Beruflich Dokumente
Kultur Dokumente
DECLARATION
I hereby declare that the project work entitled COMPUTER NUMERICALLY CONTROLLED
MACHINES is an authentic record of my own work carried out at BHEL (GO+NDWAL) as
requirements of six months Industrial Training for the award of the degree of B
.E. at University Institute of Engineering & Technology, Panjab University, Chan
digarh under the guidance of Mr.Tejinder Singh and Mr.Sanjeev, during January 4,
2013 to July 3, 2013
SARAVPREET SINGH DHILLON UE 95083
Date : June 12, 2013
Certified that the above statement made by the student is correct to the best of
our knowledge and belief.
Mr.Sanjeev Kumar
Mr.Tejinder Singh HOD
+
+
2
INDEX
OVERVIEW OF THE ORGANISATION
INTRODUCTION POWER TRANSMISSION & DISTRIBUTION (T & D) INDUSTRIES TRANSPORTAT
RENEWABLE ENERGY MISSION INTERNATIONAL OPERATIONS TECHNOLOGY UPGRADATION AND R&
D 1 3 4 4 5 5 6 6
1
PROJECT REPORT
Introduction Configuration of CNC Systems 12
Input Device Machine Control Unit Machine Tool Driving System Feedback Systems D
isplay Unit 13 15 15 16 17 21
9
BHEL caters to core sectors of the Indian Economy viz., Power Generation s & Tra
nsmission, Industry, Transportation, Telecommunication, Renewable Energy, Defens
e, etc. BHEL has already attained ISO 9000 certification for quality management,
and ISO 14001 certification for environment management and OHSAS 18001 certific
ation for Occupational Health and Safety Management Systems. The Company today e
njoys national and international presence featuring in the Fortune International
-500 and is ranked among the top 10 companies in the world, manufacturing power g
eneration equipment. BHEL is the only PSU among the 12 Indian companies to figur
e in Forbes Asia Fabulous 50 list.
BHARAT HEAVY ELECTRICALS LTD.
An Overview:
6
BHEL today is the largest Engineering Enterprise of its kind in India with excel
lent track record of performance, making profits continuously since 1971-72.
BHEL s vision is to become a world-class engineering enterprise, committed to en
hancing stakeholder value. The company is striving to give shape to its aspirati
ons and fulfill the expectations of the country to become a global player.
BHEL business operations cater to core sectors of Indian Economy like.
ustry Transportation Transmission Defenses etc.
Power Ind
The greatest strength of BHEL is its highly skilled and committed employees. Eve
ry participative style of management all these have engendered development of a
committed and motivated workforce setting new benchmarks in terms of productivit
y, quality and responsiveness. employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career plan
ning, a positive work culture.
POWER TRANSMISSION & DISTRIBUTION (T & D)
BHEL offer wide ranging products and systems for T & D applications. Products ma
nufactured include power transformers, instrument transformers, dry type transfo
rmers, series and stunt reactor, capacitor tanks, vacuum and SF circuit breakers
gas insulated switch gears and insulators. A strong engineering base enables th
e Company to undertake turnkey delivery of electric substances up to 400 kV leve
l series compensation systems (for increasing power transfer capacity of transmi
ssion lines and improving system stability and voltage regulation), shunt compen
sation systems (for power factor and voltage improvement) and HVDC systems (for
economic transfer of bulk power). BHEL has indigenously developed the state-of-t
he-art 7
controlled shunt reactor (for reactive power management on long transmission lin
es). Presently a 400 kV Facts (Flexible AC Transmission System) project under ex
ecution.
INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, suga
r, fertilizer, refinances, petrochemicals, paper, oil and gas, metallurgical and
other process industries. The range of system & equipment supplied includes: ca
ptive power plants, co-generation plants DG power plants, industrial steam turbi
nes, industrial boilers and auxiliaries. Water heat recovery boilers, gas turbin
es, heat exchangers and pressure vessels, centrifugal compressors, electrical ma
chines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric
filters, reactors, fluidized bed combustion boilers, chemical recovery boilers
and process controls.
TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and tract
ion propulsion systems. In the area of rolling stock, BHEL manufactures electric
locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP,
both for mainline and shunting duly applications. BHEL is also producing rolling
stock for special applications viz., overhead equipment cars, Special well wago
ns, Rail-cum-road vehicle etc., Besides traction propulsion systems for in-house
use, BHEL manufactures traction propulsion systems for other rolling stock prod
ucers of electric locomotives, diesel-electric locomotives, electrical multiple
units and metro cars. The electric and diesel traction equipment on India Railwa
ys are largely powered by electrical propulsion systems produced by BHEL. The co
mpany also undertakes retooling and overhauling of rolling stock in the area of
urban transportation systems. BHEL is geared up to turnkey execution of electric
trolley bus systems, light rail systems etc. BHEL is also diversifying in the a
rea of port handing equipment and pipelines transportation system.
8
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and ren
ewable sources of energy include: wind electric generators, solar photovoltaic s
ystems, solar lanterns and battery-powered road vehicles. The Company has taken
up R&D efforts for development of multi-junction amorphous silicon solar cells a
nd fuel based systems.
MISSION
The leading Indian engineering enterprise providing quality products systems and
services in the fields of energy, transportation, infrastructure and other pote
ntial areas.
The design and construction of Computer Numerically Controlled(CNC) machines dif
fers greatly from that of conventional machine tools.This difference arises from
the requirements of higher performance levels.The CNC machines often employ the
various mechatronics elements thathave been developed over the years. However,
the quality and reliability of these machines depends on the various machine ele
ments and subsystems of the machines. There are some of the important constituen
ts parts and aspectsof CNC machines to be considered in their designing, for exa
mple Machinestructure, Guideways, Feed drives, Spindle and Spindle bearings, Mea
suringsystems, Controls, Software and Operator interface, Gauging, Toolmonitorin
g.The control of a machine tool by means of stored information throughthe comput
er is known as Computer Numerically Controlled. Theinformation stored in the com
puter can be read by automatic means andconverted into electrical signals, which
operate the electrically controlledservo systems. Electrically controlled servo
systems permits the slides of amachine tool to be driven simultaneously and at
the apporopriate feeds anddirection so that complex shapes can be cut, often wit
h a single operationand without the need to reorient the workpiece.Computer Nume
rically Control can be applied to milling machines,Lathe machines, Grinding mach
ines, Boring machines, Flame cutters,Drilling machines etc. 9
International Operations
BHEL has, over the years, established its references in around 60 countries of t
he world, ranging for the United States in the West to New Zealand in the Far Ea
st. These references encompass almost the entire product range of BHEL, covering
turnkey power projects of thermal, hydro and gas-based types, substation projec
ts, rehabilitation projects, besides a wide variety of products, like transforme
rs, insulators, switchgears, heat exchangers, castings and forgings, valves, wel
l-head equipment, centrifugal compressors, photo-voltaic equipment etc. Apart fr
om over 1110MW of boiler capacity contributed in Malaysia, and execution of four
prestigious power projects in Oman, Some of the other major successes achieved
by the Company have been in Australia, Saudi Arabia, Libya, Greece, Cyprus, Malt
a, Egypt, Bangladesh, Azerbaijan, Sri Lanka, Iraq etc. The Company has been succ
essful in meeting demanding customer s requirements in terms of complexity of th
e works as well as technological, quality and other requirements viz extended wa
rrantees, associated O&M, financing packages etc. BHEL has proved its capability
to undertake projects on fast-track basis. The company has been successful in m
eeting varying needs of the industry, be it captive power plants, utility power
generation or for the oil sector requirements. Executing of Overseas projects ha
s also provided BHEL the experience of working with world renowned Consulting Or
ganisations and inspection Agencies. In addition to demonstrated capability to u
ndertake turnkey projects on its own, BHEL possesses the requisite flexibility t
o interface and complement with International companies for large projects by su
pplying complementary equipment and meeting their production needs for intermedi
ate as well as finished products.
Technology Upgradation and Research & Development
To remain competitive and meet customers expectations, BHEL lays great emphasis
on the continuous upgradation of products and related technologies, and develop
ment of new products. The Company has upgraded its products to contemporary leve
ls through continuous in 10
PROJECT REPORT
CNC SYSTEMS
The definition of CNC given by Electronic Industry Association (EIA) is as follo
ws:
A system in which actions are controlled by the direct insertion of numerical dat
a at some point. The system must automatically interpret at least some portion o
f this data.
In a simple word, a CNC system receieves numerical data, interpret the data and
then control the action accordingly.
