Computer Numerical Control System

the basics of the core of CNC machine tool-CNC unit: functionsworking principleshardware configuration and software structure
to view the main features of CNC unit in more general terms: stressing why things are handled the way they are even more than the specific techniques used with any one particular CNC machine tool be able to easily zero in on any kind of CNC machine tool

two typesnumerical control (NC)

(have to read the program each time a part is runthey have no means of

editing existing programs)

computer numerical control (CNC)

(can store and allow editing of loaded programs)

4.1.1 NC system
The NC machine can be divided into three basic areas:
control unit + drive mechanisms + the machine
The most basic function of any NC machine is automaticprecise

and consistent motion control

All forms of NC equipment have two or more directions of motion--called axes
These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path)

conventional machine tools: motions are by manually turning cranks and hand-wheels NC machines: motions are actuated by servomotors under control of the NCand guided by the part program

the motion type (rapid, linearand circular) the axes to move the amount of motion and the motion rate (feed rate) are programmable

An NC command tells the drive motor to rotate a precise amount of angle The rotation of the drive motor in turn rotates the ball-screw The ball-screw drives the linear axis A feedback device at the opposite end of the ball-screw allows the control to confirm that the commanded number of rotations has taken place

numerical data :
for controlling the relative motion between cutting tool and piece part the component dimensions ( from engineering drawings--the geometric data), to define feed rates,

spindle speedstool identification numbers and miscellaneous functions

(to perform such operations as tool or work changingor coolant control--the technological data).

The combination of all this numerical information in a sequence is a part program the process of creating the data in a correctly structured format is programming
Numerical controls use standard microelectronic modules that have been developed for computer hardware (special modules needed in servocontrol circuits )

CNC system and functions of CNC unit

Controls today are soft-wiredwhich allows greater flexibility in changing and upgrading the computer control The modern CNC machine tool is software drivencomputer controls are programmed instead of hard-wired
CNC system: is a special computer system that is equipped with certain interface circuits and servo driversand can do part or all the works an NC system do by running the software stored in its memories

CNCs have expandable memories that can store large numbers of programsplus subroutines and correction data extensive memory capacity : sophisticated graphic displays and dynamic simulation

CNCs comprises:

CNC unit feed motion servo subsystem spindle servo subsystem and some auxiliary control cells.

Machine tool I/O circuits and devices Operation panel PLC Spindle servo cell Keyboard CNC Control Unit Feed motion servo cells Feed drivers Detect device Spindle driver Machine tool

I/O Devices

CNCs comprises: CNC unit

feed motion servo subsystem spindle servo subsystem and some auxiliary control cells.

CNC unit is the core of the whole CNC system It is composed of hardware and software Hardware: is made up of microprocessors electronic memory modules I/O interfaces, and position control modulesetc software controls all functions of the machine, manages all local programming, and graphic simulation of the cutting

hardware and the software work together to do all functions:

graphic display, HMI (Human-Machine Interface) system diagnosis implementing of various complex tool-path controlling, compensation algorithms intelligent controlling online programming and Web communicationsetc)

main functions and features of CNC unit

Controlling function

the number of control axes and synchronously control axes:

linear axes and rotate axes, basic axes and auxiliary axes (The more the number of controlled axesespecially the number of axes being controlled synchronouslythe more powerful functions of the CNC unit, and the more complex structure of the CNC unitthe more difficulty of programming.)

Preparatory function

G function, describes the motion modes of CNC machine

The motion modes comprise instructions of basic motions dwellplane selections, coordinate system settings tool compensations reference point return fixed operation circles and metric/inch unit transferetc

Interpolation function

interpolation by using software real-time calculations

Linear interpolationcircular interpolationhelical interpolation and polar coordinate interpolation Feed function

Feedrate designation (machining centers only allow the feed rate to be specific in per-minute format: inches or millimeters per minute; Turning centerswhich have position encoders in their spindlesalso allow feed rate to be specified in per-revolution format: inches or
millimeters per revolution)

Feed Rate Override: multiple position switch on control panel allows the operator to change the programmed feed rate during cutting (The switch is usually segmented in 10 percent increments that range from 0 percent through 200 percent )

Rapid motion to minimize non-productive time during the machining cycle

to command motion at the machines fastest possible rate Common uses for rapid motion: non-cutting motion | include : positioning the tool to and from cutting positions moving to clear clamps and other obstructions

Spindle function specify the spindle speed On operation panelthere is a button to turn the spindle on and offas well as a rheostat to control spindle speed

Miscellaneous function allow a variety of special functions

Miscellaneous functions are typically used as

programmable switches (spindle on/offcoolant on/offand so on)

Compensation function allow the CNC user to allow for unpredictable conditions related to tooling

Tool length compensationcutter radius compensation and tool nose radius compensation
enable the CNC machine to adjust cutting tool to zero in the right position when wear occurs on cutter tool or changing of cutting tool

Technical parameters compensation,

( fixture offset NRZ(Non-return-to-Zero) of axis while counter-moving distortion of machine tool

any unpredictable situations during programming a form of compensation to deal with the problem

