INTRODUCTION

Deveopment of Computer Numerically Controlled

(CNC) machnes s an outstandng contrbuton to the
manufacturng ndustres. It has made possbe the automaton
of the machnng process wth exbty to hande sma to
medum batch of quanttes n part producton.
Intay, the CNC technoogy was apped on basc meta
cuttng machne ke athes, mng machnes, etc. Later, to
ncrease the exbty of the machnes n handng a varety of
components and to nsh them n a snge setup on the same
machne, CNC machnes capabe of performng mutpe
operatons were deveoped. To start wth, ths concept was
apped to deveop a CNC machnng centre for machnng
prsmatc components combnng operatons ke mng,
drng, borng and tapng. Further, the concept of mut-
operatons was aso extended for machnng cyndrca
components, whch ed to the deveopment of turnng centers.
ADVANTAGES OF CNC AC!INE
Hgher exbty
Increased productvty
Consstent quaty
Reduced scrap rate
Reabe operaton
Reduced non productve tme
Reduced manpower
Shorter cyce tme
Hgh accuracy
Reduced ead tme
|ust n tme (|IT) manufacture
Automatc matera handng
Lesser oor space
Increased operaton safety
1
Machnng of advanced matera
2
3
CNC S"STES
INTRODUCTION
Numerical control (NC) s a method empoyed for
controng the motons of a machne too sde and ts auxary
functons wth nput n the form of numerca data. A computer
numerca contro (CNC) s a mcroprocessor-based system to
store and process the data for the contro of sde motons and
auxary functons of the machne toos. The CNC system s
the heart and bran of a CNC machne whch enabes the
operaton of varous machne members such as sdes,
spndes, etc. as per the sequence programmed nto t,
dependng on the machnng operatons.
The man advantage of a CNC system es n the fact that
the sks of the operator htherto requred n the operaton of a
conventona machne s removed and the part producton s
made automatc.
The CNC systems are constructed wth a NC unt
ntegrated wth a programmabe ogc controer (PLC) and
some tmes wth an addtona externa PLC (non-ntegrated).
The NC contros the spnde movement and the speeds and
feeds n machnng. It cacuates the traversng path of the
axes as dened by the nputs. The PLC contros the perphera
actuatng eements of the machne such as soenods, reay
cos, etc. Workng together, the NC and PLC enabe the
machne too to operate automatcay. Postonng and part
accuracy depend on the CNC system's computer contro
agorthms, the system resouton and the basc mechanca
machne accuracy. Contro agorthm may cause errors whe
computng, whch w reect durng contourng, but they are
very neggbe. Though ths does not cause pont to pont
postonng error, but when mechanca machne n accuracy
are present, t w resut n poorer part accuracy.
4
Ths chapter gves an overvew of the conguraton of the
CNC system, nterfacng and ntroducton to PLC programmng.
CONFIGURATION OF T!E CNC S"STE
Fi#$% shows a schematc dagram of the workng prncpe
of a NC axs of a CNC machne and the nterface of a CNC
contro.
CNC &y&tem
Fi#$% Sc'ematic dia#ram o( a CNC mac'ine tool
5
NC
PL
C
Servo Drive Servo Motor
Spindle Head
Work piece
Table
Encoder
Position Feedback
Tacho
Generator
Velocit
Feedback
Tape !eader
Tape P"nch
#ther Devices
Machine
Ele$ents
%np"ts
#"tp"ts
Lead
Scre&
Co$$and
val"e
Proximity switches
Limit switches
Relay coils
Pressure switches
Float switches
A CNC system bascay conssts of the foowng:
Centra processng unt (CPU)
Servo-contro unt
Operator contro pane
Machne contro pane
Other perphera devce
Programmabe ogc controer (PLC)
Fi#$) gves the typca numerca contro conguraton of
Hnumerk 3100 CNC system
6
Basc Bocks of the CNC Machnes
7
Central *roce&&in# Unit (C*U)
The CPU s the heart and bran of a CNC system. It accepts the
nformaton stored n the memory as part program. Ths data s
decoded and transformed nto specc poston contro and
veocty contro sgnas. It aso oversees the movement of the
contro axs or spnde whenever ths does not match the
programmed vaues, a correctve acton s taken.
A the compensatons requred for machne accuracy (ke
ead screw ptch error, too wear out, backash, etc.) are
cacuated by the CPU dependng upon the correspondng
nputs made avaabe to the system. The same w be taken
care of durng the generaton of contro sgnas for the axs
movement. Aso, some safety checks are but nto the system
through ths unt and the CPU unt w provde contnuous
necessary correctve actons. Whenever the stuaton goes
beyond contro of the CPU, t takes the na acton of shuttng
down the system n turn the machne.
Speed Control Unit
Ths unt acts n unson wth the CPU for the movement of the
machne axes. The CPU sends the contro sgnas generated for
the movement of the axs to the servo contro unt and the
servo contro unt convert these sgnas nto the sutabe dgta
or anaog sgna to be fed to the machne too axs movement.
Ths aso checks whether machne too axs movement s at
the same speed as drected by the CPU. In case any safety
condtons reated to the axs are overrued durng movement
or otherwse they are reported to the CPU for correctve acton.
Ser+o,Control Unit
8
The decoded poston and veocty contro sgnas, generated
by the CPU for the axs movement forms the nput to the
servo-contro unt. Ths unt n turn generates sutabe sgnas
as command vaues. The servo-drve unt converts the
command vaues, whch are nterfaced wth the axs and the
spnde motors (Fi#$%).

The servo-contro unt receves the poston feedback sgnas
for actua movement of the machne too axes from the
feedback devces (ke near scaes, rotary encoders, resoves,
etc.). The veocty feedback s generay obtaned through
tacho generators.