A Vertical Machining Center
12
INTRODUCTION
Numerical control (NC) is a method employed for controlling the motions of a mac
hine tool slide and its auxiliary functions with input in the form of numerical
data. A computer numerical control (CNC) is a microprocessor-based system to sto
re and process the data for the control of slide motions and auxiliary functions
of the machine tools. The CNC system is the heart and brain of a CNC machine wh
ich enables the operation of various machine members such as slides, spindles, e
tc. as per the sequence programmed into it, depending on the machining operation
s. The main advantage of a CNC system lies in the fact that the skills of the op
erator hitherto required in the operation of a conventional machine is removed a
nd the part production is made automatic. The CNC systems are constructed with a
NC unit integrated with a programmable logic controller (PLC) and some times wi
th an additional external PLC (non-integrated). The NC controls the spindle move
ment and the speeds and feeds in machining. It calculates the traversing path of
the axes as defined by the inputs. The PLC controls the peripheral actuating el
ements of the machine such as solenoids, relay coils, etc. Working together, the
NC and PLC enable the machine tool to operate automatically. Positioning and pa
rt accuracy depend on the CNC system s computer control algorithms, the system r
esolution and the basic mechanical machine accuracy. Control algorithm may cause
errors while computing, which will reflect during contouring, but they are very
negligible. Though this does not cause point to point positioning error, but wh
en mechanical machine inaccuracy is present, it will result in poorer part accur
acy. Computer Numerical Control (CNC) is a specialized and versatile form of Sof
t Automation and its applications cover many kinds, although it was initially de
veloped to control the motion and operation of machine tools. Computer Numerical
Control may be considered to be a means of operating a machine through the use
of discrete numerical values fed into the machine, where the required input te
chnical information is stored on a kind of input media such as floppy disk, hard
disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine follows a pred
etermined sequence of machining operations at the predetermined speeds necessary
to produce a work piece of the right shape and size and thus according to compl
etely predictable results. A different product can 13
Inputs
Output
Machine Elements
s
Fig.1 Schematic diagram of a CNC machine tool
Proximity switches Limit switches Relay coils Pressure switches Float switches
A CNC system consists of the following 6 major elements:
a. b. c. d. e. f.
Input Device Machine Control Unit Machine Tool Driving System Feedback Devices D
isplay Unit
16
Input Devices
a. Floppy Disk Drive Floppy disk is a small magnetic storage device for CNC data
input. It has been the most common storage media up to the 1970s, in terms of d
ata transfer speed, reliability, storage size, data handling and the ability to
read and write. Furthermore, the data within a floppy could be easily edited at
any point as long as you have the proper program to read it. However,this method
has proven to be quite problematic in the long run as floppies have a tendency
to degrade alarmingly fast and are sensitive to large magnetic fields and as wel
l as the dust and scratches that usually existed on the shop floor.
b. USB Flash Drive A USB flash drive is a removable and rewritable portable hard
drive with compact size and bigger storage size than a floppy disk. Data stored
inside the flash drive are impervious to dust and scratches that enable flash d
rives to transfer data from place to place. In recent years, all computers suppo
rt USB flash drives to read and write data that make it become more and more pop
ular in CNC machine control unit.
USB Flash Drive c. Serial communication The data transfer between a computer and
a CNC machine tool is often accomplished through a serial communication port. I
nternational standards for serial communications are
established so that information can be exchanged in an orderly way. The most com
mon interface between computers and CNC machine tools is referred to the EIA Sta
ndard RS-232. Most of the personal computers and CNC machine tools have built in
RS232 port and a standard RS-232 cable is used to connect a CNC machine to a co
mputer which enables the data transfer in reliable way. Part programs can be dow
nloaded into the memory of a machine tool or 17
quick change tooling system, etc also contribute to the high accuracy and high r
epeatability of CNC machines.
Different Machine Tools
Driving System
The driving system is an important component of a CNC machine as the accuracy an
d repeatability depend very much on the characteristics and performance of the d
riving system. The requirement is that the driving system has to response accura
tely according to the programmed instructions. This system usually uses electric
motors although hydraulic motors are sometimes used for large machine tools. Th
e motor is coupled either directly or through a gear box to the machine lead scr
ew to moves the machine slide or the spindle. Three types of electrical motors a
re commonly used.