Enhanced function graphic display function CRT or LCD displayer: show programsparametersvarious compensation datacoordinates fault information part graphs; monitor dynamic cutter tool paths while machining

Self-diagnosis function various diagnosis programs : prevent faults occurring or going worse to shorten the time of broken-down
Communication function RS-232-C communications (serial) port personal computers Some form of communications software allow transmissions

communications networks------usually referred to as DNC systems

Some CNC units support for MAP (Manufacturing Automation Protocol)

connect with industry communication nets to

fulfill the needs of FMS and CIMS

Programming function Manual programming

all CNC programmers should have a good understanding of manual programming techniques regardless of whether or not they are used

conversational (shop-floor) programming

created using graphic and menu-driven functions visual check

and CAM system programming

helps the programmer in three major areas keeps the programmer from having to do math calculations makes easy to program different kinds of machines with the same basic language helps with certain basic machining practice functions

4.2 Functional interface between hardware and software in CNC unit

CNC unit : hardware + software work together to perform all functions of CNC unit different characters: Hardware higher speed more expensive software flexible slow on processing

proportion between hardware and software is determined by cost-performance of the CNC unit
(In the earlier NC equipmentsall functions were implemented by hardware; computer was introduced into CNC system)

participations of computer different in different CNC units in different time

four different functional interfaces between hardware and software:

Speed control

Pretreatment

Interpolation

Servo motor

1 2 3 4

Program
Hardware

Position

Input

Software Software Software

Hardware

Detector
Hardware

Hardware

Software

Hardware

4.3 HARDWARE ARCHITECTURE OF CNC UNIT

Micro-processors + electronic memory modules

+ I/O interfaces + position control modules

Types of CNC Unit

determined by the architecture of printed circuit boards:

All-in-one board architecture and multi-functional modules architecture

determined by the number of microprocessors:

single microprocessor and multi-microprocessors

determined by the manufacturing fashions:

ordinary personal computer architecture and special purpose architecture

determined by the opening degree :

close architecture PC-plug-in-NC architecture NC-plug-in-PC architecture software based open architecture

All-in-one board architecture

Comprises: main boardposition control cardPLC carddisplayer card and power supply

Main board is a big printed circuit board other functional cards are small size each is installed in a card rack on the main board

Multi-functional modules architecture CNC unit is divided into several function modules: CNC control moduleposition control card PLC cardgraph display card and communication card, etc Hardware and software are designed with modularization method each function module is made
of printed circuit of same size

customers can establish their own CNC units by combining their selected function modules into the card racks of a motherboardconnected by industry
standard busIPC bus or STD bus

e.g.: a holonomic CNC lath system of this architecture modules can be connected together by industry standard bus: IPC (Industry PC) bus or STD bus

Single microprocessor architecture only one microprocessor (on duty of controlling and occupying the system bus )which processes various NC tasks by time-sharing in a centralized control way simple and can be implemented easily centralized controllingits performances and abilities are limited by the byte lengthdata widthaddress abilityand calculating speed of microprocessor.

Multi-microprocessors architecture three kinds of multi-microprocessor architectures: distributed system master-and-servant system

bus based multi CPU system

distributed system a communication network route between microprocessors Interactions within microprocessors and shared resources via network communication technology

Master-and-servant system
a master microprocessor: control the bus; access the resources attached with the bus; control and monitor servant microprocessors; coordinate the operations of servant microprocessors;
(others) servant microprocessors: do what the master microprocessor command; cannot do decision-making and scheduling;

all independent systems

The communication: by interactive responses through I/O interface or by duplex RAM

Bus based multi CPU system

a parallel main bus links several microprocessor systems

Microprocessors cannot be divided into master and servant :
each CPU can directly access all the system resources, can use all of their own resources freely and independently CUPs compete to occupy the parallel bus ?? bus-intermediator is used to assign and manage priority of each CPU
at one timeonly one CPU with higher prioritycan use the parallel bus

IPC based CNC system

CNC unit : base on industry computer (IPC) platform built by plugging in certain control cards and NC software IPC platform has made CNC unit cheaper and cheaper and easily be substituted when fault occurs

NC-plug-in-PC
IPC+ PMAC (Programmable Multi-Axis Control Card )
|

plugged in the card rack of IPC ( On PMAC cardhigh speed DSP is used as CPU high performances on motion control and PLC control )

PMAC card (itself is a NC system) can be used independently:

Its opened programs library package can be used on Windows platform to establish control system as users purpose.

open architecture motion control

4.4 CNC SYSTEM SOFTWARE

In CNC system: software codes fall into two groups

user software and system software

User software: part program It is compiled into a program with various G-codes and M-codes according to the process sequence System software: an operating system It is specifically designed for the type of machine that it is destined to control. be sorted into two packages managing software and control software

To execute the part program: CNC unit compiles the codes into the format does preparatory and interpolation functions (control software) all functions of control software are implemented under the supervision and coordination of (managing software)
system software previously written in Assemble Language achieve higher executing speed take more time in the course of development; now written in advanced languagessuch as C or C++etc

