CNC Controller Research Articles

Mechatronic technological system based on CNC and intelligent mechatronic mechanism

A mechatronic technological system (MTS) has been developed. It consisting of a CNC metal-cutting machine tool and a mechatronic spindle, made on the basis of an intelligent mechatronic mechanism (IMM). The main elements of the technological system – the CNC and IMM devices – are parts of a single hierarchical, two-level control system, representing, respectively, the upper and lower control levels in this system. The upper control level – the CNC device – ensures stabilization of the kinematic parameters of machining (displacement, speed, acceleration) and their software change in accordance with the CNC control program. The lower control level – the IMM device – ensures stabilization of the power parameters of mechanical machining (cutting axial force and torque) and their software change in accordance with the technological requirements for the surface quality and the physical-and-mechanical state of the surface layer of the machined parts. At both control levels (the upper and lower ones), closed automatic control systems “by deviation” of the adjustable kinematic (upper control level) and power (lower control level) parameters of mechanical machining are functioning. Moreover, the automatic control system of the lower control level of the hierarchy in relation to a similar automatic control system of the upper control level, implements the method of automatic control “by disturbance”. This, in addition to directly ensuring surface finish and surface integrity, allows improving the quality of stabilization of kinematic cutting parameters at the upper control level. Experimental studies of MTS were carried out when machining parts from various materials (steel, polymer composite materials, superhard crystals and stones, other difficult-to-machine materials).

A Mechatronics Approach to Design a General CNC Controller

A Mechatronics Approach to Design a General CNC Controller

A Mechatronics Approach to Design a General CNC Controller

A Mechatronics Approach to Design a General CNC Controller

Multivariable Iterative Learning Control Design for Precision Control of Flexible Feed Drives.

Advancements in machining technology demand higher speeds and precision, necessitating improved control systems in equipment like CNC machine tools. Due to lead errors, structural vibrations, and thermal deformation, commercial CNC controllers commonly use rotary encoders in the motor side to close the position loop, aiming to prevent insufficient stability and premature wear and damage of components. This paper introduces a multivariable iterative learning control (MILC) method tailored for flexible feed drive systems, focusing on enhancing dynamic positioning accuracy. The MILC employs error data from both the motor and table sides, enhancing precision by injecting compensation commands into both the reference trajectory and control command through a norm-optimization process. This method effectively mitigates conflicts between feedback control (FBC) and traditional iterative learning control (ILC) in flexible structures, achieving smaller tracking errors in the table side. The performance and efficacy of the MILC system are experimentally validated on an industrial biaxial CNC machine tool, demonstrating its potential for precision control in modern machining equipment.

ACHIEVING THE REQUIRED MACHINING ACCURACY BY CORRECTING ERRORS USING VARIABLES OF PARAMETRIC FUNCTIONS

Nowadays, the machine-building complex is actively saturated with high-tech equipment, without which an enterprise cannot enter the global market or keep up with its competitors. And it's not just about using systems with artificial intelligence elements as scientific and technical solutions to improve quality and reduce production costs. It is also about reducing the time required to prepare products for production and bringing them to the consumer ahead of schedule. Today, the most preferred method in the competitive struggle is to equip CAD/CAM production with computer-aided design systems. With their help, engineering and technology services cannot only design models of new products but also generate CNC control software for manufacturing parts on CNC machines. At the same time, program frames composed in G-codes have several drawbacks, the main one being a "rigid" algorithm of action, i.e., the lack of variability for final solutions when the required accuracy is achieved by correcting the numerical values of the coordinates of the points of formation of individual surfaces in the PC. In this case, the operator largely intuitively corrects individual program frames based on his or her own experience, which is almost impossible without appropriate calculations for controllers with linear-circular and angular motions. In addition, after some such changes, the program loses its geometric adequacy to the part drawing, and by correcting one element of the shaped profile, we invariably violate the laws of contact with neighboring elements specified in the drawing. The paper considers the analytical geometry apparatus that allows a line on a double curvature surface, the theoretical trajectory of tool movement, to be represented not as a set of scalar points but in a vector representation, considering its possible torsion. This approach is ensured by parametric programming with computational frames of point coordinates and logical transitions, determining the angles of inclination of the cutter axis relative to the normal to the surface in the case of multi-axis machining. However, the main advantage of this method is the ability to correct processing errors not by local changes in the numerical values of the coordinates, but by introducing correction coefficients into the equation of the shape formation trajectory - reactors for the appearance of errors in the shape or location of surfaces, arising, for example, from elastic movements. The value of the coefficients per group of personnel can be set in the process of research and industrial production and change depending on the properties of the blanks. For example, according to the current standards, variations in hardness of up to 10-12% were allowed for the blanks of rolling mill rolls. The article presents the experimental data of the research of the correction task in a parametric form and the results of their application for machining parts with radius cutters in real production..