9
The feedback sgnas are passed on to the CPU for further
processng. Thus the servo-contro unt performs the data
communcaton between the machne too and the CPU.
As expaned earer, the actua movements of the sdes on
the machne too s acheved through servo drves. The
amount of movement and the rate of movement are controed
by the CNC system dependng upon the type of feedback
system used, .e. cosed-oop or open-oop system (Fi#$-).
Closed-loop System
The cosed-oop system s characterzed by the presence of
feedback. In ths system, the CNC system send out commands
for movement and the resut s contnuousy montored by the
system through varous feedback devces. There are generay
two types of feedback to a CNC system -- poston feedback
and veocty feedback.
Operator Pane.
10
11
S'STEM (
S%N)ME!%* S%EMENS
+ ,
- ,
+.
-.
P#WE! #N
Emere!cy "to#
$ycle
Fg.2 Typca numerca contro conguraton of
Hnumerk 3100 $%$ system
&a#e Pu!cher &a#e Rea'er
Po&er
S"ppl
NC PLC/
Lo0ic )nit
Machine
Control
Panel
E1pansion
Machine
Control
Panel
L"(2
L"(1
PLC 23 e1ternal
LSM,
Lo0ic S"b
$od"le
POSITION FEEDBACK
A cosed-oop system, regardess of the type of feedback
devce, w constanty try to acheve and mantan a gven
poston by sef-correctng. As the sde of the machne too
moves, ts movement s fed back to the CNC system for
determnng the poston of the sde to decde how much s yet
to be traveed and aso to decde whether the movement s as
per the commanded rate. If the actua rate s not as per the
requred rate, the system tres to correct t. In case ths s not
possbe, the system decares faut and ntates acton for
dsabng the drves and f necessary, swtches oh the machne)

Open-oop postonng contro
Close-loop positioning control
12
$om#ariso!
$ircuit
"to# at
*ero
$omma!'
$ou!ter
"u+tractio!
$ircuit
Positio!
$o!trol
&a#e rea'er
$o!troller
"er,o (otor
Lea' "crew
&a+le
-m#li.ier
$ou!t
$om#arator
-cti,e
/u..er
"torae
&a#e rea'er
"er,o (otor
Lea' "crew
&a+le
-m#li.ier
Positio! .ee'+ac0 si!al
Error
"i!al
&ra!s'ucer
Fi#$- Open-and Cosed-oop postonng system
VELOCITY FEEDBACK
In case no tme constrant s put on the system to reach the
na programmed poston, then the system may not produce
the requred path or the surface nsh accuracy. Hence,
veocty feedback must be present aong wth the poston
feedback whenever CNC system are used for contourng, n
order to produce correct nterpoaton and aso speced
acceeraton and deceeraton veoctes. The tacho generator
used for veocty feedback s normay connected to the motor
and t rotates whenever the motor rotates, thus gvng an
anaog output proportona to the speed of motor. The anaog
votage s taken as speed feedback by the servo-controer and
swft acton s taken by the controer to mantan the speed of
the motor wthn the requred mts.
O*EN,.OO* S"STE
The open oop system acks feedback. In ths system, the CNC
system send out sgnas for movement but does not check
whether actua movement s takng pace or not. Stepper
motors are used for actua movement and the eectroncs of
these stepper motors s run on dgta puses from the CNC
system. Snce system controers have no access to any rea
tme nformaton about the system performance, they cannot
counteract dsturbances appearng durng the operaton. They
can be utzed n pont to pont system, where oadng torque
on the axa motor s ow and amost constant.
SERVO,DRIVES
As shown n Fi#$% the servo-drve receves sgnas from the
CNC system and transforms t nto actua movement on the
machne. The actua rate of movement and drecton depend
upon the command sgna from CNC system. There are varous
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types of servo-drves, vz., dc drves, ac drves and stepper
motor drves. A servo-drve conssts of two parts, namey, the
motor and the eectroncs for drvng the motor.
O*ERATOR CONTRO. S"STE
Fi#$/ shows a typca Hnumerk 3100 CNC system's operator
contro pane. The operator contro pane provdes the user
nterface to factate a two-way communcaton between the
user, CNC system and the machne too. Ths conssts of two
parts:
Vdeo Dspay Unt (VDU)
Keyboard
VIDEO DIS*.A" UNIT (VDU)
The VDU dspays the status of the varous parameters of the
CNC system and the machne too. It dspays a current
nformaton such as:
Compete nformaton of the bock currenty beng
executed
Actua poston vaue, set or actua dherence, current feed
rate, spnde speed
Actve G functons
Man program number, subroutne number
Dspay of a entered data, user programs, user data,
machne data, etc.
Aarm messages n pan text
Soft key desgnatons
In addton to a CRT, a few LEDs are generay provded to
ndcate mportant operatng modes and status.
Vdeo dspay unts may be of two types:
1. Monochrome or back and whte dspays
2. Coor dspays
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O*ERATORS AND AC!INE *ANE.

15
S'STEM (
S%N)ME!%* S%EMENS
+ , - , +.
-.
P#WE! #N
Emere!cy "to#
$ycle
Control ele$ents and indicators o4 the operator5s panel
Proram i! #roress
Fee' hol'
Positio! !ot yet reache'
1(achi!e i! motio!2
-larm
/asic 'is#lay
&ool com#e!satio!
*ero o..set
&est
Part #roram
C!T
LE34i!'icator
For assi!me!t
5. 0eys
$ha!e to actual
,alue 'is#lay
$ha!e o. 'is#lay
Lea. .orwar's
Lea. +ac0war's
Riht4Le.t $ursor
Reset cha!eo,er
-ssi!me!t o. 0eys
$a!cel wor'
-lter wor'
E!ter wor'
$ha!e o,er to
customer 'is#lay
5#erator ui'a!ce
6es7%o
3elete i!#ut
"tart
Fi#$/ Operator contro pane of Hnumerk
3100 system
-''ress
8eys9%umerical
0ey+oar'
0E"1OARD
A keyboard s provded for the foowng purposes:
Edtng of part programs, too data, and machne
parameters.
