass 3 to 10 times the motor's holding voltage, and about 1.25 to 2 times the coils rated current.
Use a motor supply voltage 3 to 10 times the motor's rated voltage.
Adjust the current limiting resistors to pass slightly less than the motors rated current when the motor is stopped.
Adjust the parallel capacitors to give an improvement in the high speed torque without over boosting the motor and burning out the motor's coils or the stepper motor drive amplifier's parts .
Test the motor for stability, and to see if the motor will overheat when running the type of tool path file that you will need to be using.
The drawing GRAPH1 effect of R/C booster circuit, shows the effect of using a capacitor across, i.e. in parallel to, the series current limiting resistor used to control the maximum current of a stepper motor. Four sets of resistors and capacitors were used in this example since the drive used was unipolar. Notice that at the maximum operating speed of 120 RPM the torque gain using the parallel capacitors is about 100 percent or so. The test conditions for GRAPH1 were: SIGMA motor #20-3424D-24244, about a 35 volt motor supply, the resistors were 25 ohm 50 watt, the capacitors were electrolytic type rated at 80 mf and 50 volts. In the schmatics at the bottom of the drawing the inductor is one of the motor coils.
If you were going to try this with a Bi-polar motor the capacitor would have to be of the non-polar type, since the voltage would be reversing across the capacitor.
This type of booster will only produce practical improvement if the load matches the motor torque in the operating area between the un-boosted and the boosted torque vs. speed on the graph. In GRAPH1 if the torque needed is over the solid line the motor will stall, and if the torque needed is below the dotted line, no difference will be noticed between the boosted and un-boosted circuits since both would operate the machine.
Notice that even with the booster used, the torque at high speed is less than at low speed. In GRAPH1 a 40 in-oz load can be used up to about 120 RPM with the booster, and only to about 75 RPM without the booster. This would be about the maximum amount of improvement that one can expect to get from this type of booster, you might get less improvement because of the inductance of your motor, the voltage ratio between the motor and motor supply, the match between your motor and load, the inertia of the load, and other such factors.