An improved development process of production plants using digital twins with extended dynamic behaviour in virtual commissioning and control – Simulation@Operations

AbstractThe challenges in automation system development are driven by short development cycles and individualization along with resource‐constraints. State of the art solutions do not provide the necessary digital tools to apply model‐based methods in automation engineering to achieve higher performing systems. To overcome these issues this paper presents a novel approach to address some of the current challenges in automation systems development using digital twins with extended dynamic behaviour. The study underscores how dynamic models can be imported through standardised interfaces into virtual commissioning (VC) tools, improving the development process by effectively utilising domain‐specific expertise. The paper highlights how these digital twins enhance not only the VC process but can also be applied to model‐based control methods. Initial experiments showcase the utility of digital twins in calculating dynamic acceleration limits during trajectory planning of CNC control and enhancing feed‐forward control. Further, the importance of parameter identification in achieving accurate system models is stressed. The initial results are promising, and future work aims to combine these methods in an industrial application involving a newly developed, individual lightweight robot, demonstrating the potential for enhanced design, accelerated development, and resource efficiency in automation systems.

Straightness Geometric Error Assessment for CNC Milling Machine

The straightness movement error of the machine tools axis contributes significantly to the straightness of the workpiece machining feature. This paper focuses on the assessment study of CNC machine tools’ straightness geometric error for obtaining recommendation information to improve machine geometric accuracy. A research method by determining measurement parameters according to ISO 230 procedure, no-load measurement of straightness vertical-horizontal geometric error using a laser interferometer, collecting data, data analysis. Data analysis calculates positional straightness deviation, mean positional deviation, systematic positional deviation, repeatability, and accuracy of straightness movement for each machine axis, and generating error compensation values for improving machine geometric error. The travelled distance of the X, Y, and Z-axis CNC milling machine tested is about 1100 mm, 560 mm, and 520 mm. The assessment result shows mean deviation straightness horizontal of X, Y, and Z-axis is 4.14 μm, 3.41μm, and 0.95 μm. The mean deviation straightness vertical of X, Y, and Z-axis is 3.75 μm, 2.63 μm, and 2.30 μm. Finally, the assessment outcome is generating error compensation values of each axis. It could be recommendation information for setting back error compensation parameter on CNC controller, hence the mean deviation of straightness geometric error machine tools to be less than 1 μm.

Real-Time Jerk Limited Feedrate Profiling and Interpolation for Linear Motor Multiaxis Machines Using NURBS Toolpaths

In this article, a NURBS toolpath feedrate profile generation algorithm for a biaxial linear motor control system is presented. High achievable velocities and accelerations of linear motor machines present new computational challenges in implementing feedrate generation and toolpath interpolation algorithms in real-time controllers. The proposed algorithm is capable of online generation of the feedrate profile with axial acceleration and jerk constraints. Each stage of the feedrate profiling algorithm is described with attention being given to both performance and implementation aspects. Furthermore, an alternative to the commonly used Taylor series interpolation method is also tested to ensure minimal interpolation errors. The feedrate profiling and interpolation algorithms’ implementation in a PC-based controller with real-time Linux kernel is described. Experimental results are presented that confirm that the algorithm is capable of limiting acceleration and jerk in the machine’s axes and it is low computation time enables real-time on-line operation in a PC-based CNC controller.

