Computer Numerical Control CNC

Conventional milling machines

Vertical milling machine

Conventional milling machines

Horizontal Milling machine architecture

How does the table move along X- Y- and Z- axes ?

Numerical Control
Numerical control is a method of automatically operating a manufacturing machine based on a code of letters, numbers, and special characters. The numerical data required to produce a part is provided to a machine in the form of a program, called part program or CNC program. The program is translated into the appropriate electrical signals for input to motors that run the machine.

NC M/C Tool Operation

NC machines
Motion control is done by: servo-controlled motors

Table Leadscrew Encoder A/C Motor ~

Servo Controller Counter Comparator

Input (converted from analog to digital value)

Hardware Configuration of NC Machine

Machine Control Unit (MCU) the brain of the NC machine.

The Data Processing Unit (DPU) reads the part program.

The Control Loop Unit (CLU) controls the machine tool operation.

Advantage of NC
Parts Produced in less time so less expensive High accuracy & high precision even with smaller batch No operator skill required, less scrap Inspection time is reduced Lead time is reduced Tool can be used optimum speed & feed Metal removal is high

Limitation of NC
High cost as compared to conventional M/c ( 5 to 10 times.

Limited programming capability at the machine tool.

Limited logic beyond direct input. High operating cost and skill people required Special training needed to the personnel manning the NC M/C tool. (part programming etc.)

Higher investments for maintains in terms of wages of highly skilled personnel and expensive spares.

CNC - History
The concept is credited to John Parson (1947). Using punched cards he was able to control the position of a machine in an attempt to machine helicopter blade. US Air Force teamed up with MIT to develop a programmable milling machine (1949).

In 1952, a three-axis Cincinnati Hydrotel milling machine was demonstrated. The term Numerical Control (NC) originated. The machine had an electromechanical controller and used punched cards. 1968 - Kearney & Trecker machine tool builders market first machining center

CNC - History
1970s - Modern NC machine has a computer on board, Computer Numerical Control (CNC). They can run unattended at over 20,000 rpm (spindler speed) with a feed rate of over 600 ipm and an accuracy of .0001 1980s - Graphics based CAM systems introduced. Unix and PC based systems available 1990- Direct Numerical Control. This eliminates paper tape punch programs and allows programmers to send files directly to machine tools 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.

Computer Numerical Control (CNC)

A CNC machine is an NC machine with the added feature of an on-board computer.

CNC MILLING

INTRODUCTION OF CNC SIEMENS CONTROLLER

HAAS CNC Machines

CNC Machines
Machining Centers, equipped with automatic tool changers, are capable of changing 90 or more tools. Can perform milling, drilling, tapping, boring on many faces.

CNC Machines
Turning Centers are capable of executing many different types of lathe cutting operations simultaneously on a rotating part.

Motivation and uses To manufacture complex curved geometries in 2D or 3D was extremely expensive by mechanical means (which usually would require complex jigs to control the cutter motions)

Machining components with repeatable accuracy

Unmanned machining operations

Advantages of CNC - Easier to program; - Easy storage of existing programs; - Easy to change a program - Avoids human errors - CNC machines are safer to operate - Complex geometry is produced as cheaply as simple ones - Usually generates closer tolerances than manual machines

CNC terminology

BLU: basic length unit smallest programmable move of each axis.

Controller: (Machine Control Unit, MCU) Electronic and computerized interface between operator and m/c Controller components: 1. Data Processing Unit (DPU) 2. Control-Loops Unit (CLU)

Controller components

Data Processing Unit: Input device [RS-232 port/ Tape Reader/ Punched Tape Reader] Data Reading Circuits and Parity Checking Circuits

Decoders to distribute data to the axes controllers.

Control Loops Unit: Interpolator to supply machine-motion commands between data points

Position control loop hardware for each axis of motion

Types of CNC machines

Based on Motion Type: Point-to-Point

or

Continuous path

Based on Control Loops: Open loop or Closed loop

Based on Power Supply: Electric or Hydraulic or Pneumatic

Based on Positioning System Incremental or Absolute

Three Basic Categories of Motion Systems

Point to Point - No contouring capability
Straight cut control - one axis motion at a time is controlled for machining Contouring - multiple axiss controlled simultaneously

Three Basic Categories of Motion Systems

Control Systems
Open-Loop Control Systems

Closed-Loop Control Systems

Open Loop Systems for Controlling Tool Movement

Open Loop System
Uses stepping motor to create movement. Motors rotate a fixed amount for each pulse received from the MCU. The motor sends a signal back indicating that the movement is completed. No feedback to check how close the actual machine movement comes to the exact movement programmed.

Closed Loop Systems for Controlling Tool Movement

Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of these motors are variable and controlled by the amount of current or fluid. The motors are connect to the spindle and the table. A position sensor continuously monitors the movement and sends back a single to Comparator to make adjustments.

Open Loop vs. Closed Loop controls

Control Systems
Open-Loop Advantages
Less complex, Less costly, and lower maintenance costs Proper calibration is not a problem

Open-Loop Limitations
Control unit assumes desired position is achieved No positioning compensation Typically, a lower torque motor Not Reliable & less accurate Optimization is not possible

Control Systems
Closed-Loop Advantages
DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001) DC motors have higher torque ranges vs.. stepper motors More Reliable Optimization is possible Closed system are faster A number of variable can be handled simultaneously

Control Systems
Closed-loop limitations
Expensive Maintenance difficult Complicated installation

Components of Servo-motor controlled CNC

Motor lead screw rotation table moves

Motor speed control

feedback

position sensed by encoder

Two types of encoder configurations

Motion Control and feedback

Encoder outputs: electrical pulses (e.g. 500 pulses per revolution) Rotation of the motor linear motion of the table: by the leadscrew The pitch of the leadscrew: horizontal distance between successive threads One thread in a screw single start screw: Dist moved in 1 rev = pitch Two threads in screw double start screw: Dist moved in 1 rev = 2* pitch

Example 1
A Stepping motor of 20 steps per revolution moves a machine table through a leadscrew of 0.2 mm pitch.

(a) What is the BLU of the system ?

(b) If the motor receives 2000 pulses per minute, what is the linear velocity in inch/min ?

Example 2
A DC servo-motor is coupled to a leadscrew (pitch 5mm) of a machine table. A digital encoder, which emits 500 pulses per revolution, is mounted on the leadscrew. If the motor rotates at 600 rpm, find (a) The linear velocity of the table

(b) The BLU of the machine

(c) The frequency of pulses emitted by the encoder.