Professional Documents
Culture Documents
Compiled & Submitted ByAnkit Awasthi Univ. Roll No. 08020G B. Tech (ECE), VII Sem. JUET, Guna
ACKNOWLEDGEMENT
We are highly thankful to B.H.E.L. engineers and technical staff or providing us vital and valuable information
We express our gratitude to Human Resource and Development department for giving us a chance to
feel the industrial environment and its working in B.H.E.L. and we are thankful to Mr. Vijay Verma, Sr.
Engineer for giving his precious time and help us in understanding various theoretical and practical aspect of
our project on CNC under whose kind supervision we accomplished our project. We are also thankful to Mr.
PREFACE
At very outset of the prologue it becomes imperative to insist that vocational training is an integral part of
engineering curriculum. Training allows us to gain an insight into the practical aspects of the various topics,
with which we come across while pursuing our B.Tech i.e. vocational training gives us practical implementation
of various topics we already have learned and will learn in near future. Vocational training always emphasizes
On my part, I pursued four weeks training at B.H.E.L. Jhansi. The training involved a study of various
departments of the organization as per the time logically scheduled and well planned given to us. It also
involved a project on CNC machines under the able guidance of Mr. Vijay Verma (Sr. Engineer in WE & S
Department).
The rotation in various departments was necessary in order to get an overall idea about the working of the
organization.
CERTIFICATE
It is hereby certified that Ankit Awasthi student of Jaypee University of Engineering & Technology (JUET), Guna has successfully carried out his summer training project on Computer Numeric Control (CNC) Machines in BHEL Jhansi.
To the best of my knowledge, this project is truly original & has not been produced whatsoever.
He sincerely completed his project with dedication & I wish him success in future.
Mr. Vijay Verma Sr. Engineer Work Engineering & service B.H.E.L. Jhansi
CORPORATE PROFILE
B.H.E.L is the largest engineering and manufacturing enterprise of its kind in India is one of the leading international companies in the field of power equipment manufacture. The first plant of BHEL was setup at Bhopal in 1956, which signaled the dawn of the heavy electrical industry in India. In the early sixties, three more major plants were set up at Haridwar, Hyderabad and Tiruchnapalli. That forms the core of the diversified product range system services that BHEL offer today. BHEL ranges of services extend from product feasibility studies to after sale services, successfully meeting diverse needs through turnkey capability. The company now has 14 manufacturing unit, 9 services centers and 4 power sectors regional centers besides project sites all over India and abroad. BHEL today is the largest engineering and manufacturing enterprise of its kind, with a well recognized track record of performance, making profit continuously since 1971-72 and paying dividends since 1976-77. BHEL manufactures over 180 products under 30major product group and cares to core sectors of Indian economy viz, power generation and transmission industry, transportation, telecommunication, defense etc. the quality and reliability of its products is due to the emphasis on design ,engineering and manufacturing to international standards by acquiring and adopting some of the best technologies from leading companies in the world, together with technology developed in its own R&D centers i.e. BHEL Hyderabad. BHEL has acquired ISO 9000 certification for its operation and has also adopted the concepts of total quality management (TQM) and environment management (EMS).
A BRIEF INTRODUCTION
By the end of the fifth year plan, it was envisaged by the planning commission that the demand for the power transformer would raise in the coming years. Anticipating the countrys requirement BHEL decided to set up a new plant, which would manufacture power and other type of transformer in addition to the capacity available at BHEL in Bhopal. The Bhopal plant was engaged in the manufacture transformers of large rating and Jhansi unit would concentrate on power transformer, traction transformer for railway etc. The unit at Jhansi was established in 9 Jan, 1974 and it is situated around in 15 kms from the city on the national highway number 26 i.e. Jhansi-lalitpur road. It is called second generation plant of BHEL it was setup in 1974 and estimated cost of Rs 16.22crores inclusive of Rs 2.1crores for township. Late Mrs. Indira Gandhi, the prime minister laid the foundation on 9thjan 1974. The commercial production of the unit began on 1976-77 with an output of Rs 53 lakh, than there has been no looking back for Jhansi. Unit of BHEL is basically engaged in the production and manufacturing of transformers of various types and capacities with growing competition in the transformer section in 1985-88 it undertook the re-powering of diesel but it took a complete year for the manufacturing to begin. In 1987-89, BHEL has taken a step further in undertaking it is also, manufacturing AC/DC locomotives.