4.4.2 Control Software

(main functions of a CNC system)

does the following work by corresponding subroutines (1) Compiling the part codes inputted by users
part codes: in ISO or EIA format Compiler: translatetrim and store decode and do decimal-binary transitions calculate tools center path considering tool radius offset pre-calculate some constants used in interpolation and
speed control process

Objective of pre-process: save time for real-time interpolation calculations ( can be done before machining or in the idle intervals while machining)

(2) Interpolation calculations to assign electrical pulses for axes a strict real time program:
demands as less as possible number of instruction codes to shorten the time for performing interpolation calculations

time is determinative
combine rough interpolation and fine interpolation: software : rough interpolation that interpolates a tiny line each time Hardware: fine interpolation by turning the tiny line into a series of single pulses and outputting the pulses

(3) Speed control aims at controlling the speed of pulses assigning

(controlling the frequency of interpolation calculation)

to guarantee the preset feed velocity

speed control subroutine: automatically speed up or slow

down the velocity to avoid pace-loss

implemented by:
software method (software timer method) hardware means (velocity code controlling an oscillator then by interrupts or queries to guarantee the feed velocity)

Further more:

software combining with speed integrator hardware

Software: processing the speed control data + Speed Integrator Hardware

constant compound velocity controlling the feed velocity can be improved greatly
can be realized

(4) Position control position loop of servo system done by either software or hardware

Position control software: compares interpolation-calculated position

with real measured position

in each sampling cycle control the motor using the difference adjust the magnification of the position loop circuit compensate the error of screw pitch
the non-return-to-zero when reverse the motion

location precision be improved

Position control implements functions on calculations:

4.4.3 Managing Software Managing software is composed of : part program I/O, display (part programtool position system parametersrunning status, alarm informationstatic and dynamic tool path) diagnosis codes (by which CNC unit can carry out self- diagnosis and spot the faults)

two groups depends on hardware: manages and drives peripheral equipment performs real time processes independent of hardware: manages timetasksmemory, synchronizes various procedures

the capability of parallel processing: many function procedures (e.g.: preparatory functions and interpolation process) need to be implemented in parallel

Input Display Control

Encoding

Interpolation

Compensation Position processing Speed process Preparatory functions

Diagnosis

I/O

the capability of real time processing: tasks of higher priority will be implemented in time tasks with lower priority will wait in queue

(For examplefrom the point of view of urgency

collision detecting procedure should have higher priority than information display procedure)

CNC system can react to the event (s) in time

system will keep in a safe status

Parallel process means:

computer implements two or more tasks at the same time or within the same time interval

improve the processing speed greatly methods to realize parallel process: time overlap: based on flow line technique staggers the processing time of procedures makes many procedures at the same time.

 resource-sharing: based on time-sharing principle

many procedures occupy CPU processing time in turn

Real time process means: CNC system react in time to the requests and events of system

methods to realize real time process: Interruption technology

many types of interruption external interruption: external monitor interruption, input interruption of keyboard / operation panel; internal timer Interruption: interpolation loop interruption, position sampling interruption;

hardware fault interruption: memory errortimer error timeout during interpolation calculation hardware fauIt (sent out by hardware fauIt
detectors when fault occurs)

software interruption: the alarm interruption when there is exception

during software execution

e.g. : various overflow error and reset

4.4.4 Architecture of CNC System Software organizing and managing mode of CNC system software

two different architectures tandem architecture interruption architecture

tandem architecture CNC system software is divided into two groups

foreground application: a real time interruption service program Realize: the real time functions
(interpolation calculationposition controllogical control of machine tool, etc.)

background application: a loop running program Realize: the input of part program some preparatory processes (encodingtool compensation calculationspeed calculation) manages tasks of procedures

work cooperatively

The system program carried out in the courses

firstsystem startup secondinitializing process then entering the loop executing of background application
During executing of background application real time interruption procedures intervene every now and then to implement real time controls

Executed by interrupting

Executed in loop

Foreground application
Fault process

Background application
Encoding Tool compensation

Position control

Speed calculation Input/Output Display

Interpolation calculation

. . .

Interruption architecture no distinction of background and foreground applications initializing procedure+ interruption service procedures with different priorities

a large multilevel interruption system

0 level interrupt service

1 level interrupt service

Initialization

2 level interrupt service

Interruption manage system (hardware+software)

N level interrupt service

e.g. Tasks division and their priorities in HuaZhong I system software eight types of tasks with different priorities (from high down to low):
Position control (4 ms) Interpolation calculation (8 ms) Data collection (12 ms) PLC task (16 ms) Tool compensation task (condition (buffer) drivable) Program codes interpreting (condition (buffer) drivable) Dynamic display (96 ms) HMI: Human-Machine-Interface (menu managedloop continuously); Position control task has the highest priority: hence has the shortest invoking time interval 4 ms HMI task has the lowest priority: is an infinite loop procedure that starts only one time

 Real Time Operating System -----RTOS

CNC

 , TCB CNC CNC CNCPCDOS WINDOWSCNC DOS WINDOWS