Automatic Control

Systems

Case Study

CNC Machine-Tool
Positional Control

Prepared by
Dr. Samy Aly Hassan
2017/2018
1
The physical configuration and block diagram representation of a CNC
machine-tool is shown in Figures 1 and 2. The fundamental control
problem here is that, by design, the lead-screw (by the use of re-
circulating ball-bearings).

Fig. 1 Computer numerically controlled machine tool.

The block diagram for the CNC machine tool control system is shown in Figure 2.

Fig. 2 Block diagram of CNC machine–tool control system.

Most machine-tool manufacturers employ velocity feedback to obtain

the necessary damping. Since overshoot in a cutting operation usually
cannot be tolerated, the damping coefficient for the system must be
unity, or greater.

2
For this study, the machine-tool configuration will be essentially the
same as shown in Figure 1, with the exception that:
(i) A gearbox will be placed between the servo-motor and the lead-
screw to provide additional torque.
(ii) The machine table movement will be measured by a linear
displacement transducer attached to the table. This has the advantage of
bringing the table ‘within the control-loop’ and hence providing more
accurate control.

Components of the closed-loop system:

1. Controller

2. Power amplifier

3. Armature controlled DC servo-motor

This arrangement is shown in schematic form in figure (3).

3
Now air gap flux Ø is proportional to if, or

where Kfd is the field coil constant.

Also, torque developed Tm is proportional to the product of the air gap
flux and the armature current:

where Kam is the armature coil constant.

Since if is constant:

where the overall armature constant Ka is:

4
When the armature rotates, it behaves like a generator, producing a back
emf eb(t) proportional to the shaft angular velocity:

where Kb is the back emf constant.

The potential difference across the armature winding is therefore:

Taking Laplace transforms of the above equation with zero initial

conditions:

Figure 4 combines equations (I), (II) and (III) in block diagram form.

Fig. 4 Block diagram representation of armature

controlled DC servo–motor.

5
4. Gearbox, lead-screw and machine-table
With reference to the following figure (free-body diagram of a
gearbox), the motor-shaft will have zero viscous friction C m, hence the
governing equation, using Laplace notation, becomes:

Free-body diagram of a gearbox

(1)
The output shaft in this case is the lead screw, which is assumed to have
zero moment of inertia Io and viscous friction Co. The free-body
diagrams of the machine-table and lead-screw are shown in the
following figure.

6
 Free-body diagrams of the machine-table and lead-screw
For lead-screw

(2)
or

(3)
Now the pitch p of the lead-screw is

(4)
Substituting equations (3) and (4) gives:

(5)
The equation of motion for the machine-table is:

7
 (6)
Equating equations (5) and (6) gives:

(7)
Taking Laplace transforms:

(8)
Equating (1) and (8) gives:

(9)
Now:

Hence,

(10)
and,

(11)
Equation (11) can be substituted into (9):

(12)
8
or ,

(13)
giving the transfer function for the gearbox, lead-screw and machine-
table as:

(14)
where the term n2Im/P may be considered to be equivalent mass of Im
referred to the machine-table.
5. Tachogenerator

or, from equation (4.105)

6. Position transducer

Block-diagram of the closed-loop system:

The system element dynamic equations can now be combined in the
block diagram shown in the following figure.

9
 Block diagram of CNC machine–tool control system.

Signal flow graph of CNC machine–tool control system.

Overall Transfer Function:

𝑋𝑜 (𝑠) 𝑃1 Δ1
=
𝑋𝑑 (𝑠) Δ
𝐾1 𝐾2 𝐾𝑎 𝑃𝑛
𝑃1 =
𝐿𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 3 + 𝑅𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 2
Δ1 = 1
Δ = 1 − (L1 + L2 + L3 )
𝐾𝑏 𝐾𝑎 𝑃𝑛
L1 = −
𝐿𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 2 + 𝑅𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠

10
 𝐾2 𝐾𝑎 𝐻2 𝑛
L2 = −
𝐿𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 2 + 𝑅𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠
𝐾1 𝐾2 𝐾𝑎 𝐻1 𝑃𝑛
L3 = −
𝐿𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 3 + 𝑅𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )𝑠 2
Then, the overall transfer function of CNC machine tool is:
𝑋𝑜 (𝑠) 𝐾1 𝐾2 𝐾𝑎 𝑃𝑛
=
𝑋𝑚 (𝑠) 𝐿𝑎 (𝑃 𝑚+𝑛 𝐼𝑚 )𝑠 +𝑅𝑎 (𝑃 𝑚+𝑛 𝐼𝑚 )𝑠 2+(𝐾𝑎 𝐾𝑏𝑃𝑛+𝐾2 𝐾𝑎𝐻2 𝑛)𝑠+𝐾1 𝐾2 𝐾𝑎 𝐻1 𝑃𝑛
2 2 3 2 2

System Parameters:
Parameter Symbol Unit Value
Resistance of the armature coil Ra Ω 0.3
Inductance of the armature coil La 𝐻 0.01
Back emf constant of the motor shaft Kb 𝑉𝑠/𝑟𝑎𝑑 0.3
Inertia of the motor shaft Im 𝐾𝑔𝑚2 0.00005
Mass of the machine table m 𝐾𝑔 50
Pitch of the lead-screw P 𝑚 0.01
Speed ratio of the gear box N 10
Controller constant K1 𝑉/𝑉 3
Amplifier constant K2 𝑉/𝑉 4
Torque constant Ka 𝑁𝑚/𝐴 0.3
Constant of displacement transducer H1 𝑉/𝑚 1
Constant of velocity transducer H2 𝑉𝑠/𝑟𝑎𝑑 0.5

Solution
F = 𝐾1 𝐾2 𝐾𝑎 𝑃𝑛
A = 𝐿𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )
B = 𝑅𝑎 (𝑃2 𝑚 + 𝑛2 𝐼𝑚 )
C = 𝐾𝑎 𝐾𝑏 𝑃𝑛 + 𝐾2 𝐾𝑎 𝐻2 𝑛
D = 𝐾1 𝐾2 𝐾𝑎 𝐻1 𝑃𝑛

11
MATLAB Programs

1. Time Domain Solutions

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.01; im=0.00005;
kb=0.3; k1=3; k2=4; h1=1; h2=0.5;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
step(num,den);
grid

Step Response
1

0.9

0.8

0.7

0.6
Amplitude

0.5

0.4

0.3

0.2

0.1

0
0 50 100 150
Time (seconds)

12
ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.01; im=0.00005;
kb=0.3; k1=3; k2=4; h1=1; h2=0.005;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
step(num,den);
grid

Step Response
1

0.9

0.8

0.7

0.6
Amplitude

0.5

0.4

0.3

0.2

0.1

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Time (seconds)

13
ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.01; im=0.00005;
kb=0.3; k1=3; k2=4; h1=100; h2=0.5;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
step(num,den);
grid

Step Response
0.01

0.009

0.008

0.007

0.006
Amplitude

0.005

0.004

0.003

0.002

0.001

0
0 0.5 1 1.5
Time (seconds)

14
Neglecting the motor inductance: La=0
ra=0.3; la=0.0; ka=0.3; m=50; n=10 ; p=0.005; im=0.000001;
kb=0.3; k1=3; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
step(num,den);
grid

Step Response
1

0.9

0.8

0.7

0.6
Amplitude

0.5

0.4

0.3

0.2

0.1

0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
Time (seconds)

15
2. Frequency Domain Solutions

2.1 Nyquist Plots

Stable System: K1 = 3

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=3; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
nyquist(num,den);
grid

16
 Nyquist Diagram
1
2 dB 0 dB -2 dB -4 dB
4 dB
0.8
-6 dB
0.6 6 dB

0.4 10 dB -10 dB

0.2
Imaginary Axis

20 dB -20 dB

-0.2

-0.4

-0.6

-0.8

-1
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
Real Axis

Critically Stable System: K1 = 4.15

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=4.15; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
nyquist(num,den);
grid