A dynamic is one its aim high adopts itself quickly to changing environment. So here we are in BHEL. Business mission To be a leading engineering enterprises providing quality product, systems and services in the field of energy, transportation, industry, infrastructure, and their potential areas Growth To ensure steady growth by enhancing the competitive edge of BHEL in existing, new areas and international operations so as to fulfill national expectation for BHEL. Profitability To provide a reasonable and adequate return on capital employed, primarily through improvement in operational efficiency, capacity utilization and productivity and generate adequate internal resources to finance the companys growth. Customer Focus To build a high degree of customer confidence by providing increased value for his money through international standards of product performance superior customer service. People Orientation To enable each employee to achieve his potential, improve his capabilities, perceive his role and responsibilities and participate and contribute to the growth and success of the company, to invest in human resources continuously and be alive to their needs. Technology To achieve technological excellence in operations by development of indigenous technologies and efficient absorption and provide competitive advantage to the company. Image To fulfil the expectations which stakeholders like government as owner, employees, customers and the country at large have from B.H.E.L.
New Manufacturing Units RANIPAT JAGDISHPUR RUDRAPUR BANGALORE (Boiler Auxiliaries Plant) (Insulator Plant) (Component and Fabrication Plant) (Industrial System Group)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Power Transformer Special Transformer ESP Transformer Freight Loco Transformer ACEMU Transformer Dry Type Transformer Bus duct Instrument Transformer Diesel Electric Locomotive
Up to 220 KV Class 250 MVA Up to 110 KVA 1000 KVA 3900-5400 KVA&6500KVA (3 Phase)
Up to 1000 KVA 25 KV(1Phase) Up to 3150 KVA Up to 15.75 KVA(Generating Voltage) VT and CT Up to 220 KV Up to 2600 HP Up to 5000 HP(25 KV AC/1500V DC) 200 Tonne
10. AC/DC Locomotive 11. Well Wagon 12. Over Head Equipment Cum Test Car 13. Dynamic Track Stabilizer 14. Ballast Cleaning Machine
1976-77 1977-78 1978-79 1979-80 1980-81 1981-82 1982-83 1983-84 1984-85 1985-86 1986-87 1987-88 1988-89 1990-91 1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 1999-00
Start of Instrument Transformer Production Start of Traction Transformer and Power Transformer (Up To132 KV) Start of HFTT type freight Locomotive Commissioning of 2,500 KV DG Set (due to server power cuts) Start of ESP Transformer Start of 220 KV Power Transformers Achieve Break Even Start of Bus duct Start of Dry Type Transformer Re powering of Diesel Locomotive Started Start of Diesel Locomotive Started Manufacturing Facilities for AC Locomotive Crossed Core Target Successful Design and Manufacturing of 400 HP 3 Axel Diesel CCI Manufacture of First 2600 HP Diesel for NTPC Successful Design and Development of 5000 HP Thyristor Control Locomotive Unit has been Awarded ISO-19001 Certificate for Quality Systems 240 MVA Power Transformers Produced First Time AC/DC Locomotives first time in India Hundredth Locomotive Manufactured 250 MVA Transformer Produced First Developed Over Head Equipment cum Test Car Diesel Hydraulic Shunting
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ROTATION REPORT
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STORE
There are separate stores for different type of material in the BHEL There are three sections in store; Control Receiving Section Custody Section Scrap Disposal Section Functions: - A list of material coming in store is prepared and Quality Control people are called for inspection. If material is found as par standard SRV (Store Receipt Voucher) is issued for each material. A total of 08 SVRs are prepared. Some materials such as Silicon oil, Transformer oil, insulating material etc are directly stored in the Bays. Scraps are also sold through unit by a MATERIAL SCRAP TRADING DELHI FABRICATION (BAY-0, 1, 2) Fabrication shop is the shop which deals with the manufacturing of transformer and locomotive components such as Tanks, Plates, and Nuts and Bolts. Fabrication shop is divided into three parts-
BAY-0
