Unit_2 PPT
Unit_2 PPT
UNIT - 2
by
Dr.K.S.Badrinathan
Unit - 2
MECHATRONIC ELEMENTS IN CNC MACHINE
TOOLS
• CNC systems - configuration of the CNC system –
interfacing – monitoring – diagnostics - machine data -
compensations for machine accuracies - PLC in CNC –
PLC programming for CNC, steps in programming and
case studies –
• Machine Structure -types of loads on CNC machine -
guide ways and types - mechanical transmission
elements - elements for rotary motion to linear motion -
ball screw and types -roller screw and types -rack and
pinion - various torque transmission elements -
requirements of feed drives and spindle drive.
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Configuration of the CNC system
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Configuration of the CNC system
• CNC system consists of:
– Central Processing Unit (CPU)
– Servo-control unit
– Operator control panel
– Machine control panel
– Peripheral devices
– Programmable Logic Controller (PLC)
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Central Processing Unit (CPU)
• Accepts the information stored in the memory as part
program
• Data is decoded and transformed into specific position
control and velocity control signals
• Oversees the movement of the control axis or spindle
and whenever this does not match with the programmed
values, a corrective action is taken
• All the compensations required for machine accuracies
(leadscrew pitch error, tool wear out, backlash, etc) are
calculated by the CPU.
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Central Processing Unit (CPU)
• Some basic safety checks are built into the system
through this unit, and continuous necessary corrective
actions will be provided by the CPU unit
• When the situation goes beyond the control of the CPU,
it takes the final action of shutting down the system and
in turn the machine.
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Servo-Control Unit
• The decoded position and velocity control signals
generated by the CPU for the axis movement forms the
input to this SCU
• SCU generates suitable signals as command values
• The command values are converted by the servo-drive
unit which is interfaced with the axes and the spindle
motors.
• SCU generates suitable signals as command values
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Servo-Control Unit
• SCU receives the position feedback signals for the actual
movement of the machine tool axes from the feedback
devices like linear scales, rotary encoders, resolvers, etc.
• The velocity feedback is generally obtained through
Tacho generators. The feedback signals are passed on to
the CPU for further processing.
• The actual movement of the slides on the machine tool is
achieved through servo drives.
• The amount of movement and the rate of movement are
controlled by the CNC system depending upon the type
of feedback system used. i.e., closed-loop or open-loop
system.
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Position Feedback
• The slide movement is fed back to the CNC system to
determine the position of the slide, to decide how much
is yet to be travelled, 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.
• If correction is not possible, then the system declares a
fault and initiates action for disabling the drives and if
necessary, switches off the machine.
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Velocity Feedback
• Velocity Feedback along with position feedback is
needed during contouring to produce correct
interpolations and specified acceleration and deceleration
velocities.
• The Tacho generator used for velocity feedback is
normally connected to the motor, and it rotates whenever
the motor rotates, thus giving an analog output
proportional to the speed of the motor.
• This analog voltage is taken as speed feedback by the
server controller and swift action is taken by the
controller to maintain the speed of the motor within the
required limits.
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Servo-Drive
• Servo-drive receives signals from the CNC system and
transforms them into actual movement on the machine.
• The actual rate of movement and direction depends upon
the command signal from the CNC system.
• Various types of servo drives –
– DC drives
– AC drives
– stepper motor drives.
• Servo-drive consists of two parts - the motor and the
electronics for driving the motor.
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Operator Control Panel
• User interface to facilitate two-way communication
between the user, the CNC system, and the machine tool.
• This consists of two parts:
– Video Display Unit (VDU)
– Keyboard.
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Operator Control Panel
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OCP -Video Display Unit (VDU)
• Displays the status of the various parameters of the CNC
system and the machine tool
• Information on the block currently being executed.
• Actual position value, set or actual difference, Current
feed rate, Spindle speed
• Active G Functions and M Functions.
• Main program number, subroutine number.
• Display of all entered data, user programs, user data,
machine data, etc.
• Alarm messages in plain text.
• Few LEDs to indicate important operating modes and
status.
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OCP - KEYBOARD
The keyboard is provided for the following purposes:
• Editing of Part programs, Tool data, and machine
parameters.
• Selection of different pages for viewing.