The DynaPath CNC WinDelta Control System

MACH Machine Tools will now use the DynaPath CNC control system across almost all of its machines. CEO David Andrew tells Machinery more

MACH 2022 is the Perfect Launchpad

MACH Machine Tools will now use the DynaPath CNC control system across almost all of its machines. CEO David Andrew tells Machinery more

CNC Control System Switch

MACH Machine Tools will now use the DynaPath CNC control system across almost all of its machines. CEO David Andrew tells Machinery more

Intelligent Air Cutting Monitoring System for Milling Process

This research proposes a method for auto-monitoring the air cutting condition of a machining process, so the air cutting time can be further improved to enhance the machining efficiency. A two-way data communication module with a CNC controller was established to achieve real-time monitoring and control function via TCP/IP protocol. The module enables the identification of the executing NC block and the cutting time during machining. The spindle load current and cutting vibration signals were used to on-line diagnose the cutting state (effective cutting or air cutting), and their associated NC codes were identified and recorded at the same time, based on the executing NC block in the CNC controller. An algorithm adopting this state change information to determine effective cutting time and air cutting time was developed and used to build an intelligent air cutting monitoring system, with a friendly human–machine interface. The system can detect air cutting time, effective cutting time, machine idle time, as well as the total machining time to improve the air cutting time to enhance the machining efficiency. Verification experiments were conducted, and the results showed the proposed method can accurately detect the air cutting occurrence and its associated NC blocks in the NC program.

IMPROVE PRODUCTIVITY THROUGH DIGITAL MANUFACTURING

In the future the digitalization and "Industry 4.0” will be in every step of the product lifecycle from design to the manufacture, service, and maintenance. Through digitalization, the companies will be able to operate and program the complex CNC machine tools that will be ready to respond more flexibly to the market demands and at the same time to boost their productivity. Work preparation and production can be breaking down further into additional process steps, ranging from tendering to quality assurance. The demand for digitalization solution can be illustrated thru the following targets and questions what every production company must define and establish: 1. How long time will be the part on the machine to be manufacturi; 2. Is that CNC machine tools (what is able and have the technical characteristics) available; 3. Are necessary new cutting tools for this new job; 4.The CNC operator is familiar with the CNC control equipment; 5. Does the workpiece tolerance correspond with the customer specifications. Is not so easy to link up all this requests and to find the best solutions in time and to have high productivity. Digital manufacturing will give us the preliminary units costs and delivery deadline that must be determined to be able to tender for a job correctly. Today, the amount of time a workpiece will require for machining can be calculated quickly reliably and very important, without trial runs, using CNC simulation solutions. This recommendations from our paper can be an answer at the production companies and the advantage of this implementations is that can be made step by step. The solution of this implementation should be in concordance with the company’s requirements and resources.

CNC Machine Technologies: A Review

Portable, interoperable, and flexible are the objectives of following generations of computer-controlled technologies G-codes have long been used by CNC production instruments for component programmers and are now seen as a roadblock in the construction of next Automation. STEP-NC is a new data structure for a younger breed of CNC machine equipment. The data architecture is a simple standards aimed particularly at sophisticated CNC manufacturing machines, putting closer to reality the goal of a standardized CNC controllers and NC code generating facilities. STEP-NC CNC machines are regarded to be the cornerstone for a more open and adaptable design. The future of STEP-NC is depicted in this research, which includes autonomously manufactured machines, STEP compliance data understanding, intelligence constituent programming generation, diagnostic and upkeep, supervision, and job capacity planning.

Machine-dynamics monitoring for L-DED operations

Laser Directed Energy Deposition is an Additive Manufacturing technology that enables repairing or coating high-added-value components. The obtained results depend on the process parameters, but also on the machine dynamics, e.g. the capability of the machine to follow the programmed trajectory at a constant velocity. In the present research work, the response of a laser machine and a FAGOR 8070 CNC control at different situations is analysed. Special attention is paid to the trajectory smoothing command of the control. The machine acceleration is found to affect the initial and final accelerations, but not the velocity reduction in the direction change. On the contrary, the value of the chordal error influences the machine deceleration in the direction change corner, whereas its influence is almost negligible in the initial and final accelerations.

PELATIHAN CNC ROUTER UNTUK BUMDES DESA HEUBEULISUK

Heubeulisuk Village is a village located in Argapuran District, Majalengka Regency. Similar to other villages, this village has a Village Owned Enterprise (BUMDes). One of the activities of the BUMDes is the production of wooden wall clocks and several other crafts made of acrylic material.
 Wood Size craftsmen until now only use a simple cutting saw to make the craft and acrylic using a hand drill. The chainsaws facilitated by the local village government are not as sophisticated as imagined.
 With the BUMDes CNC Router machine, it is able to increase the amount of production and minimize the production time required. In this service program scheme, training on the use of CNC Routers for BUMDes Heubeulisuk will be carried out starting assembling, preparing cutting/chiseling tools, making CAD models, CNC controllers to execution/feeding of workpieces.