These are the fabrication shops established in 1978 and mainly deal with fabrication with fabrication work of transformers and locomotive. Different processing machines in this BAY are as follows: CNC FLAME CUTTING MACHINE (2 nos.) By the use of this machine, we can cut different shapes in our products via Oxy-Acetylene Flame through a copper nozzle. This machine can cut upto 300mm thick sheet. One of the machines has 4 burners while the other has 2 burners, which can work simultaneously. Maker Flame Axes 3.5m. Drive D.C. Drive ESAB Germany made Oxy-Acetylene Flame Two axis x & y. In X-axis, tool can move upto 7m & in Y-axis it can move upto
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BENDING MACHINE Principle Hydraulically operated Pistons Used2 way. It is up/down switch operated & has 3 cast iron Pressure Gauge is used to read out the pressure applied. The pressure applied may vary upto 250
solid cylinders. Stopping mechanism used is nut & screw mechanism to prevent the ram blade from collapsing
ROLLING MACHINE This machine is used for decreasing the roll thickness. The roller material used is High Carbon Steel. It has two rollers and one bending roller. In this machine, gears are used for speed reduction of the rollers to give uniform and better thickness and good surface finish.
FLATTENING MACHINE Principle Hydraulically operated This machine is used to straighten the job. The flattening load is applied by hydraulic method where the hydraulic oil of suitable grade is used. The capacity of this machine is 100 tonnes.
RADIAL DRILLING MACHINE (2 nos.) In this machine, tool can move radially. In it the drill tool is cooled using cutting oil mixed with water. Different drill tools are used from 2mm to 100mm diameter.
SHEARING MACHINE Principle Knife cutting via hydraulic pressure This machine is used for simple cutting in the metal sheets. Cutting range is 2mm to 6mm. Suitable materials for use are Al, Standard Steel & Cu. This is also hydraulically operated.
BAY- 1, 2
These bays are known as assembly bays. In these bays, different operations to be performed are:Fitting In this section, as the name suggests, we fit different components as per the drawing requirements. Welding In this section, we weld the different components of different drawing by permanent joints. The different types of welding done here (SAW) & manual arc welding. Testing When our tank for the transformer is completed, then we check the leakage tests on the tank, which are of two types:1. AT (Air leakage test) In this test, first we fill the tank by compressed air and dip the tank in the soap solution for bubble test. 2. VT (Vacuum test) Shot Blasting PlantWhen we check the leakage by satisfying result then we use SHOTBLASTING for removing the carbon layer from the surface of the tank. In the SHOT BLASTING, we use the small rings with the high pressure of 7kg. Overhead Cranes (2 nos.) are metal inert gas (MIG), Submerge Arc Welding
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BAY-3
It is split in two parts, half is consist of machine shop and the other half is consist of winding of dry type transformer. There is different type machines used in section. These are listed below. 1. Tool Cutter grinder Used for cutting tool also grinding them. 2. Hydraulic surface grinder It is consist of magnetic platform. Cooling oils is used as coolant. 3. Drill sharp machine It is used for sharping the drill bits by means of grinding wheel. 4. Vertical grinder machine It is used for grinding purpose. 5. Hydraulic power press Used for straightening the material, capacity of this machine is 25 tones. 6. Resistance brazing machine Used for overlap connections. 7. Bend saw machine It is used for cutting circular object. In this machine blade thickness is inch. 8. Electric furnace Used for heating the object. 9. Hydraulic punching machine Used for making small pieces of material for desire purpose. Range of this machine is 12mm to 250mm. 10. Hydraulic shearing machine Used for cutting the material in range between 12mm to 25mm. 11. Lathe machine There are mainly three types of lathes are there these are listed as below. Turret lathe Used for heavy duty. Range of this machine is 250mm to 300mm. Capstone lathe Used for light work, range of this machine is 20mm to 150mm. Center lathe It is used for light work and range of this machine is 20mm to 200mm.
