Design of Open Architecture Controller for
PC-based NC Machines
Abstract
Open Architecture Controller (OAC) is currently a popularly used concept in automation and control industry
since computer was widely in system control. The benefits of ease of operation, interfacing, networking, and
system diagnostics are possible when machines can combine the technologies of CNC and PC. This paper
presents an introduction of a simple controller into existing machine in order to control tool path through
program modules and control algorithm from a PC.
1. Introduction
Designs of today’s CNC machine are developed with
the capabilities such as multi-axis control, error
compensation and multi-process manufacture (e.g.
combined mill/turn/laser and grinding machines).
Programming task is increasingly more difficult to
fulfill these capabilities due to the fact that G-code, a
50-years-old language, is still employed by these
machine tools. Thus the machines themselves
become less adaptable. However, the trend towards
open architecture control, based on OSACA and
open modular architecture controller (OMAC),
where third party software can be used at the
controller working within a standard windows
operating system, can overcome this problem.
Remarkably, the application of software controllers,
where PLC logic is embedded in software rather in
hardware, presents a recognizable industrial
development [1]. The author also mentioned lack of
adaptability, portability, and intelligence of modern
machine tools using G-code (ISO 6983) for part
programming and presented advantages of part
programming using STEP-NC which has more open
and adaptable architecture, making it easier to
integrate with other manufacturing facilities.
Developing open architecture computer numerical
control result a kind of software architecture that fits
in with a general computer and is independent of a
control vendors, while the same time, a
communication standard among computer hardware,
an operating system and application software must
be built [2]. An open system, as defined by IEEE
(IEEE 1003.0, 1990), provides capabilities that
enable properly implemented applications to run on
a variety of platforms from multiple vendors,
interoperate wit other system applications and
present a consistent style of interaction with user.
Closed architecture design of many advanced CNC
controllers and supporting hardware, such as those
of Siemens, Allen Bradley, Fanuc, and Mitsubishi,
make researchers in this area difficult or impossible
to incorporate advanced control schemes within the
CNC itself [3]. This problem can be eliminated by
designing open architecture controllers as a flexible
control system which can be attached to a wide
variety of machine tool systems. An open
architecture controller should be flexible in
hardware as it is in software control levels. It must
be standard to allow hardware and software
developed by any engineer or technician, and its
integration with other controllers, cell control
systems and high level planning systems. The
machine tool open controller should permit the
integration of independent application program
modules, control algorithms, sensor and computer
hardware developed by different manufacturer [4].
An open architecture system can be either hardware
or software. The openness of hardware is limited due
to the compatibility of software and hardware. The
openness of software is usually easily done by
adding some module available. Therefore software
development is widely done nowadays.
2. Open Architecture Platform
In this research the base system is a NovaMill 3-axis
milling machine model 1996. Timing belts and ball
screw system are used in transmission system
transferring the torque from axis motor (stepper
motor) to the table. Motors used are bipolar stepper
motors having 50-pole rotor, allowing 200steps/rev
by using full step control. Commercial stepper motor
drivers G201, manufactured by Geckodrive Inc, are
equipped with each motors since this product
provides space saving, high power output, and
easiness to use [5]. The driver accepts clock pulses
and direction signals and translates these signals into
appropriate phase currents in the motor.
Communication interface of the system is supported n = 1... N
by a personal computer, Pentium Pro 200MHz
The incremental movements must be greater than
processor, 62MB RAM; through 25-pin parallel port
(or LPT port) with +5V output voltage. Data port machine resolution ∆f x , y , z in order to ensure tool
H378 is assigned as the base address of LPT1 for movement is done perfectly in each increment.
outputting data on the parallel port’s data line (pin 2
to 9). Pin 25 supplying +5VDC TTL logic for the  x − xA yB − y A z B − z A 
transformer in the controller is connected from pin 5 ∆f x , y , z ≥ Max B , ,  Or
on the mouse port which carries +5VDC.
 N N N 

The software with built-in Graphic User Interface  x − x A yB − y A z B − z A 

(GUI) in this research is coded in Visual Basic 6.0
environment. To access LPT port in Visual Basic,
port.dll library (for Windows 98 only) is needed to
add in to the system folder C:\Windows\System.
N > Max B , , 
 ∆f x , y , z ∆f x , y , z ∆f x , y , z 
 
Circular arc interpolation is a kind of non linear
movement which can be simplified into linear one:

∆f x , y , z ≥ Max ( Rdϕ cos α , Rdϕ sin α )