FAULT DIAGNOSIS OF COMPUTER NUMERICAL CONTROL (CNC) MACHINE USING CLOUD KNOWLEDGE BASE AND MONITORING SYSTEM

In the world of manufacturing, numerical control machine occupies a major role. Recent studies on CNC machines aim to rapidly evolve CNC Controller towards smart production and flexible production lines.As an essential part of system reliabilityanalysis, fault classification analysisiscritical in the aspects of reliability design improvement. Most original Equipmentmanufactures do not accept the effect of machine reactions on component qualitywhen the equipment fails. The errorscomingfrom servo parameters for the absolute system are indicated by newlyproduced CNC machines. Alarm information isusedonly for attention, warning, and not for safeguardingworkpiecesagainst direct harm to quality. This paperaims to develop a faultdiagnosis system of the CNC through monitoring the alarm panel of CNC drivers using a webcam, raspberry pi 3, Optical Character Recognition (OCR) and cloud knowledge base. By using the proposed diagnostic system, the efficiency, accuracy, speed of development, and maintenance of the CNC controllers are improved. في عالم التصنيع ، تحتل آلة التحکم الرقمى بالحاسب دورا رئيسيا. تهدف الدراسات الحديثة على آلات CNC إلى التطور السريع لوحدات التحکم CNC نحو الإنتاج الذکي وخطوط الإنتاج المرنة. کجزء أساسي من تحليل موثوقية النظام ، يعد تحليل تصنيف الأخطاء أمرا بالغ الأهمية في جوانب تحسين تصميم الموثوقية. لا تقبل معظم الشرکات المصنعة للمعدات الأصلية تأثير تفاعلات الماکينة على جودة المکونات عند تعطل الالة.يتم الإشارة إلى الأخطاء الناتجة عن معلمات المؤازرة للنظام المطلق بواسطة آلات CNC المنتجة حديثا. تستخدم معلومات الإنذار فقط للانتباه والتحذير وليس لحماية قطع العمل من الضرر المباشر بالجودة. تهدف هذه الورقة إلى تطوير نظام تشخيص الأعطال في CNC من خلال مراقبة لوحة إنذار محرکات ماکينة التحکم الرقمى بالحاسب باستخدام کاميرا الويب ، و Raspberry pi 3 ، والتعرف البصري على الأحرف (OCR) ، وقاعدة المعرفة السحابية.وبالتالى من خلال نظام التشخيص المقترح ، يتم تحسين الکفاءة والدقة وسرعة التطوير والصيانة لوحدات التحکم CNC.

Grinding machine CNC with noble integrated motion control system

According to research progress and applying technology of CNC control system architecture, this paper discusses three kinds of CNC control systems: Open CNC system, embedded CNC system and PLC CNC system, and a new architecture is proposed. The paper illuminates that integrated motion control system architecture is a new concept of CNC, by which it has high precision and low cost. In this paper, a grinding machining controller using this structure is described and verified by software.

PART PROGRAM DEPENDENT LOSS FORECAST FOR ESTIMATING THE THERMAL IMPACT ON MACHINE TOOLS

During machining occurring losses conduct into the machine tool and lead to deformations that im-pair the machining accuracy. Thus, high effort is invested into the compensation of thermo-elastic er-rors. One new approach is to use the information extractable from part programs in combination with CNC controller systems to forecast occurring losses in terms of a look ahead function. The method al-lows the evaluation of part programs with respect to its thermal influence on the machine tool. There-fore, the method is applied on selected part programs, resulting loss distributions are discussed in terms of their thermal impact, and potential follow-up strategies are stated.

VERICUT - CONFIGURING CNC SYSTEMS FOR TURNING CENTER WITH SUB-SPINDLE

This report discusses the configuration of some preparatory and auxiliary commands for the Fanuc 18i TB CNC system for a counter-spindle lathe using special macros called Vericut macros. In most cases, this is necessary because the Vericut library of machines and CNC systems does not have the specific machine and system or do not correspond to the actual ones, i. e. there is no match between them. The need to configure the CNC control system is related to the fact that it is possible to perform simulation, optimization and verification of control programs in a virtual environment before proceeding to the processing of workpieces on the real machine.