Problems in CNC

Diagnose
Unit 5
Content
• Problems in Mechanical components
• Problems in Electrical components
• Problems in Pneumatic Systems
• Common Faults and their remedies
• Fault-Finding Techniques
• Online fault finding techniques
• Adaptive Control system in CNC
• Types of Adaptive Control
• Applications of Adaptive Control
Introduction
• A CNC machine consist of a number of electrical, mechanical,
pneumatic/hydraulic, electronic components.

• The person operating a CNC should know the common problems in

these components, so that if not able to find the fault at least may
diagnose the symptoms or use diagnose tool.
Problems in Mechanical components
• The mechanical component of CNC consist of bed, tail/head stock, slideways,
tool pallets & switches
1. BED: As CNC’s operate on higher rpm, forces develop due to rapid
acceleration & tend to bend or deform the bed leading to error up to
40µmm. This can also be due to heating effect causing misalignment.
2. To avoid these:
- thermally symmetrical designs are made
- air-conditioning of room is done
Problems in Mechanical components
2. Slideways , Tool pallets
The wear & tear of slideways cause misalignment & consequently the
error in finish & accuracy.
In order to avoid these:
- hardened beds are used
- a hardened strip is used
- recirculating ball& screw
Problems in Mechanical components
3. Mechanical switches
The mechanical switches are used to
determine end positions of travel. These
are mostly ON-OFF type to sense
• End points
• Arrival of work piece
• End of cutting
The usual problems in them is that they
fail to give correct responses if their
-alignment is incorrect
-actuating lever bent
-dirt & foreign matter b/w contacts
Problems in Electrical components
• In CNC electrical components include
following three types of devices :
a) Switching devices. These
components ON or OFF some
electrical devices such as motor
b) Solenoids : actuates either a
pneumatic or hydraulic valve
c) Drive system - motor
 Problems in Pneumatic/Hydraulic Systems
• Pneumatic system consist of actuators which are driven by air pressure. The
actuators have three components.
-cylinder
-piston
-valve

The main problem with the pneumatic system is compressibility of air. A

regulator can be used to expand stored air to proper working pressure.
 Common Faults & Remedies
1. Sensors
if there are faults in a measurement system then the sensor might be at
fault. A simple test is to substitute the sensor with new one & to check
the results. It is also possible to check the voltage & current.

2. Switches & Relays

Dirt & particles of waste material between switch contacts is a common
source of incorrect functioning of mechanical switches
Common Faults & Remedies
3. Motors
Maintenance of Both D.C & A.C motors involves correct lubrication .
With D.C motors the brushes wear & can require changing .

Setting of new bushes need to be in accordance with the

manufacturer’s specification.

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 Common Faults & Remedies
4. Hydraulic & pneumatic systems
A common cause of faults with Hydraulic & pneumatic systems is dirt.
Small particles of dirt can damage seals, block orifices cause valve spools
to jam.

Thus filters should be regularly checked & cleaned.

Leaks in hoses , pipes & fittings are common faults.
Fault-Finding Techniques
• Fault finding techniques include
1. Visual inspection. Just carefully looking at a faulty system may
reveal the source of a fault.e,g an integrated circuit loose in its
holder or any extra solder bridging tracks.
2. Multimeter.
3. Oscilloscope. also known as a scope, CRO, DSO or, an O-scope)
1. is a type of electronic test instrument that allows observation of constantly
varying signal voltages,
2. potential differences as a function of time,
 Fault-Finding Techniques
• Logic Probe. The purpose of a logic probe is
to examine the logic states (0 and 1)
• Logic Pulser: used to inject controlled
pulses into the circuit
• Current tracer: sense pulsing current in the
circuit
• Logic clip:
• Logic comparator:

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Online fault finding techniques
• GNC (Graphic Numeric Control)

• Four steps for GNC

1. Recognition of machined surface
2. Tool path generation
3. Tool path verification
4. Collision detection

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ADAPTIVE CONTROL SYSTEMS
It is the technique of automatically adjusting of cutting
parameters such as speeds, feeds and depth of cuts etc. to an
optimum satisfaction level during machining operation and
the maximum metal removal which will result in minimum
machining cost.

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 ADAPTIVE CONTROL (AC)
Programmer set the cutting parameter based on his/her knowledge and experience

Adaptive control machining improve production rate and reduce machining cost by
calculating and setting of optimal parameters during machining.

This calculation is based on measurements of process variables in real time and

followed by a subsequent on-line adjustments in the parameters subjected to
machining constraints in order to optimize the performance of the overall system.

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 Block Diagram of Adaptive control system

Tape NC System Drive command

Position feedback

Adaptive Me
control as ure
d Pa
ram
ete
•Constraints rs
•Performance index
•Strategy Sensors
The three functions of adaptive control :

1. Identification function
Current performance of the process or system - index of performance
Feedback system is used for information

2. Decision function
How the control mechanism should be adjusted to improve process performance. pre-programmed
logic is used for this
Decision function is a logic function

3. Modification function
It is a physical or mechanical change in the system.
It is a hardware function rather than a software function.
The modification involves changing the system parameters or variables so as to drive the process
towards a more optimal state.
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ADAPTIVE CONTROL SYSTEMS
TYPES:-
• Adaptive control with optimization (ACO)
• Adaptive control with constraints (ACC)
• Geometric Adaptive control (GAC)

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 1.Adaptive control with optimization

In this system the performance is optimized according to the given performance index

Index of performance
• is usually a economic function i.e. ,maximum production rate or minimum
machining cost

• It’s a ratio of work material removal rate (MRR) to tool wear rate (TWR)

• Index of performance= MRR

TWR

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2. Adaptive control with constraints
• In this system the machining conditions such as feed rate or speed are
maximized within given limits of machine and tool constraints

Adaptive controllers are fed by signals of following three sensors:-

• TCM sensor (tool condition monitor eg camera)

• Tool vibration sensor
• Spindle torque sensor

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Important constraints for ACC
•Max or min spindle speed
•Max allowed torque
•Max or min allowed chip load
•Max permitted feed rate
•Max allowed vibration

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3. Geometric Adaptive Control
• Used in finish machining operations
• Cutting speed is taken constant, machining feed is manipulated
• Sensors are mounted on the spindle to measure tool deflection, spindle
motor current.

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Advantages of Adaptive control
•Increased production rates
•Increased tool life
•Greater part protection
•Less operator intervention
•Easier part programming
•Less time required for part program

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