Since Max(sin α , cos α ) = 1

a −b
⇒ ∆f x , y , z ≥ R
N
R ( a − b)
⇒N≤
∆f x , y , z

Figure 1: Electrical connection

3. Interpolation Algorithms
Two common methods in linear multi axis control
are serial and concurrent control. Serial multi-axis
control is simple by controlling each motor
separately either the X-axis or Y-axis, during the
operation. However accumulative machining error
and jerky movement of the table are still the major
problems which can be overcome by the second Figure 2 Circular arc descriptions
method. Instead of driving the axes sequentially,
The Bezier curve is a parametric curve which
concurrent control drives the motor simultaneously
appears reasonably smooth at all scales as opposed
so that the tool could move absolutely straight along
to polygonal lines, which don’t scale nicely. Bezier
the line. The algorithm is quite complicated due to
curves can be interpolate by a set of many linear
difference of the speeds of each motor, meaning that
segments made by Qi(t).
each stepper motor has to start as well as stop its
movement at the same time with the other motors.
Line is composed by linear movement of small
segments longer than the resolution of the machine
called Basic Length Unit (BLU) ∆f x , y , z :

xB − x A
x(t ) = x(n∆t ) = x A + n. Figure 3 Intermediate points on the Bezier curve
N
n
y − yA
y (t ) = y (n∆t ) = y A + n. B Q(t ) = ∑Vi Bi , n (t )
N i =0

z − zA
z (t ) = z (n∆t ) = z A + n. B
N
 n Figure 4 Repeatability accuracy
Bi , n (t ) =  (t )i (1 − t ) n − i , 0 ≤ t ≤ 1 The accuracy of circular movement is tested by
i machining 5 circles which have the designed
n n! diameter of 20mm. The diameter D1, D2 and D3 at
  = , i = 0,..., n three different positions are measured.
 i  i!(n − i )!
Mean diameter: 20.018
The smaller the increment of t, the smaller ∆x, ∆y ,
Variance:
and the finer the interpolated curve. The algorithm is
summarized in three steps as follows: 1 5 2
σ= ∑ ( D − D ) = 0.004
- Step 1: Define (N-1) intermediate points along 5 −1 j = 1 i
the entire path
- Step 2: Check whether the tool maintains the So, D = 20.018±0.004

contact along the entire path ∆x, ∆y ≥ ∆f x , y , z . Or the error is 18µm ± 4

Only the points which satisfy the condition are Circle 1 Circle 2 Circler 3 Circle 4 Circle 5
selected to be intermediate points on the final 20.021 20.013 20.028
D1 20.0351 20.0190
tool path. 2 2 6
20.009 20.025
- Step 3: Tool path forming: connect all the D2 20.0311 20.0212 20.0090
selected Qi(t) in the step 2 to form the final tool 5 7
path. 20.012 20.020 19.995
D3 20.0203 20.0116
5 4 8
4. Experimental results and discussion 20.014 20.021 20.016
Di 20.0255 20.0132
4 6 7
In this research, basic interpolations previously
described are used to generate tool path for 2.5D ∆D i 0.0136 0.0191 0.0191 0.0418 0.0117
contour and 2.5D pocket with our milling machine
NovaMill. The dimensional accuracy of linear,
Roundness:
circular arc and Bezier curve movements were tested
via actual machining. The experiments to testify the 1 5
efficiency of over-cutting method is also presented. R= ∑ ∆D j = 0.021
The experiments are conducted on aluminum alloy. 5 j =1
All dimensions are measured on a Computerized To measure the machining accuracy of Bezier curve,
Measurement Microscope which has a resolution of 5 experiments are carried out to find the coordinate
0.1 micrometer. of 5 different point at t=0, 0.25, 0.5, 0.75, and 1.0.
To test repeatability of the machine, the tool follows The errors on X-axis and Y-axis are then charted in
the trajectory mad of 10 horizontal lines (15mm) and the figure below.
10 vertical lines (15mm). The repeatability on X- Bezier curve machining accuracy
axis and Y-axis are given: 0.04

Rx = 0.005mm 0.03
0.027
0.02 0.0203

Ry = 0.010mm 0.01 0.0105

0 0 point
1 2 -0.009 3 4 5
-0.01 Error X
-0.013
-0.02 -0.0196 Error Y

-0.03
-0.033
-0.04 -0.041
-0.05

Figure 5 Machining accuracy of the Bezier curve

To explain the results, there are several factors
affecting the accuracy and repeatability of the
system:
- Mechanical part: the axes are driven by
stepper motors which have limitations on
accuracy. In order to enhance the accuracy
and repeatability, DC servo motor is
 recommended because of higher accuracy. envelope (229x152x114). Further possible
The ball screws also have back lash which development is suggested to work with both
affects the repeatability of the machining hardware side and software side.
- Computer interface: pulse signals sent to
drivers may have been lost on LPT port
interface. This problem also causes
inaccuracy of machining. Since in this
research, open-loop control is used, this
problem cannot be overcome.
However, the following figures show the ability of
the system to machine a 2.5D impeller and a Bezier
swept surface which can be further improved by
implementation of both hardware and software.

Figure 6 2.5D impeller

Figure 7 Bezier swept surface

5. Conclusion
An Open Architecture Controller has been
implemented on a milling machine. Hardware and
software are integrated into the system. The
openness allows the system to be expanded easily.
Although tool path generation is limited to 2.5D
contours and 2.5D convex pockets, application
modules can be easily added in future works. The
experiments were conducted to validate the
accuracy, repeatability, and machinability of the
system.
Machining hard material is still a major limitation of
the system because the table is currently driven by
stepper motors, which can only work at low torque.
Next, the work piece size is limited to the working
References

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Mechatronic, Vol. 5, No. 4, pp. 401-420.
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5. Manual document for G201 driver,
www.geckodrive.com