2.2 Configuration of CNC System A CNC system consists of the following, namely~ © Operator Control Pane! Machine Control Panel Central Processing Unit Servo Control Unit, Programmable Logic Controller Other Peripheral Devices eoeeo CNC system PLC Floppy drive/ hard disk J: memory Nc ke Command value Spindle head 5 Encoder Lead screw es Servo motor Velocity Be, iia Teedback Om Tacho Table ‘generator Servo drive Postion feedback Inputs Machine elements [outputsOperator Control Panel: The adjacent figure shows @ typical operator contro! panel. The operator control panel provides the user interface to facilitate a two- way communication between the user, CNC system and the machine tool. This consists of two parts- @ Screen display unit @ Keyboard Screen Display Unit: The SDU displays the status of the various parameters of the CNC system and the machine tool. It displays the following information for example; @ Main program number, subroutine number @ Display of all entered data, user programs, user data, machine data etc. @ Complete information on the block currently being executed @ Actual position value, set or actual difference, current feed rate, spindle speed @ Active G functions, miscellaneous functions (described in later chapters) @ Alarm messages in plain text @ Soft key descriptionIn addition to this, a few LED lamps are generally provided to indicate important operating mades and their status. Keyboard: A keyboard serves the following purpose, @ Editing of part programs, tool data, machine parameters @ Selection of different pages for viewing Machine Control Panel (MCP): It is the direct communication interface between the operator and the NC system, enabling the operation of the machine through the CNC system, During program execution, the CNC controls the axis motion, spindle function or tool function on a machine tool, depending upon the part program stored in the machine memory. Before starting the machining process, machine should be ready with the following tasks completed, @ Establishing a correct reference point @ Loading the system memory with the required part program @ Loading and checking of tool offsets, zero offsets, etc. To complete these preparatory functions, system must be operated in the specific operating mode. Central Processing Unit (CPU): The CPU is the brain of the CNC system. Machining part programs are stored in memory of CPU. CPU decodes the data and converts it into position control and velocity control signals. It keeps a continuous watch on movements of axes and spindle rpm and corrects it whenever this does not match with the programmed values. To run the machine in acceptable and allowable accuracy limit, CPU calculates the compensations (e.g. backlash, lead screw pitch error, tool wear compensation) required on the basis of corresponding inputs given to it. Similarly, it controls the signals generated by the system for the axis movement. CPU also checks continuously for any abnormal conditions in the system and corrects the same simultaneously. If the situation goes beyond control of the CPU, it finally shuts down the system and eventually the machine.Axis Speed Cards: Machine axes speed is controlled by these cards, which work according to CPU. A servo-contrel unit receives signal from CPU and converts Suitably to feed them to a servo-drive for machine tool axis movement. This also confirms that whether the machine tool axis movement is at the same speed commanded by CPU. In case of any overrun or under run during movement, they are reported immediately to the CPU for corrective or stopping action. Servo-Control Unit: CPU generates the control signals for position and velocity to initiate the axis movement. Servo-control unit has these signals as input. This unit further generates suitable signals as command values. Servo- drive unit transforms these command values and motion is seen at table axis and spindle motor end. Position feedback is received by the servo-control unit for the actual movement of the machine axes, from the feedback devices (e.g. rotary encoders, resolvers, linear scales). The velacity feedback is obtained through tacho generators. These feedback signals are passed on to the CPU far further processing, In this way, servo-contral unit performs as communication nede between the machine tool and CPU. As stated earlier, the actual movement of the slides on the machine tool is achieved through the servo drives. The amount of movement and the rate of movement is controlled by the CNC system depending upon the feedback system employed, i.e. closed-loop or open-loop system. Servo-drives: The servo-drive receives signals fram the CNC and transforms it into actual movement on the machine. The actual rate of movement and direction depend upon the command signal fram the CNC system. There are various types of servo-drives, e.g. DC drives, AC drives and stepper motor drives. A servo-drive consists of two parts mainly, the motor and the electronics for driving the motor. Closed-Loop System: It is described by the presence of feedback arrangement. In this system, the CNC system sends out commands for movement and the result is continuously monitored by the system through various feedback devices. Generally, there are two types of feedback to a CNC system position feedback and velocity feedback.vosition reeapack: A closed-loap system, regardless af the type of feedback device, will constantly try to achieve and maintain a given position by self- correcting. As the slide of the machine tool moves, its movement is fed back to the CNC system for determining the position of the slide to decide how much yet to be traveled and also to decide whether the movement is as per the commanded rate. If the actual rate is not as per the required rate, the system tries to correct it. In case it is not possible, the system declares a fault and initiates action for disabling the drives and if necessary, switches off the machine. Velocity Feedback: In case no time limitation is specified for the system to reach the final programmed position, then the system may not develop the required path or surface finish accuracy. Velocity feedback must be present there along with the position feedback whenever CNC systems are used for contouring, in order to produce correct interpolations and also ‘specified acceleration and deceleration velocities. The tacho generator used far velocity feedback is normally connected te the motor and it rotates whenever the motor rotates, thus giving an analog output proportional to the speed of the motor. This analog valtage is taken as speed feedback by the servo-contraller and swift action is taken by the controller to maintain the speed of the motor within the required limits. Open-Loop System: The open-loop system has no feedback arrangement. In this system, ‘the CNC system sends aut signals for movement but does not check whether actual movement is taking place or not, Stepper motors are used for actual movement and the stepper motors receive signals from the CNC system, Since real time information regarding system performance is not available to system controllers, they can not counteract disturbances appearing during the operations. They can be utilized in point-to-point system, where loading torque on the axis motors is low and almost constant, Programmable Logic Controller (PLC): Earlier contro! panels were having hard wires for connecting different electrical components in it. PLC offered a replacement for the same. PLC has EPROM (Erasable Programmable Read Only Memory) which can be reprogrammed without hardware changes whenever required. Some mentionable points are-Flexible and reusatle, Substantial input / output capacity, Increased functions, Inbuilt timers and counters, Enhanced large memory etc. The inputs for the PLC can be limit switches, push buttons, pressure switches, flow swtches, proximity sensors, heat sensors, selector switches, level switches, step less wheel switches, relay contacts, float switches, optical sensors, reed switches etc. The output can be solenoid coils, magnet coils, relay coils, starters for motor or other devices, indication lamps, LED displays etc. PLC has only the control circuit to operate at designated voltage. The external devices ar2 powered separately to actuate them. Other Peripheral Devices: These include communication equipment, programming units, keyboard, printer, flash card reader, external hard drive, CD drive etc.