Seecton of dherent pages for vewng.
Seecton of operatng modes, e.g. manua data nput.
Seecton of feed rate overrde and spndes speed
overrde.
Executon of part programs.
Executon of other to functons.
AC!INE CONTRO. *ANE. (C*)
It s the drect nterface between operator and the NC
system, enabng the operaton of the machne through
the CNC system. Fi#$2 shows the MCP of Hnumerk
3100 system.
Durng program executon, the CNC contros the axs
moton, spnde functon or too functon on a machne
too, dependng upon the part program stored n the
memory. Pror to the startng of the machne process,
machne shoud rst be prepared wth some specc
tasks ke,
Estabshng a correct reference pont
Loadng the system memory wth the requred part
program
Loadng and checkng of too ohsets, zero ohsets,
etc.
For these tasks, the system must be operated n
specc operatng mode so that these preparatory
functons can be estabshed.
16
Control element& o( t'e ac'ine Control *anel
ode& o( Operation
Generay, the CNC system can be operated n the foowng
modes:
Manua mode
Manua data nput (MDI) mode
Automatc mode
Reference mode
Input mode
Output mode, etc.
ANUA. ODE
In ths mode, movement of a machne sde can carred out
manuay by pressng the partcuar |og button (+ or -). The
sde (axs) s seected through an axs seector swtch or
through ndvdua swtches (e.g., X+, X-, Y+, Y-, Z+, Z-, etc.).
The feed rate of the sde movement s prexed. CNC system
aows the axs to be |ogged at hgh feed rate aso. The axs
movement can aso be acheved manuay usng a hand whee
17
+ ,
- ,
+.
-.
P#WE! #N
Emere!cy "to#
$ycle
(o'e selector
"witch
"#i!'le s#ee'
o,erri'e
Fee'rate9ra#i' tra,erse
o,erri'e
Ra#i' tra,erse acti,ate
3irectio! 0eys
"#i!'le
#FF #N
Fee'
:ol'9"tart
$ycle start
NC #N
8ey o#erate' switch
.or i!#ut i!hi+it
/loc0 search
"i!le
+loc0
3ry Ru! /loc0
3elete
Ra#i' &ra,erse
5,erri'e acti,e
(a!ual e!co'er acti,e
i!
;4a!' *4axis res#)
Fi#$2 Machne contro pane of Hnumerk
3100 system
nterface nstead of |og buttons. In ths mode sdes can be
moved n two ways:
Contnuous
Incrementa
18
CONTINUOUS ODE
In ths mode, the sde w move as ong as the |og button
s pressed)
INCREENTA. ODE
Hence the sde w move through a xed dstance, whch
s seectabe. Normay, system aows |oggng of axes n 1, 10,
100, 1000, 10000, ncrements. Axs movement s at a prexed
feed rate. It s ntated by pressng the proper |og+ or |og- key
and w be mted to the no of ncrements seected even f the
|og button s contnuousy pressed. For subsequent movement
the |og button has to be reeased and once agan pressed.
ANUA. DATA IN*UT (DI) ODE
In ths mode the foowng operaton can be performed:
Budng a new part program
Edtng or deetng of part program stored n the system
memory
Enterng or edtng or deetng of:
------ Too ohsets (TO)
------ Zero ohsets (ZO)
------ Test data, etc.
TEAC!,IN
Some system aows drect manua nput of a program
bock and executon of the same. The bocks thus executed
can be checked for correctness of dmensons and
consequenty transferred nto the program memory as part
program.
*.A"1AC0
19
In settng up modes ke |og or ncrementa, the axs can
be traversed ether through the drecton keys or va the hand
whee, and the end poston can be transferred nto the system
memory as command vaues. But the requred feed rates,
swtchng functons and other auxary functons have to be
added to the part program n program edtng mode.
Thus, teach-n and payback operatng method aows a
program to created durng the rst component prove out.
AUTOATIC ODE (AUTO AND SING.E 1.OC0)
In ths mode the system aows the executon of a part
program contnuousy. The part program s executed bock by
bock. Whe one bock s beng executed, the next bock s
read by the system, anayzed and kept ready for executon.
Executon of the program can be one bock after another
automatcay or the system w execute a bock, stop the
executon of the next bock t t s ntated to do so (by
pressng the start button). Seecton of part program executon
contnuousy (Ato) or one bock at a tme (Sin!le Blo"#) s
done through the machne contro pane.
Many systems aow bocks (snge or mutpe) to be retraced
n the opposte drecton. Bock retrace s aowed ony when a
cyce stop state s estabshed. Part program executon can
resume and ts executon begns wth the retraced bock. Ths
s usefu for too nspecton or n case of too breakage.
Program start can be ehected at any bock n the program,
through the BLOCK SEARCH facty.
REFERENCE ODE
Under ths mode the machne can be referenced to ts
home poston so that a the compensatons (e.g., ptch error
compensaton) can be propery apped. Part programs are
generay prepared n absoute mode wth respect to machne
zero. Many CNC systems make t compusory to reference the
sdes of the machne to ther home postons before a program
s executed whe others make t optona.
IN*UT ODE AND OUT*UT ODE (I3O ODE)
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In ths mode, the part programs, machne setup data, too
ohsets, etc. can be oaded/unoaded nto/from the memory of
the system from externa devces ke programmng unts,
magnetc cassettes or oppy dscs, etc. Durng data nput,
some systems check for smpe errors (ke party, tape
format, bock ength, unknown characters, program aready
present n the memory, etc.). Transfer of data s done through
a RS232C or RS422C port.
