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loading and
unloading station pallet changer
Mill-turn center/
A mill-turn
center that
combines
lathe features
with second
active spindle
can turn as
well as mill a
part.
Mill-turn center/
High-speed machine tool/
Three high
high-speed spindle: >20,000 rpm
high-feed-rate drives: >600 ipm
high precision: <0.0001-in accuracy
5.1 Historical Development/
Position/
The invention of the NC machine tool is a
major technological evolution in
manufacturing.
NC is the foundation for many modern
manufacturing technologies
5.2 PRINCIPLES OF NUMERICAL CONTROL
/
Definition of NC/
a system in which actions are controlled by
direct insertion of numerical data at some
point. The system must automatically interpret
this data.
PTP motion-control /
To move the machine table or spindle to a specified position
so that machining operations may be performed at that point.
Path taken to reach the specific point is not defined.
Movement from one point to the next is non-machining, it is
made as rapidly as possible.
5.3.1 Motion Control/
Stepping motor/
is an electromechanical actuator that translates
digital electrical signals into fixed mechanical rotation.
Stator 30 30
Rotor
UVW
30
step angle/
UUVVVWW
15
When the pattern of the signals shifts, the motor rotates one step angle
5.3.3 Power Drives/
Stepping motor/ : pulse control
When the pattern of the
Three-phase motor
clockwise
signals shifts, the motor Step U V W
stepping
rotates one step angle.
1 1 0 0
The direction of rotation
2 0 1 0
depends on the pattern-
shifting direction. 3 0 0 1
v K t P168
Figure 5.15
5.3.4 Positioning system
/
Incremental positioning system/
absolute positioning system/
Incremental encoder
The output is a series of electric pulses.
There is no reference of the actual position.
5.4.3.2 Position transducer
/
Absolute encoder
An external device is needed to denote the reference on
the encoder shaft home position
Actual position is got by keeping track of the output
and accumulating the position count.
5.4.3.2 Position transducer
/
1. Key components
Tool magazine/
Tool changer/
Spindle/
Column/
Controller/
Machine table/
Driver motor/
Leadscrew/
Way/
Stepping Bearing
Coupling
Motor
Ball-bearing
leadscrew and nut
5.4.4 Leadscrew/
Leadscrew and nut converts rotational motion to linear motion
Pitch () of leadscrew is defined as the distance between
adjacent screw threads
preloaded ball-bearing
leadscrew
5.4 NUMERICAL-CONTROL SYSTEM
/
The leadscrew is coupled
with the machine table
through a nut
The machine table is
confined to a linear motion
by two slides (ways).
5.4 NUMERICAL-CONTROL SYSTEM
/
2. BLU (basic length unit)/
BLU is the minimum length distinguishable by
the control unit.
In an open-loop servo system, each pulse of
the stepping signal, which stepping motor
receives, turns the motor a small fixed angle
(step angle). This movement is also translated
to the table to move a distance of one BLU.
5.4 NUMERICAL-CONTROL SYSTEM
/
Open-Loop Servo system Z1 1
BLU p
Z2 360
Carriage
Gear box Z
2
Stepping bearing
Coupling
Motor
Z1 ball-bearing
( ) leadscrew and nut p (mm)
5.4 NUMERICAL-CONTROL SYSTEM
/
Open-Loop Servo system/
Example:
A system has the BLU=0.001 in. It is desired to move the
table 5 in. at a speed (feed rate) of 6 ipm. Please calculate
the pulse rate and pulse count.
pulse ratespeed/BLU
6 ipm/0.001 ipp6000 pulses/min100 pulses/s
pulse countdistance/BLU5/0.0015000 pulses
5.4 NUMERICAL-CONTROL SYSTEM
/
BLU (basic length unit)/
In a closed-loop servo system, the machine BLU
is determined by the leadscrew pitch and
the position transducer resolution.
The rotational position-transducer resolution
coupled to the leadscrew has N pulses per
revolution resolution:
BLUp/N
5.4 NUMERICAL-CONTROL SYSTEM
/
Close-Loop Servo system/
Example
An NC machine uses a 0.1-in. pitch leadscrew and a
100-pulse/rev encoder.
