Perform Computer

Controlled Machine
Maintenance
K11-24-01 / LA2

ADTECKEMAMAN/BTPM/SANI
  CNC : Computerized Numerical Control (Computer + Numerical
Control)
What is a CNC  Numerical control is a programmable automation in which is
controlled by Number, Letters and Symbols.
Machine?
 Used in the manufacturing sector that involves the use of
computer to control machine tools like lathes, mills and grinders.
 • To manufacture complex curved geometries in 2D or 3D was
extremely expensive by mechanical means (which usually would
require complex jigs to control the cutter motions)
Why is CNC • Machining components with high Repeatability and Precision
Machining • Unmanned machining operations
necessary? • To improve production planning and to increase productivity
• To survive in global market CNC machines are must to achieve
close tolerances.
Main Parts of
CNC Machine
  These are the devices which are used to input the part program in
the CNC machine. There are three commonly used input devices
and these are punch tape reader, magnetic tape reader and
computer via RS-232-C communication.

Input Devices:
  It is the heart of the CNC machine. It performs all the controlling
action of the CNC machine, the various functions performed by
the MCU are
It reads the coded instructions fed into it.
Machine It decodes the coded instruction.
It implements interpolation ( linear, circular and helical ) to generate
Control Unit axis motion commands.
It feeds the axis motion commands to the amplifier circuits for
(MCU): driving the axis mechanisms.
It receives the feedback signals of position and speed for each drive
axis.
It implements the auxiliary control functions such as coolant or
spindle on/off and tool change.
  A CNC machine tool always has a slide table and a spindle to
control of the position and speed. The machine table is controlled
in X and Y axis direction and the spindle is controlled in the Z axis
direction.

Machine Tool:
  The driving system of a CNC machine consists of amplifier circuits,
drive motors and ball lead screw. The MCU feeds the signals (i.e. of
position and speed) of each axis to the amplifier circuits. The
control signals are than augmented (increased) to actuate the
drive motors. And the actuated drive motors rotate the ball lead
screw to position the machine table.

Driving
System:
 About Linear motor drive
 A machine is only as good as its controller and its motion control
system, since it is directly responsible for the movement of the
axes. The Linear-motor drive system is superior to a rotary motor
with ball screw drive system. The linear motor drive system relies
on direct feedback from a linear scale for positioning, reporting an
exact position and not a theoretical position.
 Sodick has accumulated a rich portfolio of knowledge and
expertise in linear motors including the know-how for the design
and production of linear motors, best suited for various types of
machines.
 Sodick's linear motors have achieved quantum improvement in
machining speed and energy saving over those of conventional
ones. The Sodick company also has focused efforts on keeping the
temperature of a linear motor at a low level to maintain high
thrust, and with respect to this aspect, Sodick's linear motors are
far ahead of similar products.
  Where linear motors used on Sodick machines?
 The following is the outline to show where the Linear Motors are
Comparison used on Sodick machines. In die-sinker EDM and machining center
all three X,Y,Z *axes are with Linear motor drive system and in
of ball screw wire-cut EDM machines X,Y,U,V axes are with Linear motor drive
drive with system.
 How long will be strength of the magnets lost ?
linear motor
 For the life of the machine
drive  Magnet degradation=<1% over 100 years
- Linear motor
  The pitch of a ball screw is never perfect. When a machine is
calibrated, values to correct the pitch error in the ball screws are
entered into parameters that the motion controller checks. The
motion controller must check these values in its calculations to
assure positioning accuracy. Therefore, when a ball screw system
Comparison is moved at a high feed rate overshoot and or undershoot will
occur and result in positioning error and also feel vibration on the
of ball screw axes. The followings are the other few reasons to note which result
in reduced positioning accuracy.
drive with  ball screw expansion
linear motor  twisting in the ball screw due to servo torque
 slop or thermal expansion in ball nut or coupler
drive  backlash in the ball screw
- Ball screw  Ballscrews will wear out, but it will not happen overnight; it is a
gradual and continuous phenomenon and which may take
approximately even 2~3 years, until it comes to notice and replace
the ball screw one should suffer from the problems.
  This system consists of transducers that acts like sensors. It is also
called as measuring system. It contains position and speed
transducers that continuously monitor the position and speed of
Feedback the cutting tool located at any instant. The MCU receives the
System: signals from these transducers and it uses the difference between
the reference signals and feedback signals to generate the control
signals for correcting the position and speed errors.
 A feedback device is mounted on the machine, which is either an
encoder or resolver.
 This device changes mechanical motion into electrical signals and
is used as a feedback.
 This feedback is sent to the error detector, which compares the
actual operation with that of the reference input.
 If there is an error, that error is fed directly to the amplifier, which
will be used to make necessary corrections in control action.
 Open loop
 Closed loop
 Rotary encoder
Encoders

Angle encoder
Linear encoder
 Refers to a system using a stepper motor, where the communication
between the controller system and motor is one way.
 The process is fairly simple. The machinist will decide what he/she
wants to accomplish and will generate the g-code and the software
will create the necessary steps and direction signals to perform the
desired task. The computer will relay this information to the controller
which then energizes the motor.
 What distinguishes open looped from a close looped system is after
the motor moves to the desired position, there is no feedback to the
controller system to verify the action.
 This is considered a drawback to the open loop system. If the motor
does not operate as instructed there is no way for the system to know
that this is occurring.
 The controller system will continue performing the next task or step
as if there is no problem until a limit switch is tripped or the operator
resets the machine. Open loop systems run the risk overloading the
machine and losing steps which can ruin the work piece or cause harm
to the machine.
 But if used effectively and not overloaded, there is no reason an open
loop system should not be suitable and function properly.
 The primary difference between an open and closed loop system
is feedback.
 A closed loop system, or one using a servo motor, has a feedback
protocol to monitor the output of the motors. Closed systems are
also able to correct any errors in position, velocity, and
acceleration and also have the ability to fault the system if the
error is too large.
 There are two types of closed loop systems; one where the system
returns the feedback to the CNC controller and another which
returns the feedback to the computer. The closed loop system
uses a feedback subsystem primarily to monitor the actual output
and correct any discrepancies from the programmed input. The
feedback system could be either analog or digital.
 Closed loop systems are very powerful and accurate because they
are capable of monitoring operating conditions through feedback
subsystems and automatically compensating for any variations in
real time with extremely accurate results.
  A monitor is used to display the programs, commands and other
useful data of CNC machine.

Display Unit:
  First the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the
program prepared, it prepares all the motion commands and
sends it to the driving system.
 The drive system works as the motion commands are send by
How CNC MCU. Drive system controls the motion and velocity of the
machine tool.
Machine  Feedback system, records the position and velocity measurement
Works of the machine tool and sends a feedback signal to the MCU.
 In MCU, the feedback signals are compared with the reference
signals and if there are errors, it corrects it and sends new signals
to the machine tool for the right operation to happen.
 A display unit is used to see all the commands, programs and
other important data. It acts as the eye of the machine.