OT!ER *ERI*!ERA.S
These ncude sensor nterface, provson for communcaton
equpment, programmng unts, prnter, tape reader/puncher
nterface, etc.
Fi#$4 gves an overvew of the system wth few perphera
devces.
*ROGRAA1.E .OGIC CONTRO..ER (*.C)
A PLC matches the NC to the machne. PLCs were bascay
ntroduced as repacement for hard wred reay contro panes.
They were deveoped to be reprogrammed wthout hardware
changes when requrements were atered and thus are
reusabe. PLCs are now avaabe wth ncreased functons,
more memory and arge nput/output capabtes. Fi#$5 gves
the generazed PLC bock dagram.
In the CPU, a the decsons are made reatve to controng a
machne or a process. The CPU receves nput data, performs
ogca decsons based upon stored programs and drves the
outputs. Connectons to a computer for herarchca contro are
done va the CPU.
The I/O structure of the PLCs s one of ther ma|or strengths.
The nputs can be push buttons, mt swtches, reay contacts,
anaog sensor, seector swtches, proxmty swtches, oat
swtches, etc. The outputs can be motor starters, soenod
21
vaves, poston vaves, reay cos, ndcator ghts, LED
dspays, etc.
The ed devces are typcay seected, supped and nstaed
by the machne too buder or the end user. The votage eve
of the ed devces thus normay determnes the type of I/O.
So, power to actuate these devces must aso be supped
externa to the PLC. The PLC power suppy s desgnated and
rated ony to operate the
nterna portons of the I/O structures, and not the ed
devces. A wde varety of votages, current capactes and
types of I/O modues are avaabe.
22
Fi#$4 Sy&tem 6it' perip'eral de+ice&
Fg.7 Generazed PLC bock dagram
INTERFACING
Interconnectng the ndvdua eements of both the
machne and the CNC system usng cabes and connectors s
caed nterfacng. Extreme care shoud be taken durng
nterfacng. Proper groundng n eectrca nstaaton s most
essenta. Ths reduces the ehects of nterference and guards
23
Pro0ra$$in0
)nits
Tape
!eader
Printers Tape
P"ncher
Processor Lo0ic
$e$or
Stora0e
$e$or
Po&er
S"ppl
%np"ts
#"tp"ts
Po&er
S"ppl
Pro0ra$$er Field
Devices
aganst eectronc shock to personne. It s aso essenta to
propery protect the eectronc equpment.
24
Cabe wres of sumcenty arge cross-sectona area must be
used. Even though proper groundng reduces the ehect of
eectrca nterference, sgna cabe requres addtona
protecton. Ths s generay acheved by usng sheded cabes.
A the cabe sheds must be grounded at contro ony, eavng
other end free. Other nose reducton technques ncude usng
suppresson devces, proper cabe separaton, ferrous meta
wre ways, etc. Eectrca encosures shoud be desgned to
provde proper ambent condtons for the controer.
ONITORING
In addton to the care taken by the machne too buder
durng desgn and nterfacng, basc contro aso ncudes
constanty actve montorng functons. Ths s n order to
dentfy fauts n the NC, the nterface contro and the machne
at an arge stage to prevent damages occurrng to the work
pece, too or machne. If a faut occurs, rst the machnng
sequence s nterrupted, the drves are stopped, the cause of
the faut s stored and then dspayed as an aarm. At the same
tme, the PLC s nformed that an NC aarm exts. In Hnumerk
CNC system, for exampe, the foowng can be montored:
Read-n
Format
Measurng crcut cabes
Poston encoders and drves
Contour
Spnde speed
Enabe sgnas
Votage
Temperature
Mcroprocessors
Data transfer between operator contro pane and ogc
unt
Transfer between NC and PLC
Change of status of buher battery
25
System program memory
User program memory
Sera nterfaces
DIAGNOSTICS
The contro w generay be provded wth test assstance for
servce purposes n order to dspay some status on the CRT
such as:
Interface sgnas between NC and PLC as we as between
PLC and machne
Fags of the PLC
Tmers of the PLC
Counters of the PLC
Input/output of the PLC
For the output sgnas, t s aso possbe to set and generate
sgna combnatons for test purposes n order to observe how
the machne react to a changed sgna. Ths smpes troube
shootng consderaby.
AC!INE DATA
Generay, a CNC system s desgned as a genera-purpose
contro unt, whch has to be matched wth the partcuar
machne to whch the system s nterfaced. The CNC s
nterfaced to the machne by means of data, whch s machne
specc. The NC and PLC machne data can be entered and
changed by means of externa equpment or manuay by the
keyboard. These data are xed and entered durng
commssonng of the machne and generay eft unatered
durng machne operatons.
Machne data entered s usuay reevant to the axs trave
mts, feed rates, rapd traverse speeds and spnde speeds,
poston contro mutpcaton factor, Kv factor, acceeraton,
drft compensaton, ad|ustment of reference pont, backash
26
compensaton, ptch error compensaton, etc. Aso the optona
features of the contro system are made avaabe to the
machne too buder by enabng some of the bts of machne
data.
CO*ENSATIONS FOR AC!INE ACCURAC"
Machne accuracy s the accuracy of the movement of the
carrage, and s nuenced by:
o Geometrc accuracy n the agnment of the sde ways
o Deecton of the bed due to oad
o Temperature gradents on the machne
o Accuracy of the screw thread of any drve screw and the
amount of backash (ost moton)
o Amount of twst (wnd up) of the shaft whch w nuence
the measurement of rotary transducers
The CNC systems oher compensaton for the varous
machnes' accuracy. These are detaed beow:
.EAD SCRE7 *ITC! ERROR CO*ENSATION
To compensate for movements of the machne sde due to n
accuracy of the ptch aong the ength of the ba screw, ptch
error compensaton s requred. To begn wth, the ptch error
curve for the entre ength of the screw s but up by physca
measurement wth the ad of an externa devce (ke aser).