Accuracy/
Control resolution() : Basic length unit (BLU)
Hardware inaccuracies
inaccuracies in the machine elements
machine-tool assembly errors
spindle runout
leadscrew backlash ()
tool deflection
thermal error
5.4.1 NC Accuracy and Repeatability
Repeatability/
It is a measure of how closely a machine repeats a given
position command
It is measured as the diameter of the circle enclosing a
target area produced by many repeated experiments
5.4 NUMERICAL-CONTROL SYSTEM
/
4. Interpolation/
In the case of the control of multiple axes, it
is needed to generate a series of fixed-sized
steps in order to approximate a geometric
feature that is not directly attainable. The
maximum deviation of the tool path is kept
within one step. The idea is interpolation.
5.4 NUMERICAL-CONTROL SYSTEM
/
4. Interpolation/
In the case of the control of multiple axes, it
is needed to generate a series of fixed-sized
steps in order to approximate a geometric
feature that is not directly attainable. The
maximum deviation of the tool path is kept
within one step. The idea is interpolation.
5.4.6 Interpolation/
52 3
Vy 6 6 2.3635 in. / min
10 3 2
5 2
2 12
49 912
5.4.6 Interpolation/
10 3 7
Vx 6 6 5.5149 in. / min
10 3
2
5 2
2 12
49 912
52 3
Vy 6 6 2.3635 in. / min
10 3 2
5 2
2 12
49 912
y Vf
5.4.6 Interpolation/ x
x
Output frequency
If: all length units in BLUs
af x
fr ax
f rx N f V f Vx
2N 2 x y
2 2 12
ax f ax V f
x 2N
N
a
fr 2
f
N
x 2
y
2 12 f
a yf 2
y 2N
y
ay V f
f
x 2
y
2 12 f
y
y Vf
5.4.6 Interpolation/ x
x
a x x 2N
f rx Nx f V f ax V f
2
x 2 y 2 12
x 2
y 2
12
f
frx X axis
DDA X Counter
f
fry Y axis
DDA Y Counter
ay y y 2N
f ry f Vf ay V f
2 N
x 2
y
2 12 x 2
y 2
12
f
x 2in. y 1 3 1
vy v f 6 83.3BLU / s
2 BLU 60
y 3in. x y 2 3 0. 001 60
2 2 2
f ry 2 N 83.3 210
ay 85
f 1 10 3
frx X axis
DDA X Counter
Example: f
fry Y axis
DDA Y Counter
BLU 0.01in.
x 1 2 1
vx v f 6 55.5BLU / s
f 1 103 Hz x y
2 2 BLU 60
2 3 0.001 60
2 2
x 2in. y 1 3 1
vy v f 6 83.3BLU / s
2 BLU 60
y 3in. x y 2 3 0. 001 60
2 2 2
The maximum deviation of the tool path is kept within one step
frx X axis
DDA X Counter
Example: f
fry Y axis
DDA Y Counter
BLU 0.01in.
x 1 2 1
vx v f 6 55.5BLU / s
f 1 103 Hz x y
2 2 BLU 60
2 3 0.001 60
2 2
x 2in. y 1 3 1
vy v f 6 83.3BLU / s
2 BLU 60
y 3in. x y 2 3 0. 001 60
2 2 2
d
Feed rate: Vf R
dt
x R cos x0
Coordinate:
y R sin y0
dx d d
R sin y yo ax=|dx/dt| and ay=|dy/dt| are
dt dt dt
values loaded into the registers
dy d d
R cos x xo in DDAs
dt dt dt
(Quadrant )
5.4.6.2 Circular interpolator/
x R cos x0
y R sin y0
dx d d d 2x d d dy d
R sin y yo R cos
dt dt dt dt 2 dt dt dt dt
dy d d 2
d y d d dx d
R cos x xo 2
R sin
dt dt dt dt dt dt dt dt
ax=dx/dt X axis When there is an
+ output from DDA Y,
DDA X Counter
f - ax is decremented.
When there is an
+ Y axis output from DDA X,
DDA Y Counter ay is incremented.
+
ay=dy/dt
Review/