Tanning Spot- Here Pb, Sn are used for tanning the connections in the job. Sulphuric Acid (H2SO4) It is used for remove the blackening of the job. Marking Table- This table is used for marking on the job for processing in different machines.
COPPER SECTION This part is only concern with copper cutting, bending, tinning etc. Machine used are as listed below. a) Shearing machine: Range 4mm to 6mm and length of the blade is 830mm. b) Hydraulic power press: Used for straightening the product. c) Tube slitting machine: This machine is developed here and is used for cutting the tube along its length and across its diameter. Its blade thickness is wheel, which is top on the machine. 3 mm. d) Fly press machine: It is fully mechanical and is used to press the job. It is operated mechanically by a
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BAY4
Here winding work of the power transformer& dry type transformer is carried out. The coil of transformer is of four types. a) Low voltage coil b) High voltage coil c) Tap coil d) Tertiary coil All the winding performed by the paper insulation copper conductor (PICC) or by continuously transposed conductor (CTC) is also made of copper. They can be arranged in different ways. a) b) c) d) Reverse section winding Helical winding Interlinked winding Half section winding
Arrangement & type of coil depends on job requirements. Also the width & thickness of the conductors are designed & decided by design department. Conductors used for winding is in the form of very long spiral wound on a spool, conductor is covered by cellulose paper insulation. For winding, first the winding mould of diameter equal to inner diameter of required coil is made. The specification of coil is given in the drawing section that interlocks with each other. This interlocking can be increased and decreased to adjust the inner diameter of coil. The moulds are of following types. a) Belly types b) Link types c) Cone types
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BAY5
It is core and punch section but in a part of it cast resin coil encapsulation plant is situated. The coils of dry type transformer are casted, cut and finally prepared. In this bay various type of lamination of core is made, they are a) Side leg: This lamination is at the extreme ends of the core which stand vertical. They are isosceles trapezium in shape with angle of 45. b) Central leg: This as the name suggests is central vertical portion of the core. It is diamond shaped with vertical edges longer. At the narrower edge well fixed joint, the angles are kept 45. c) Yoke: The horizontal lamination of the core is called yoke. They are also isosceles trapezium in shape with angles of 45. one side is kept longer than the other for making a
Slitting machine: It is used to cut CRGO sheets in different width. It has a circular cutter whose position can be changed as per the requirement. CNC cropping line pneumatic: It contains only one blade which can rotate 90 about the sheet. It is operated pneumatically. CNC cropping line hydraulic: It is also used to cut the CRGO sheet it contains two blades, one is fixed and other rotates 90 above the sheet. It is operated hydraulically. M4 quality sheet 0.230.27 mm thickness is used. CNC per hour Consumption: 75 kWh CNC per hour Expenditure: 375 Rs.
BAY-6
This shop is divided into two parts one is traction transformer winding and other one consist of assembly of traction transformer. These transformers are used in locomotive used in the AC locomotive called freight locomotive transformer. These are mainly of two types: Single phase (5400 KVA) and three phase (6500 KVA). For local train EMU (Electrical multiple unit transformers) is to be used. These are also two types: Single phase (1000 KVA) and three phase (1500 KVA). The major difference is that it has various output terminals. The various outputs are required to supply the machine of different rating mounted on the loco. A tap changer (0-32 taps) is also provided and is used to obtain supply of different rating power.
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BAY8
This bay was established in the year 1974. It is one of the earliest bays to setup. It involved in the manufacturing of instruments transformer like 132KV and 220KV voltage/ current transformer. ESP transformer is also manufactured here. INSTRUMENT TRANSFORMER: These are of two types a) Current transformer (C.T.) b) Voltage transformer (V.T.)
