Boiler Control for Industrial Application using PIC

There are 2 type of Stepper Motor;

Bipolar Stepper Motor
Unipolar Stepper Motor

Unipolar Stepper Motors

The unipolar stepper motor has five or six wires and four coils (actually two coils divided by center connections on each coil). The center connections of the coils are tied together and used as the power connection. They are called unipolar steppers because power always comes in on this one pole.

Bipolar stepper motors

The bipolar stepper motor usually has four wires coming out of it. Unlike unipolar steppers, bipolar steppers have no common center connection. They have two independent sets of coils instead. You can distinguish them from unipolar steppers by measuring the resistance between the wires. You should find two pairs of wires with equal resistance. If you’ve got the leads of your meter connected to two wires that are not connected (i.e. not attached to the same coil), you should see infinite resistance (or no continuity).

Like other motors, stepper motors require more power than a microcontroller can give them, so you’ll need a separate power supply for it. Ideally you’ll know the voltage from the manufacturer, but if not, get a variable DC power supply, apply the minimum voltage (hopefully 3V or so), apply voltage across two wires of a coil (e.g. 1 to 2 or 3 to 4) and slowly raise the voltage until the motor is difficult to turn. It is possible to damage a motor this way, so don’t go too far. Typical voltages for a stepper might be 5V, 9V, 12V, 24V. Higher than 24V is less common for small steppers, and frankly, above that level it’s best not to guess.

To control the stepper, apply voltage to each of the coils in a specific sequence. The sequence would go like this:

Step	wire 1	wire 2	wire 3	wire 4
1	High	low	high	low
2	low	high	high	low
3	low	high	low	high
4	high	low	low	high

To control a unipolar stepper, you use a Darlington Transistor Array. The stepping sequence is as shown above. Wires 5 and 6 are wired to the supply voltage.

To control a bipolar stepper motor, you give the coils current using to the same steps as for a unipolar stepper motor. However, instead of using four coils, you use the both poles of the two coils, and reverse the polarity of the current.

The easiest way to reverse the polarity in the coils is to use a pair of H-bridges. The L293D dual H-bridge has two H-bridges in the chip, so it will work nicely for this purpose.

Once you have the motor stepping in one direction, stepping in the other direction is simply a matter of doing the steps in reverse order.

Knowing the position is a matter of knowing how many degrees per step, and counting the steps and multiplying by that many degrees. So for examples, if you have a 1.8-degree stepper, and it’s turned 200 steps, then it’s turned 1.8 x 200 degrees, or 360 degrees, or one full revolution.

Two-Wire Control

Thanks to Sebastian Gassner for ideas on how to do this.

In every step of the sequence, two wires are always set to opposite polarities. Because of this, it’s possible to control steppers with only two wires instead of four, with a slightly more complex circuit. The stepping sequence is the same as it is for the two middle wires of the sequence above:

Step	wire 1	wire 2
1	low	high
2	high	high
3	high	low
4	low	low

The circuits for two-wire stepping are as follows:

Unipolar stepper two-wire circuit:

Biolar stepper two-wire circuit:

Programming the Microcontroller to Control a Stepper

Because both unipolar and bipolar stepper motors are controlled by the same stepping sequence, we can use the same microcontroller code to control either one. In the code examples below, connect either the Darlington transistor array (for unipolar steppers) or the dual H-bridge (for bipolar steppers) to the pins of your microcontroller as described in each example. There is a switch attached to the microcontroller as well. When the switch is high, the motor turns one direction. When it’s low, it turns the other direction.

The examples below use the 4-wire stepping sequence. A two-wire control program is shown for the Wiring/Arduino Stepper library only.

Wire pins 9-12 of the BX-24 to inputs 1-4 of the Darlington transistor array, respectively. If you’re using the PicBasic Pro code, it’s designed for a PIC 40-pin PIC such as the 16F877 or 18F452. Use pins PORTD.0 through PORTD.3, respectively. If you’re using a smaller PIC, you can swap ports, as long as you use the first four pins of the port.

Note that the wires read from left to right. Their numbers don’t correspond with the bit positions. For example, PORTD.3 would be wire 1, PORTD.2 would be wire 2, PORTD.1 would be wire 3, and PORTD.0 would be wire 4. On the BX-24, pin 9 is wire 1, pin 10 is wire 2, and so forth.