Then the requred compensaton at predetermned ponts s
fed n to the system. Whenever a sde s moved, these
compensaton are automatcay added up by the CNC system
(Fi#$8)
FIG.8 TYPICAL ERROR CURVE
27
Re.ere!ce
#oi!t
Positi,e e!'
limit
Pitch error 1um2
&o !eati,e
e!' limit
1AC0.AS! CO*ENSATION
Whenever a sde s reversed, there s some ost moton due to
backash between nut and the screw; a compensaton s
provded by the CNC system for the moton ost due to
reversa, .e. extra movement s added nto the actua
movement whenever reversa takes pace. Ths extra
movement s equa to backash between the screw and the
nut. Ths has to be measured n advance and fed to the
system. Ths vaue keeps on varyng due to wear of the ba
screws, hence the compensaton vaue has to be updated
reguary from tme to tme
FIG.9 BACKLASH COMPENSATION
SAG CO*ENSATION
Inaccuracy due to sag n the sde can be compensated by the
system. Compensatons requred aong the ength of the sde
have to be physcay measured and fed to the system. The
system automatcay adds up the compensaton to the
movement of the sde.
TOO. NOSE CO*ENSATION
Too nose compensaton normay used on too for turnng
centers. Whe machnng chamfers, anges or turnng curves,
t s necessary to make aowance for the too tp radus; ths
radus s known as radius compensation. As shown n Fi#$%9
28
M
M
Positi,e +ac0lash 1the
usual case2
&a+le &a+le
/allscrew
E!co'er
E!co'er
/ac0lash
&oothe' wheel
%eati,e +ac0lash
/ac0lash here
E!co'er actual ,alue #rece'es the
ta+le mo,eme!t
-ctual mo,eme!t o. the ta+le #rece'es the
e!co'er measureme!t
(a), f the aowance s nt made, the edges of the too tp
radus woud be postoned at the programmed X and Z
coordnates, and the too w foow the path AB and the taper
produced w be ncorrect. In order to obtan correct taper, too
poston has to be ad|usted.
It s essenta that the radus at the tp of the too s fed to the
system to make an automatc ad|ustment on the poston and
movement of the too to get the correct taper on the work. In
Fi#$%9 (b) the dstance Xc s the ad|ustment necessary at the
start of the cut and dstance Zc s the ad|ustment at the end of
the cut.
Fg.10 Too nose radus compensaton
CUTTER DIAETER CO*ENSATION
The dameter of the used too may be dherent from the actua
vaue because of regrndng of the too or due to non-
avaabty of the assumed too. It s possbe to ad|ust the
reatve poston of cutter sze and ths ad|ustment s known as
cutter dameter compensaton.
29
+ ,2637
+ 7
- 7
- 2737
+ ,/637
- (737
(i!imum ra'ius
o. ta#er
3atum
Positio!
8
+ 7
- 7
- 2737
3atum
Positio!
&ool
+ 7
9
-c
+ ,/637
+c
; 3070
FIG$%% TOO. OFFSETS
TOO. OFFSET
A part program s generated keepng n mnd a too of a
partcuar ength, shape and thckness as a reference too. But
durng the actua mountng of toos on the machne, dherent
toos of varyng engths, thckness and shapes may be
avaabe. A correcton for dmenson of the toos and
movements of the work pece has to be ncorporated to gve
the exact machnng of the component. Ths s known as too
ohset. Ths s the dherence n the postons of the centre ne
of the too hoder for dherent toos and the reference too.
When a number of toos are used, t s necessary to determne
the too ohset of each too and store t n the memory of the
contro unt. Fi#$%% expans the functon of the too ohset.
Normay, t s found that the sze of the work pece (dameter
or ength) s not wthn toerance due to wear of the too; t s
30
Re.ere!ce tool
&ool !o)1
*R<"etti! 'ista!ce .or
re.ere!ce tool
;R<"etti! 'ista!ce .or
re.ere!ce tool
; o..set .or
tool !o)2
* o..set .or
tool !o)2
&ool !o)2
*R
*R
;R
*0
;0
the possbe to edt the vaue of ohsets to obtan the correct
sze. Ths s known as tool wear compensation.
31

*.C *ROGRAING
The prncpe of operaton of a PLC s determned essentay by
the PLC program memory, processor, nputs and outputs.
The program that determnes PLC operaton s stored n the
nterna PLC program memory. The PLC operates cyccay, .e.
when a compete program has been scanned, t starts agan at
the begnnng of the program. At the begnnng of each cyce,
the processor examnes the sgna status at a nputs as we
as the externa tmers and counters and are stored n a
process mage nput (PII). Durng subsequent program
scannng, the processor the accesses ths process mage.
To execute the program, the processor fetches one statement
after another from the programmng memory and executes t.
The resuts are constanty stored n the process mage output
(PIO) durng the cyce. At the end of a scannng cyce, .e.
program competon, the processor transfers the contents of
the process mage output to the output modues and to the
externa tmers and counters. The processor then begns a new
program scan.
STEP 5 programmng anguage s used for wrtng user
programs for SIMATIC S5 programmabe controers. The
program can be wrtten and entered nto the programmabe
controer as n:
Statement st (STL), Fi#$%) (a)
Contro system owchart (CSF), Fi#$%) (b)
Ladder dagram (LAD), Fi#$%) (c)
:a;
32
"tateme!t list
"&L
- = 2)3
- = 4)1
5 = 3)2
< > 1)6
- = 2)3
- = 2)3
-
%
3
5
R
= 2)3
= 4)1
= 3)2 > 1)6
"tateme!t
5#era!' 5#eratio!