Stepping Motor A stepping motor is a device that converts the electrical pulses
into discrete mechanical rotational motions of the motor shaft. This is the simp
lest device that can be applied to CNC 20
machines since it can convert digital data into actual mechanical displacement.
It is not necessary to have any analog-to-digital converter nor feedback device
for the control system. They are ideally suited to open loop systems.
However, stepping motors are not commonly used in machine tools due to the follo
wing drawbacks: slow speed, low torque, low resolution and easy to slip in case
of overload. Examples of stepping motor application are the magnetic head of flo
ppy-disc drive and hard disc drive of computer, daisy-wheel type printer, X-Y ta
pe control, and CNC EDM Wire-cut machine.
Stepping Motor
FEEDBACK SYSTEMS
Following are the two types of control systems used in the CNCmachines 1. Open l
oop control system. 2. Closed loop control system.
1. Open loop control system:21
In an open loop system the machine slides are displacedaccording to the informat
ion loaded from the part program into thecontrol system. Hence there is no measu
rement of slide position and nofeedback signals for comparison with the input si
gnal. The correctmovement of slide entirely d epends upon the ability of the dri
vesystems to move the slide through the required exact distance.The most common
method of driving the lead screw is by a stepper motor. The stepper motors are t
he simplest way for converting detailelectrical signals into proportional moveme
nt. As there is no check onthe slide position, the system accuracy depends upon
the motors abilityto step through the exact number of steps provided at the inpu
t asshown in fig.
2. Closed loop control system:A closed loop system is as shown in fig. sends bac
k a signal to thecontrol unit from a measuring device called as transducer. Thet
ransducer is attached to the slide ways. The signal indicates the actualmovement
and position of the slides.The control unit continues to adjust the position of
the slide untilit arrives its destination, this system has feedback. Although mo
recostly and complex than open loop system, these system gives moreaccurate posi
tioning. For this type of system, servomotors are used
22
23
Feedback Device
In order to have a CNC machine operating accurately, the positional values and s
peed of the axes need to be constantly updated. Two types of feed back devices a
re normally used, positional feed back device and velocity feed back device. a.
Positional Feed Back Devices There are two types of positional feed back devices
: linear transducer for direct positional measurement and rotary encoder for ang
ular or indirect linear measurement.
Linear Transducers - A linear transducer is a device mounted on the machine tabl
e to measure the actual displacement of the slide in such a way that backlash of
screws; motors, etc would not cause any error in the feed back data. This devic
e is considered to be of the highest accuracy and also more expensive in compari
son with other measuring devices mounted on screws or motors.
Linear Transducer (Courtesy of Heidenhain)
Rotary Encoders - A rotary encoder is a device mounted at the end of the motor s
haft or screw to measure the angular displacement. This device cannot measure li
near displacement directly so that error may occur due to the backlash of screw
and motor etc. Generally, this error can be compensated for by the machine build
er in the machine calibration process. 24
Programming Systems
Two types of programming modes, the incremental system and the absolute system,
are used for CNC. Both systems have applications in CNC programming, and no syst
em is either right or wrong all the time.
Positioning reference point Systems: 1- Incremental 2- Absolute
Most controls on machine tools today are capable of handling either incremental
or absolute programming.
Incremental program locations are always given as the distance and direction fro
m the immediately preceding point . Command codes which tell the machine to move
the table, spindle, and knee are explained here using a vertical milling machin
e as an example:
A workpiece dimensioned in the incremental system mode
28
A X plus (X+) command will cause the cutting tool to be located to the right of th
e last point. A X minus (X-) command will cause the cutting tool to be located to
the left of the last point. A Y plus (Y+) command will cause the cutting tool to b
e located toward the column. A Y minus (Y-) will cause the cutting tool to be loca
ted away from the column. A Z plus (Z+) command will cause the cutting tool or spi
ndle to move up or away from the workpiece. A Z minus (Z-) moves the cutting tool
down or into the workpiece. In incremental programming, the G91 command indicate
s to the computer and MCU (Machine Control Unit) that programming is in the incr
emental mode.
29
Absolute program locations are always given from a single fixed zero or origin p
oint (Fig. 7). The zero or origin point may be a position on the machine table,
such as the corner of the worktable or at any specific point on the workpiece. I
n absolute dimensioning and programming, each point or location on the workpiece
is given as a certain distance from the zero or reference point.
