PROBLEM WITH NC MACHINE Part programming mistakes: — In preparing the punched tape, part programming mistakes are common. — The mistakes can either be syntax or numerical errors. Non optimal speeds and feeds: — In NC machines the control system does not provide the opportunity to make changes in speeds and feeds during the cutting process. Punched tape: — Another problem related to programming is the tape itself. Tape reader: — The tape reader that interprets the punched tape is the least reliable hardware component of the machine. Controller: — The NC controller unit is hard wired. This means that its control features cannot be easily alerted to incorporate improvements into the unit.INTRODUCTION: CNC MACHINES © What is a CNC Machine? © CNC: Computer and Numeric Control ® Conventionally, an operator decides and adjusts various machines parameters like feed , depth of cut etc. depending on type of job , and controls the slide movements by hand. In a CNC machine functions and slide movements are controlled by motors using computer programs.Vertical knee milling machineVertical boring machinesINTRODUCTION: CNC MACHINES Computer numerical control is an NC system that utilizes a dedicated, stored program computer to perform some or all of the basic numerical control functions. By integrating a computer processor, computer numerical control, or “CNC” as it is now known, allows part machining programs to be edited and stored in the computer memory as well as permitting diagnostics and quality control functions during the actual machining. All CNC machining begins with a part program, which is a sequential instructions or coded commands that direct the specific machine functions. The part program may be manually generated or, more commonly, generated by computer aided part programming systems.INTRODUCTION: CNC MACHINES * CNC can control the motions of the work-piece or tool, the input parameters such as feed, depth of cut, speed, and the functions such as turning spindle on/off, turning coolant on/off. * Dedicated microprocessors are built into the control to perform basic and advanced NC functions. Control signals in CNC systems are in the form of binary words, where each word contains fixed number of bits. * 32 bits or 64 bits are commonly used, representing different axial positions.INTRODUCTION: CNC MACHINES CNC machines offer the following advantages in manufacturing. Higher flexibility: This is essentially because of programmability, programmed control and facilities for multiple operations in one machining center. Increased productivity: Due to low cycle time achieved through higher material removal rates and low set up times achieved by faster tool positioning, changing, automated material handling etc. Improved quality: Due to accurate part dimensions and excellent surface finish that can be achieved due to precision motion control and improved thermal control by automatic control of coolant flow. Reduced scrap rate: Use of Part programs that are developed using optimization procedures Reliable and Safe operation: Advanced engineering practices for design and manufacturing, automated monitoring, improved maintenance and low human interactionINTRODUCTION: CNC MACHINES On the other hand, the main disadvantages of CNC systems are . Relatively higher cost compared to manual versions More complicated maintenance due to the complex nature of the technologies Need for skilled part programmers. The above disadvantages indicate that CNC machines can be gainfully deployed only when the required product quality and average volume of production demand it.CNC MACHINES COMPONENTS OF CNC SYSTEMS Any CNC system consists of following components: 1. Part program 2. Program input device 3. Machine control unit p . Drive system 5. Machine tool 6. Feedback systemMACHINECONTROLLERUNIT IMICU The machine control unit (MCU) is the backbone of CNC systems. Consists of some electronic hardware that reads the NC program, interprets it and conversely translates it for mechanical actions of the machine tool. Following six functions are being done by MCU: Read coded instructions * Decode coded instructions Implement interpolations to generate axis motion commands Feed axis motion commands to amplifier circuits to drive axis mechanisms Receive the feed back signals of position and speed for each drive axis * Implement auxiliary control functions such as coolant ON/OFF, ON/OFF, and tool changeMACHINE CONTROLLER UNIT MCU Dell 2135CN & 2155CN Machine Control Unit Board (MCU)MACHINE CONTROLLER UNITMICU The MCU may be of three types : * Housed MCU Machine Control Unit May be mounted on the machine tool or may be built in the casing of the Machine. * Machine Control Unit It is enclosed in a separate cabinet which is installed at some remote or same place near to the machine. * Swing Around MCU Machine Control Unit It is directly mounted on the machine, which can swing around it and can be adjusted as per requirement of the operator’s position.Housed MCU Machine Control UnitMachine Control UnitSwing Around MCU Machine Control Unit(G&MCodeProgram) MCU CNC program ComputerNumericalControl Master ControlUnit \ Inputs to MCU. Axis drive system The Axis amplifier Electrical velocity 4 I i increases the | | | | | | | | | 1 commend to correct position error electrical current from the CNC control unit ‘Axis position feedback {octal valve)MACHINE CONTROLLERUNITMICU *The CNC program contains all the G&M code of that is interpreted by the motion control unit. *When the machine is instructed to move to a position in X, Y (lathe), or XY and Z (for a 3 axis machine) then a designated number of pulses are sent to the axis drive amplifier. *This in turn pulses the drive motor which moves the machine table or axis. *There is axis feedback from the drive motor which is fed back into the axis drive amplifier to ensure that the motor has moved the correct amount of divisions. *As the machine table or tool moves there is a linear encoder which reads the actual position of the table/tool and feeds this back to the motion control unit. This will be compared to the original value and the control unit will adjust the amount of pulses needed to move the tool/table to the correct position.A TYPICAL CNC LATHE/MILLING MACHINE PROGRAM BEING INTERPRETED BY THE MACHINE CONTROL UNIT CNC Program G' ind M codes. Send signals to Encoder a x00 =| serointerfacefor [+ ,Setvointerface 14) Servomotors ist congs re axis z X and Z axis fo amplify signals move axis Positional data To.contralunit s Electrical pulse to Request IsT01 IsTO1 TOt fitted ye T no 8 4 Send signal Encod Mo4 Seine Servointerface |,| Servomotorsto |_| Encoder _ s200 >| 0 Spindle to amplify signals rotate spindle sends ye at inter Fo-controlunit remo 8 Send signals to Encoder Got Al at, 2] servointertacetor f*} _Seneinterface le! Servomotors Ls! sone re axis X and Z axis o amply signals move ax's Positional data posit ye + Program Continues To control unit sTYPES OF CNC MACHINE CONTROL UNITS v FANUC CONTROLL v¥ SIEMENS v¥ GSK ¥ MECH 3 etcCNC MACHINES FUNCTIONS: ¢ The principles function of CNC are: — Machine Tool Control — In-process compensation — Improved programming and operating features — Diagnostics