:b; $o!trol system .low
chart $"F
:c; La''er 'iaram L-3
= 2)3 = 4)1
FIG$%) *ROGRAA1.E CONTRO..ER
The statement list descrbes the automaton task by means of
mnemonc functon desgnatons.
The contro system owchart s a graphc representaton of the
automaton task.
The adder dagram uses reay adder ogc symbos to
represent the automaton task.
The statement s the smaest STEP 5 program component. It
conssts of the foowng:
Operaton, .e. what is to be done?
E.g. A = AND operaton (seres connecton)
O= OR operaton (parae connecton)
S= SET operaton (actuaton)
Operand, .e. what s to be done wth?
E.g. I 4.5, .e. wth the sgna of nput 4.5
The operand conssts of:
Operand denter (I = nput, O = output, F = ag, etc.)
Parameter, .e. the number of operand denters
addressed by the statement. For nputs, outputs and ags
(nterna reay equvaents), the parameter conssts of the
33
= 2)3
5#era!' i'e!ti.ier
Parameter
= 3)2
byte and bt addresses, and for tmers and counter, byte
address ony.
The statement may ncude absoute operands, e.g. I 5.1, or
symboc operand, e.g. I LS1. Programmng s consderaby
smped n the ater case as the actua pant desgnaton s
drecty used to descrbe the devce connected to the nput or
output.
Typcay, a statement takes up one word (two bytes) n the
program memory.
34
STRUCTURED *ROGRAING
The user program can be made more manageabe and
straghtforward f t s broken down nto reatve sectons.
Varous software bock types are avaabe for constructng the
user program.
Pro!r$m %lo"#s &PB' contan the user program broken
down nto technoogcay or functonay reated sectons (e.g.
program bock for transportaton, montorng, etc.). Further
bocks, such as program bocks or functon bocks can be
caed from a PB.
Or!$ni($tion %lo"#s &OB) contan bock cas
determnng the sequence n whch the PBs are to be
processed. It s therefore possbe to ca PBs condtonay
(dependng on certan condtons).
In addton, speca OBs can be programmed by the user to
react to nterruptons durng cycc programmng processng.
Such an nterrupt can be trggered by a montorng functon f
one or severa montored events occur.
Fn"tion %lo"# &FB) s bock wth programs for recurrent
and usuay compex functon. In addton to the basc
operatons, the user has a extended operaton at hs dsposa
for deveopng functon bocks. The program n a functon bock
s usuay not wrtten wth absoute operands (e.g. I 1.5) but
wth symboc operands. Ths enabes a functon bock to be
used severa tmes over wth dherent absoute operands.
For even more compex functons, standard functon bocks are
avaabe from a program brary. Such FBs are avaabe, e.g.
for ndvdua contros, sequence contros, messages,
arthmetc operatons, two step contro oops, operator
communcatons, stng, etc. These standard FBs for compex
functons can be nked t the user program |ust ke user
35
wrtten FBs smpy by means of a ca aong wth the reevant
parameters.
T)e Se*en"e %lo"# &SB)contan the step enabng
condtons, montorng tmes and condtons for the current
step n sequence cascade. Sequence bocks are empoyed, for
exampe, to organse the sequence cascade n communcaton
wth a standard FB.
T)e d$t$ %lo"#s &DB) contan a xed or varabe data of
the user program.
36
C"C.IC *ROGRA *ROCESSING
The bocks of the user program are executed n the sequence
n whch they speced n the organzaton bock.
INTERRU*T DRIVEN *ROGRA *ROCESSING
When certan nput sgna changes occur, cycc processng s
nterrupted at the next bock boundary and an OB assgned to
ths event s started. The user can formuate hs response
program to ths nterrupt n the OB. The cycc program
executon s the resumed from the pont at whch t was
nterrupted.
TIE CONTRO..ED *ROGRA
E:ECUTION
Certan Obs are executed at the predetermned tme ntervas
(e.g. every 100ms, 200ms, 500ms, 1s, 2s, and 5s). For ths
purpose, cycc program executon s nterrupted at the bock
boundary and resumed agan at ths pont, once the reevant
OB has been executed. Fi#$%- gves the organsaton and
executon of a structured user program.
37
P/1
P/2 F/3
F/2
5/1
STRUCTURED *ROGRAING
P/
F/
P/ F/
5ra!isatio! +loc0 15/2
Proram +loc0 1P/2 Fu!ctio! +loc0 1P/2
$ycle executio!
5/
38
Fi#$%- Or#ani&ation and e;ecution o( a
&tructured u&er pro#ram
E:A*.ES OF *.C *ROGRA
Before attemptng to wrte a PLC program, rst go through the
nstructon set of the partcuar anguage used for the
equpment, and understand the meanng of each nstructon.
Then study how to use these nstructons n the program
(through ustraton exampes gven n the manua). Once the
famarzaton task s over, then start wrtng the program.
Foow the foowng steps to wrte a PLC program.
Lst down each ndvdua eement (ed devce) on the
machne as Input/Output.
Indcate aganst each eement the respectve address as
denter durng eectrca nterfacng of these eements wth
the PLC.
Break down the compete machne auxary functons that
are controed by the PLC nto ndvdua, sef contaned
functons.
Identfy each ndvdua functon as separate bock
(PBxx/FBxx)
Once the PBs and FBs for each functon are dented, take
them one by one for wrtng the program.
Lst down the precondtons requred for the partcuar
functon separatey.
Note down the address of the sted eements.
Wrte down the ow chart for the functon.