A workpiece dimensioned in the absolute system mode. Note: All dimensions are gi
ven from a known point of referenc
A X plus (X+) command will cause the cutting tool to be located to the right of th
e zero or origin point. A X minus (X-) command will cause the cutting tool to be l
ocated to the left of the zero or origin point. A Y plus (Y+) command will cause t
he cutting tool to be located toward the column.
30
A Y minus (Y-) command will cause the cutting tool to be located away from the col
umn. In absolute programming, the G90 command indicates to the computer and MCU
that the programming is in the absolute mode.
Point-to-Point or Continuous Path
CNC programming falls into two distinct categories . The difference between the
two categories was once very distinct. Now, however, most control units are able
to handle both point-topoint and continuous path machining. A knowledge of both
programming methods is necessary to understand what applications each has in CN
C.
CNC POSITIONING SYSTEM
Point-To-Point OR Positioning
Continuous Path OR Contouring
Point-to-Point Positioning
Point-to-point positioning is used when it is necessary to accurately locate the
spindle, or the workpiece mounted on the machine table, at one or more specific
Iocations to perform such operations as drilling, reaming, boring, tapping, and
punching (Fig. 9). Point-to-point positioning is the process of positioning fro
m one coordinate (XY) position or location to another, performing the machining
operation, and continuing this pattern until all the operations have been comple
ted at all programmed locations. 31
Fig. 10 Types of contour machining (A) Simple contour; (B) complex contour
Interpolation
The method by which contouring machine tools move from one programmed point to t
he next is called interpolation. This ability to merge individual axis points in
to a predefined tool path is built into most of todays MCUs. There are five metho
ds of interpolation: linear, circular, helical, parabolic, and cubic. All contou
ring controls provide linear interpolation, and most controls are capable of bot
h linear and circular interpolation. Helical, parabolic, and cubic 33
interpolation are used by industries that manufacture parts which have complex s
hapes, such as aerospace parts and dies for car bodies. Linear Interpolation Lin
ear Interpolation consists of any programmed points linked together by straight
lines, whether the points are close together or far apart . Curves can be produc
ed with linear interpolation by breaking them into short, straight-line segments
. This method has limitations, because a very large number of points would have
to be programmed to describe the curve in order toproduce a contour shape. A con
tour programmed in linear interpolation requires the coordinate positions (XY po
sitions in two-axis work) for the start and finish of each line segment. Therefo
re, the end point of one line or segment becomes the start point for the next se
gment, and so on, throughout the entire program.
An example of two-axis linear interpolation.
Circular Interpolation The development of MCUs capable of circular interpolation
has greatly simplified the process of programming arcs and circles. To program
an arc (Fig. 12), the MCU requires only the coordinate 34
positions (the XY axes) of the circle center, the radius of the circle, the star
t point and end point of the arc being cut, and the direction in which the arc i
s to be cut (clockwise or counterclockwise) See Fig. . The information required
may vary with different MCUs.
For two-dimensional circular interpolation the MCU must be supplied with the XY
axis, radius, start point, end point, and direction of cut.
Programming Format
Word address is the most common programming format used for CNC programming syst
ems. This format contains a large number of different codes (preparatory and mis
cellaneous) that transfers program information from the part print to machine se
rvos, relays, micro-switches, etc., to manufacture a part. These codes, which co
nform to EIA (Electronic Industries Association) standards, are in a logical seq
uence called a block of information. Each block should contain enough informatio
n to perform one machining operation.
35
G- Codes
Group Code Function
01 01 01 01
G00 G01 G02 G03
Rapid positioning Linear interpolation Circular interpolation clockwise (CW) Cir
cular interpolation
counterclockwise (CCW) 06 06 G20* G21* G24 00 00 G28 G29 G32 07 07 07 08 (+) dir
ection 08 direction G44 Tool length compensation minus (-) G40 G41 G42 G43 Inch
input (in.) Metric input (mm) Radius programming (**) Return to reference point
Return from reference point Thread cutting (**) Cutter compensation cancel Cutte
r compensation left Cutter compensation right Tool length compensation positive
08
G49
Tool length compensation cancel
38
M11 M30
Clamps off Program stop, reset to start
Block of Information
CNC information is generally programmed in blocks of five words. Each word confo
rms to the EIA standards and they are written on a horizontal line. If five comp
lete words are not included in each block, the machine control unit (MCU) will n
ot recognize the information, therefore the control unit will not be activated.