17
 Nyquist Diagram
1.5
2 dB 0 dB -2 dB

4 dB -4 dB
1

6 dB -6 dB

0.5
10 dB -10 dB
Imaginary Axis

20 dB -20 dB
0

-0.5

-1

-1.5
-1.5 -1 -0.5 0 0.5 1 1.5
Real Axis

Unstable System: K1 = 5

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=5; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];

18
nyquist(num,den);
grid

Nyquist Diagram
2
2 dB 0 dB -2 dB

1.5

4 dB -4 dB
1
6 dB -6 dB
0.5 10 dB -10 dB
Imaginary Axis

20 dB -20 dB
0

-0.5

-1

-1.5

-2
-2 -1.5 -1 -0.5 0 0.5 1
Real Axis

2.2 Bode Plots

Stable System: K1 = 3

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=3; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
19
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
bode(num,den);
grid

Bode Diagram
0

-20
Magnitude (dB)

-40

-60

-80

-100
0
Phase (deg)

-90

-180

-270
-1 0 1 2 3
10 10 10 10 10
Frequency (rad/s)

Critically Stable System: K1 = 4.15

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=4.15; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);

20
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
bode(num,den);
grid

Bode Diagram
20

0
Magnitude (dB)

-20

-40

-60

-80

-100
0
Phase (deg)

-90

-180

-270
0 1 2 3
10 10 10 10
Frequency (rad/s)

Unstable System: K1 = 5

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=5; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;

21
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
bode(num,den);
grid

Bode Diagram
20

0
Magnitude (dB)

-20

-40

-60

-80

-100
0
Phase (deg)

-90

-180

-270
0 1 2 3
10 10 10 10
Frequency (rad/s)

22
2.3 Nichole's Plots
Stable System: K1 = 3
ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;
im=0.000001; kb=0.3; k1=3; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
nichols(num,den);
grid

Nichols Chart
40
0 dB
0.25 dB
0.5 dB
20 1 dB -1 dB
3 dB
6 dB -3 dB
0 -6 dB
-12 dB
Open-Loop Gain (dB)

-20 -20 dB

-40 -40 dB

-60 -60 dB

-80 -80 dB

-100 -100 dB

-120 dB
-120
-360 -315 -270 -225 -180 -135 -90 -45 0
Open-Loop Phase (deg)

23
Critically Stable System: K1 = 4.15

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=4.15; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
nichols(num,den);
grid

Nichols Chart
40
0 dB
0.25 dB
0.5 dB
20 1 dB -1 dB
3 dB
6 dB -3 dB
0 -6 dB
-12 dB
Open-Loop Gain (dB)

-20 -20 dB

-40 -40 dB

-60 -60 dB

-80 -80 dB

-100 -100 dB

-120 dB
-120
-360 -315 -270 -225 -180 -135 -90 -45 0 45 90 135 180
Open-Loop Phase (deg)

24
Unstable System: K1 = 5

ra=0.3; la=0.01; ka=0.3; m=50; n=10; p=0.005;

im=0.000001; kb=0.3; k1=5; k2=4; h1=1; h2=0.001;
F=k1*k2*ka*p*n;
A=la*(p*p*m+n*n*im);
B=ra*(p*p*m+n*n*im);
C=ka*kb*p*n+k2*ka*h2*n;
D=k1*k2*ka*h1*p*n;
num=[0 0 0 F];
den=[A B C D];
nichols(num,den);
grid

Nichols Chart
40
0 dB
0.25 dB
0.5 dB
20 1 dB -1 dB
3 dB
6 dB -3 dB
0 -6 dB
-12 dB
Open-Loop Gain (dB)

-20 -20 dB

-40 -40 dB

-60 -60 dB

-80 -80 dB

-100 -100 dB

-120 dB
-120
-360 -315 -270 -225 -180 -135 -90 -45 0 45 90 135 180
Open-Loop Phase (deg)

25