39
P/ F/
5/
INTERRU*T,DRIVEN E:ECUTION
*oint& at 6'ic' interrupt,dri+en
pro#ram can <e in&erted
Start and =ni&' o( interrupt,dri+en
pro#ram e;ecution
Transate the ow chart nto PLC program usng the
nstructons aready famarzed.
Compete the program transaton of a ndvdua functons
n smar nes.
Check the ndvdua bocks ndependenty and correct the
program to get the requred resuts.
Organze a the program bocks n the organzaton bock
dependng upon the sequence n whch they are supposed to
be executed as per the man machne functon ow chart.
Check the compete program wth a the bocks
ncorporated n the na program.
E+$mple ,- Spindle ON
*recondition& Feed<ac> element& Addre&& Fault
indication Addre&& Remar>
Too camp Pressure swtch I 2.4 Lamp
O 2.1
|ob camp Proxmty swtch I 3.2 Lamp
O 1.7
Door cose Lmt swtch I 5.7 Lamp
O 4.0
Lubrcaton ON PLC output bt O 1.0 Lamp
O 7.7
Drve ready Input sgna from I 4.6 Lamp
O 0.4
Drve unt
PB 12 wrtten s the ndvdua functon modue for spnde ON
for a the precondtons checked and found satsfactory. Ths
functon s requred to be executed ony when the spnde
rotaton s requested by the NC n the form of a bock n the
part program.
Whenever NC decodes the part program bock, t n turn
nforms the PLC through a xed buher ocaton that spnde
rotaton s requested. Say Fag bt F 100.0 s dented for ths
40
nformaton communcaton. Wth ths data, spnde ON
functon modue can be recaed n the organzaton bock OB1
as foows.
OB 1
..
A F 100.0
|C PB12
..
..
BE
Now, spnde ON functon modue PB12 w be executed ony
when F 100.0 s set. Otherwse the functon executon w be
bypassed.

41
F.O7 C!ART
42
"&-R&
&55L $L-(P
?5/ $L-(P
355R $L5"E3
L@/R=$-&=5%
5%
3R=AE RE-36
-%6 F-@L&
35 "P=%3LE 5%
=%3=$-&E
F-@L&
=%3=$-&E
F-@L&
=%3=$-&E
F-@L&
=%3=$-&E
F-@L&
=%3=$-&E
F-@L&
"&5P
"P=%3LE
P/12
-% = 2)4 &ool !ot clam#e'
< > 2)1 3is#lay .ault lam#
-% = 3)2 ?o+ !ot clam#e'
< > 1)7 3is#lay .ault lam#
-% = 5)7 3oor !ot close'
< > 4)0 3is#lay .ault lam#
-% > 1)0 Lu+ricatio! !ot o!
< > 7)7 3is#lay .ault lam#
-% = 4)6 3ri,e !ot rea'y
< > 0)4 3is#lay .ault lam#
$omme!ts
5% = 2)4 &ool !ot clam#e'
5% = 3)2 ?o+ !ot clam#e'
5% = 5)7 3oor !ot close'
5% > 1)0 Lu+ricatio! !ot o!
5% = 4)6 3ri,e !ot rea'y
R > 67)3 Reset s#i!'le e!a+le +it
/E$ /loc0 e!' co!'itio!ally
- = 2)4 &ool clam#e'
- = 3)2 ?o+ clam#e'
- = 5)7 3oor close'
- > 1)0 Lu+ricatio! 5%
- = 4)6 3ri,e rea'y
" > 67)3 "et s#i!'le e!a+le +it
/E /loc0 e!'
Exit
6E"
6E"
6E"
6E"
6E"
%5
%5
%5
%5
%5
%5
6E"
43
E%3
A *RO?ECT RE*ORT
ON
COMPUTER - NUMERICALLY CONTROLLED
AT
BHEL, HARIDWAR
Submtted n parta fument
of the requrement for the award of
B.Tech n
Eectroncs & Communcaton
Engneerng.
Submtted By:
Abhshek Mtta
Ro No. 0403231005
44
45
A *RO?ECT RE*ORT
ON
COMPUTER - NUMERICALLY CONTROLLED
MACHINES.
AT
BHEL, HARIDWAR
Submtted n parta fument
of the requrement for the award of
B.Tech n
Eectroncs & Communcaton
Engneerng.
Submtted By:
Abhshek
46
Ro No. 0403231004
STAMP OF AUTHENTICITY STAMP OF AUTHENTICITY
Ths s to certfy that Mr. Mr. ABHISHEK MITTAL ABHISHEK MITTAL
pursung
B.Tech B.Tech n ELECTRONICS & COMMUNICATION ELECTRONICS & COMMUNICATION
from
A.B.E.S. ENGINEERING COLLEGE A.B.E.S. ENGINEERING COLLEGE@ GHAZIABAD GHAZIABAD, has
undergone ndustra tranng on
ACOMPUTER NUMERICALLY CONTROLLED COMPUTER NUMERICALLY CONTROLLED
MACHINES MACHINES" "
w.e.f. 16
th
|une 2007 to 16
th
|uy 2007 at 1!E.@
!ARID7AR$
47
Auth. Sgnature
MR. B.C.
SHARMA
Co- Coordnator Vocatona Tranng
H.R.D.C.
BHEL, Hardwar
ACKNOWLEDGEMENT ACKNOWLEDGEMENT
T'e (ollo6in# proBect report on
CNC ac'ine 6ould not 'a+e
materialiCed 6it'out t'e &upport
and #uidance o( R$ 1$C$
S!ARA$ I am +ery #rate(ul to
'im (or pro+idin# me 6it' 'i&
preciou& time and 'elpin# me$
y t'an>& to all t'e &upportin#
&taD at 1!E. oEce (or &'o6in#
48
me around t'e +ariou&
eFuipment& in u&e$
.a&t <ut not t'e lea&t I 6ould li>e
to t'an> my (amily mem<er&
6'o&e in+alua<le &upport made
t'i& 6'ole proBect po&&i<le$

PREFACE PREFACE
Wth the ongong revouton n Eectroncs and
Communcaton Engneerng where nnovatons
are takng pace at the bnks of an eye, t s
mpossbe to keep the pace wth the emergng
trends.