Using the example shown in Fig. 17 , the five words are as follows: N001 represe
nts the sequence number of the operation. G01 represents linear interpolation X1
2345 will move the table 1.2345 in. in a positive direction along the X axis. Y0
6789 will move the table 0.6789 in. along the Y axis. M03 Spindle on CW.
A complete block of information consists of five words.
40
25
4. Dimension the part clearly so that its shape can be understood without making
mathematical calculations or guesses. 5. Define the part so that a computer num
erical control cutter path can be easily programmed.
Machine Zero Point
The machine zero point can be set by three methodsby the operator, manually by a
programmed absolute zero shift, or by work coordinates, to suit the holding fixt
ure or the part to be machined. MANUAL SETTING - The operator can use the MCU co
ntrols to locate the spindle over the desired part zero and then set the X and Y
coordinate registers on the console to zero.
Stored zero shifts (G54...G59) Programmed zero shift (G92)
The relationship between the part zero and the machine system of coordinate
R = Reference point (maximum travel of machine) M = Machine zero point (X0,Y0,Z0
) of machine coordinate system. W = Part zero point workpiece coordinate system.
43
Under G54 ... G59 the actual machine coordinates of part zero are stored in the
stored zero offsets memory and activated in the part program. Under G92 the actu
al machine coordinates are inserted and used on the G92 line of the part program
.
ABSOLUTE ZERO SHIFT - The absolute zero shift can change
the position of the coordinate system by a command in the CNC program. The progr
ammer first sends the machine spindle to home zero position by a G28 command in
the program. Then another command (G92 for absolute zero shift) tells the MCU ho
w far from the home zero location, the coordinate system origin is to be positio
ned, Fig. 19. The sample commands may be as follows: N1 G28 X0 Y0 Z0 (sends spin
dle to home zero position) N2 G92 X4.000 Y5.000 Z6.000 (the position the machine
will reference as part zero)
44
The Power Supply Unit When you plug a small flash drive up to your USB port, the
computer powers the device through the port. When you plug a larger device, say
a printer for example, you have to use an external power source because the com
puter is not capable of supplying sufficient power. This condition means that yo
u have to plug that device into the computer as usual, but you also have to plug
a second line to an auxiliary power source, such as the 110V outlet on your wal
l. The same conditions are true for CNC devices. They require a low-voltage
communication line, through which the computer tells the machine what to do, and
a power source that provides the power for moving, cutting, and other such oper
ations. A power converter, usually referred to as the power supply unit (PSU), is
often used to change the form of the supplied power from alternating current (AC
) from the power grid, to direct current (DC) that is more easily used by the ma
chines drive motors. The power supply handles large voltages and currents that co
uld be harmful to the NC circuitry. Therefore, the power source, motor drivers,
and motors are often separated from the computer with a circuitry protection sys
tem that isolates surges in electrical power.
45
The Circuitry Protection System The circuitry protection system contains a break
out board to isolate signals from the computer, distribute the signals to the de
sired drivers, and also allows easy hook up of peripherals such as limit switche
s that feed information back to the computer. Fuses are also part of the circuit
ry protection system. Fuses could save the equipment in case of electrical spike
s, shorts, or faulty wiring. A low-voltage communication signal passes from the
computer through the breakout
board unchanged to the motor drivers. This isolated your computer from the CNC c
ontroller circuit but allows the signals to carry through to your motor drivers.
The motor drivers The motor drivers receives the communication signal and and t
hen coordinates pulses of the desired current and voltage to elicit the movement
in the drive motors. The motor drivers may communicate position information one
way to the motor (open loop system), or send and receive position information(c
losed loop system), depending on the users choice of drive system. More on these
systems may be found in the drivers sections.
CNC Controller Components Setup
The figure below shows the typical setup of the CNC controller components, such
as that for a 3 axis CNC router. The system is composed of a computer with NC co
ntrol software, the controller box, and the drive motors. The controller box inc
ludes a breakout board, power source (not shown), and motor drivers. The breakout
board provides the circuitry protection and signal distribution inside the contr
oller box.
