The traditional solution with corrosion problems was to seal the stepper motor in order to prevent moisture that leads to inside corrosion. Shaft seals and end cap/housing seals will delay, but not stop the incursion of moisture into the stepper motor. Moisture will finally find a way through any seal helped by temperature fluctuations. Once the moisture is inside the motor, the seals act as a barrier to any remotion of the moisture. In addition, shaft seals normally cause a loss of 4 to 20% of motor torque due to the rubbing friction. What's more, as the motors repeatedly carry out cycles of heating and cooling again and again, the air inside the stepper motor expands and shrinks. As the air inside the step motor shrinks, a small amount of moisture is inhaled inside the stepper motor. This eventually bring about some internal corrosion, to which hybrid stepper motors are susceptible in particular.

A New Design Technique For Stepper Motor Prevent Corrosion

Currently, a new design technique produces corrosion-proof and waterproof stepper motors, extending the stepper motor life in harsh rugged environment. Stepper motors used at outdoors condition are susceptible to temperature extremes and moisture, causing internal corrosion that quickly shortens stepper motor life, and causing early stepper motor failure also. However, the new technique to preventing corrosion and early failure uses a system of rugged corrosion proof coatings that are applied to all metallic surfaces both inside and outside the stepper motor, protecting them from moisture and corrosion.

The coatings that were antecedently used were not rugged enough to protect the soft-iron magnetic and metallic materials inside a stepper motor during its design life. The new technique applies the coating to every surface and structure inside and outside the stepper motor, including the stepper motor rotor, stator, and housing. It essentially coats every surfaces that could potentially rust, such as steel and aluminum. The material selections and coatings are tailored for each stepper motor component. For example, the permanent magnets, aluminum end housings, and steel laminations use coatings, and promoted base materials as required to protect the components from corrosion, while maintaining the stepper motor's performance.

Part two