There s an atttude that the whoe of the human
race s born wth. It s the envronment that makes
sure that whether the resut of ths atttude s
vsbe or otherwse. A we panned, propery
49
executed and evauated ndustra tranng heps a
ot ncucatng a professona atttude. It provdes
a nkage between the student and ndustry to
deveop an awareness of ndustra approach to
probem sovng, based on a broad understandng
of process and mode of operaton of organzaton.
Durng ths perod, the student get rea, rst hand
experence for workng n the actua envronment.
Most of the theoretca knowedge that has been
ganed durng the course of ther studes s put to
test here. Apart from ths, the student gets an
opportunty to earn the atest technoogy, whch
mmensey heps them n budng ther career.
Industra tranng has become an mportant part
n students currcuum as t now ony makes hm
aware of workng condton of an ndustry t aso
heps hm n brdgng the gap that exsts between
an nsttuton and an ndustry. The ndustra
tranng s of hgh mportance n hepng hm
physoogcay for the transformaton.
I had the opportunty to have a rea experence on
many ventures whch ncreased my sphere of
knowedge to a great extent. I got a chance to
earn many technooges and was aso
organzaton BHEL, HARIDWAR.
BHEL, HARIDWAR gves opportunty to students of
many dscpnes n hepng them prepare for the
50
bg |ump. They conduct tranng for organzaton,
whch exce n ther own eds of operatons. The
manager of the department heps the tranee n
budng an nsde to the workng of the
department rotatona programmed asts for one
week.
At the end of the duraton the tranee s evauated
on the bass of hs performance durng ths
tranng perod ad accordngy a certcate s
awarded, whch s a bg hep for the student.
51
CONTENTS
AC0NO7.EDGEENT$
STA* OF AUT!ENTICIT"$
*REFACE$
INTRODUCTION TO 1!E.$
CNC S"STE$
1ASIC 1.OC0S OF CNC AC!INE$
ODES OF O*ERATION
INTERFACING$
ONITORING$
DIAGNOSTICS$
CO*ENSATION$
*.C *ROGRAING
STRUCTURED *ROGRAING$
TIE CONTRO. *ROGRA E:ECUTION$
52
BHEL, HARIDWAR BHEL, HARIDWAR
1!E. s the argest engneerng and
manufacturng enterprse n Inda n the energy-
reated/nfrastructure sector, today. 1!E. was
estabshed more than 40 years ago, usherng n
the ndgenous Heavy Eectrca Equpment
ndustry n Inda - a dream that has been more
than reazed wth a we-recognzed track record
of performance. The company has been earnng
prots contnuousy snce 1971-72 and payng
dvdends snce 1976-77.
1!E. manufactures over 180 products under 30
ma|or product groups and caters to core sectors
of the Indan Economy vz., Power Generaton &
Transmsson, Industry, Transportaton,
Teecommuncaton, Renewabe Energy, etc. The
wde network of 1!E.'s 14 manufacturng
dvsons, four Power Sector regona centres, over
100 pro|ect stes, eght servce centers and 18
regona omces, enabes the Company to prompty
serve ts customers and provde them wth
sutabe products, systems and servces --
emcenty and at compettve prces. The hgh
eve of quaty & reabty of ts products s due
to the emphass on desgn, engneerng and
manufacturng to nternatona standards by
acqurng and adaptng some of the best
53
technooges from eadng companes n the word,
together wth technooges deveoped n ts own
R&D centres.
1!E. has acqured certcatons to Ouaty
Management Systems (ISO 9001), Envronmenta
Management Systems (ISO 14001) and
Occupatona Heath & Safety Management
Systems (OHSAS 18001) and s aso we on ts
|ourney towards Tota Ouaty Management.

1!E. has
Instaed equpment for over 90,000 MW of power
generaton -- for Uttes, Captve and Industra
users.
Supped over 2,25,000 MVA transformer
capacty and other equpment operatng n
Transmsson & Dstrbuton network up to 400 kV
(AC & DC).
Supped over 25,000 Motors wth Drve Contro
System to Power pro|ects, Petrochemcas,
Reneres, Stee, Aumnum, Fertzer, Cement
pants, etc.
Supped Tracton eectrcs and AC/DC ocos to
power over 12,000 kms Raway network.
54
Supped over one mon Vaves to Power Pants
and other Industres.
1!E.'s operatons are organsed around three
busness sectors, namey *o6er, Indu&try -
ncudng Transmsson, Transportaton,
Teecommuncaton & Renewabe Energy - and
O+er&ea& 1u&ine&&. Ths enabes 1!E. to have
a strong customer orentaton, to be senstve to
hs needs and respond qucky to the changes n
the market.
1!E.'s vson s to become a word-cass
engneerng enterprse, commtted to enhancng
stakehoder vaue. The company s strvng to gve
shape to ts aspratons and fu the expectatons
of the country to become a goba payer.
The greatest strength of 1!E. s ts hghy sked
and commtted 42,600 empoyees. Every
empoyee s gven an equa opportunty to
deveop hmsef and grow n hs career.
Contnuous tranng and retranng, career
pannng, a postve work cuture and partcpatve
stye of management - a these have engendered
deveopment of a commtted and motvated
workforce settng new benchmarks n terms of
productvty, quaty and responsveness.
55
56