• Selection of operating modes. e.g., Manual data input,
jog, etc.
• Selection of spindle speed and feed rate override
• Execution of part programs.
• Execution of other tool functions.
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Machine Control Panel (MCP)
• Direct 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 depending
upon the part program stored in the memory.
• Before starting the machining process, the machine
should first be prepared with some specific tasks like,
– Establishing a correct reference point.
– Loading the system memory with the required part
program.
– Loading and checking of tool offsets, zero offsets, etc.
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Other Peripherals
• Sensor interface
• Provision for communication equipment
• Programming units
• Printer
• Tape reader / punch interface, etc.
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Programmable Logic Controller (PLC)
• PLCs are a replacement for hard-wired relay control
panels.
• Can be re-programmed without hardware changes when
requirements change and thus are re-usable.
• In the CPU, all the decisions are made relative to
controlling a machine or a process.
• The CPU receives input data, performs logical decisions
based on stored programs, and drives the outputs.
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Programmable Logic Controller (PLC)
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Programmable Logic Controller (PLC)
• The I/O structure of PLCs is one of their major strengths.
• The inputs can be pushed buttons, limit switches, relay
contacts, analog sensors, selector switches, thumbwheel
switches, proximity sensors, pressure switches, float
switches, etc.
• The output can be motor starters, solenoid valves,
position valves, relay coils, indicator lights, LED
displays, etc.
• The type of I/O is determined by the voltage level of the
field devices.
• So, power to actuate these devices must also be supplied
external to the PLC.
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Interfacing
• Interconnecting the individual elements of both the
machine and the CNC system using cables and
connectors is called interfacing.
• Extreme care should be taken during interfacing.
• Proper grounding in electrical installations is essential.
• This reduces the effects of interference and guards
against electronic shocks to personnel.
• It is also essential to properly protect the electronic
equipment.
• Cable wires of sufficiently large cross-sectional area
must be used.
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Interfacing…
• Despite proper grounding, signal cables require
additional protection. This is generally attained by using
shielded cables.
• All the cable shields must be grounded at control system
end only, leaving the other end free.
• Other noise reduction techniques include using
suppression devices, proper cable separation, ferrous
metal wire ways, etc.
• Electrical enclosures should be designed to provide
proper ambient conditions for the controller.
• The power supply to the controller should match with the
supplier’s specifications.
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Shielded Cable
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Monitoring
• The machine control includes active monitoring
functions.
• This is to identify faults in the NC, the interface control,
and the machine at an early stage to prevent damage
occurring to the workpiece, tool, or machine.
• If a fault occurs first the machining sequence is
interrupted, the drives are stopped, and the causes of the
fault are stored and then displayed as an alarm.
• At the same time, the PLC is informed that an NC alarm
exists.
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Monitoring
Various parameters that can be monitored are:
• Measuring circuit cables
• Position encoders and drives
• Spindle speed
• Voltage
• Temperature
• Data transfer between the Operator control panel and the
logic unit
• Transfer between NC and PLC
• Change of status of buffer battery
• System Program memory
• User Program memory
• Serial Interfaces
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Diagnostics
• The control will generally be provided with the test
assistance for service purposes to display some status on
these CRT such as:
– Interface signals between NC and PLC.
– Interface signals between PLC and the machine.
– Flags of the PLC
– Timers of the PLC
– Counters of the PLC
• For the output signals, it is also possible to set and
generate signal combinations for test purposes in order to
observe how the machine reacts to a changed signal.
• This simplifies troubleshooting considerably.
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Machine Data
• CNC system is designed as a general purpose control
unit that must be matched with a particular machine to
which the system is interfaced.
• The CNC is interfaced with the machine by means of
data that is machine specific.
• The NC and PLC machine data can be entered and
changed by means of an external equipment or manually
by the keyboard.
• These data are fixed and entered during the
commissioning of the machine and generally left
unaltered during machine operations.
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Machine Data…
• Machine data is relevant to the axis travel limits, feed
rates, rapid travel speeds and spindle speeds, position
control manipulation factor, Kv factor, acceleration, drift
compensation, adjustment of reference point, backlash
compensation, pitch error compensation, etc .
• The optional features of the control system are made
available to the machine tool builder by enabling some
of the bits of machine data.
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