In the figure above, you
46
can see the computer is connected to the breakout board, usually through the pri
nter port (DB25). There are many types of breakout boards; some of very high qua
lity and great protection, and lower budget options that do not offer much prote
ction. The best models employ opto-isolators, which use a light signals to trans
mit data across an air gap. These devices provide complete conductive isolation
between the controller circuit and your computer. As a note, the computer is ful
ly capable of connecting directly to the drivers and driving the motors, but thi
s setup puts your computer at risk. The first figure is an idealized block diagr
am of your CNC electrical system. A little more detail has been added in the fig
ure below to show the conceptual layout of signal wires (light black) and power
wires (heavy black).
Although your computer will run on 110VAC, the CNC machine may run on 110VAC, or
220VAC, or 480VAC, and may be single phase, three phase, etc This power enters t
he controller box and will be distributed by the power supply. For most machines
, the power supply will convert the incoming power from alternating current (AC)
to direct current (DC). This DC supply will be of a lower voltage, such as 12V,
24V, 36V, or higher. The power supplied depends on you CNC controller component
s, specifically the motor drivers.
47
The "Signals"
The signal lines coming from the computer operate on 5V DC supplied by the compu
ter communication port, and is a square wave form called a Transistor-to-Transis
tor Logic (TTL) signal. This signal is essentially a series of small pulses from
0V to +5V that represent 0s and 1s in a binary computer language. This signal is
a form of a Pulse-Width Modulated (PWM) signal where the length of the pulse is
varied to indicate information. The width of the pulse determines the binary cod
e sent; either a 0 or a 1 as communicated by the computer and interpreted by the mot
or driver. More on the signals may be found in the signals page.
The signal from the computer to the breakout board is the same as that from the
breakout board to the motor driver. Remember, the breakout board provides circui
t protection and signal distribution. Therefore, the signal coming out of the br
eakout board is also a 5V TTL signal of the same form. However, as discussed pre
viously, the signal after the driver has been conditioned as needed to provide t
he large move voltage and current needed to drive the machine.
50
Breakout Boards
Breakout boards are a common electrical components that take a bundled cable and
breaks out each conductor to a terminal that can easily accept a hook-up wire for
distribution to another device. They are a common item in electronic projects a
nd enable easy, clean installation of electronic devices. The image at right sho
ws a simple DB25 breakout circuit board from Winford Engineering. The breakout b
oard is positioned between your computer or indexer and the motor drivers and se
rves two purposes in the CNC control system: circuit protection and signal distr
ibution. Here we will describe the boards function in the CNC control system and
what you need to know about how to select one to suit your need 51
Z
X
Numerical Control Of The Machine S Y
Z
EEPROM OR TAPE INPUT
Control
Microprocessor
ROM
Spindle Position
X,Y,Z Positions
Motor Driver
Spindle Motor 54 X,Y,Z Spindle Motors
MACHINE SPECIFICATIONS
GENERAL INFORMATION
Manufacturer
Model
c System 6MB 4000 kg
TABLE
Working area
Control unit
STROKES
x-axis stroke in the crosswise
direction of the table
y-axis stroke in the longitudinal direction of the table
z-axis stroke in the vertical direction of the spindle head Distance between the
spindle nose and top of the table
560 mm
350 mm
400 mm
150-550 mm
SPINDLE HEAD
Spindle nose contour
NT 40 60-600 rpm Stepless (s 4 digit) AC 5.5 kW (30 min)
Spindle speed
55
Spindle motor
FEED
Least increment
0.001 mm 3600 mm/min 13000 mm/min
Cutting feed rate
Rapid traverse
CNC machines are widely used in the metal cutting industry and are best used to
produce the following types of product: Parts with complicated contours Parts r
quiring close tolerance and/or good repeatability Parts requiring expensive jigs
and fixtures if produced on conventional machines Parts that may have several e
ngineering changes, such as during the development stage of In cases where human
errors could be extremely costly Parts that are needed in a hurry Small batch l
ots or short production runs
a prototype
Some common types of CNC machines and instruments used in industry are as follow
ing: Drilling Machine Lathe / Turning Centre Milling / Machining Centre Turre
ress and Punching Machine Wirecut Electro Discharge Machine (EDM) Grinding Machi
ne Laser Cutting Machine Water Jet Cutting Machine
And Most important For Electronics industry is that CNC Milling and Drilling is
used for Manufacturing Of PCB .( Printed Circutiry Board)..
60