CURRENT TRANSFORMER
It is a step down transformer. Higher current is not directly measured rather it is stepped down to lower measurable values by the current transformer, which is generally low. Body The main body is a bushing, it also acts as insulator in which winding is placed. The CT has a bottom and top chamber. The top chamber is the cylindrical tank of mild steel. It has terminals for connection of HV coils. It has Below the top chamber there is bushing made of porcelain.
a glass window to indicate the oil level. It has several folds and rain sheds to provide a specific electrical field distribution and long leakage path. Some bushings are of cylindrical while modern one is conical as amount of oil porcelain used is reduced without any undesirable effect. Bottom chamber house is the secondary winding. There is also connection box to which the connection low voltage (LV) is made.
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Windings The primary winding consists of hollow copper/aluminium pipe bent form of U, where aluminium is used for low rating. For higher rating a set of wire is passed through the pipe. For still higher rating, copper pipe is used and for highest rating copper pipe with copper wire passing through it is used. This arrangement depends on the current carrying capacity. The bent portion of primary is in the bottom chamber where as the free end is the top chamber. The straight portion lies inside the bushing. The primary is wound with crepe paper insulation goes in increasing as we go downwards in the bottom chamber. The free ends are provided with ferrules, which are small hollow cylinder through which wires can pass connection to the primary, are made through these ferrules. The secondary is divided in a number of coils for different set of tapings. Connections are different taping are made in connection box. Each coil has an annular core of CRGO (silicon steel).
VOLTAGE TRANSFORMER
This is also step-down transformer the out of construction is the same as that of C.T. It has also a top chamber, bushing and a bottom chamber. The difference is only in windings. Windings The primary winding is of thick wire having a few turns. The winding is heavily insulated with paper insulation. It has a hollow cylinder passing centrally through it, which houses the secondary winding. It is cleaned and painted with either enamel or epoxy paint. The customer gives the choice of paint. Epoxy paint is generally used in chemical plant and seashore installation. Terminals are then marked and rating and diagram plate is fixed. The job is sent to shipping department which takes care of its dispatch by packing in the wooden boxes. DIFFERENCE: In current transformer, primary has less turns then secondary and vice versa.
The Electro static precipitator rectifier transformer is used for environmental application. It is used to filter the suspended charge in the waste uses of an industry. They are of particular use in thermal power station and cement industry. The ESP is a single phase transformer. It has primary and secondary windings. The core is laminated and is made up of CRGO sheet. It is a step up transformer. An AC reactor is connected in series with primary coil. The output of the transformer must be DC which is obtained by rectifying AC using a bridge rectifier (bridge rectifier is a combination of several hundred diodes). A radio frequency choke (RF choke) is connected in series with the DC output for the protection of secondary circuit and filter circuit. The output is chosen as negative terminal because the particles of carbon (impurity) are positively charged. The dc output from the secondary is given to a set of plate arrange one after the other. Impurity particles being positively charged stick to these plates, which can be jerked off by hammer. For this, a network of plant has to be set up all across the plants .This is very costly process in comparison with the transformer cost. A relevant is also provided to prevent the transformer from bursting, as higher pressure develops inside it. It is the weakest point in the transformer body. An oil temperature indicator and the secondary supply spark detector are also provided. One side of the transformer output is taken and the other side has a marshalling box which is the control box of the transformer.
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Tendering
1. Tender requirements of the customer comprises of the following specifications: A. Technical specifications/requirements. B. C. D. 2. A. B. C. 3. A. B. C. 4. 5. customer. Contract Agreement: On the opening of the technical bid, the commercial bid of technically qualified tenders is opened & order is placed on the lowest value tender, which is followed by negotiations if required. Estimated Cost of the project/requirements. Estimated Time of completion of the project. Other information. Open Tender published in news, dailies open for all. Limited Tender issued to limited parties. Single Party Tender issued to parties on property basis. Engineering department for technical acceptance. Production planning & control for delivery period. Central dispatch cell for mode of transportation & transportation charge.
Types of tender:
Offer: If tender is feasible as obtained from reports of other departments, offer is submitted to the
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TESTING
TRANSFORMER TESTING In this shop testing on the transformer is carried out in one section and for loco in other section. In transformer testing section there are for MG. sets. The electrical specification of the entire test is already given. These tests are done on demand of customer on transformer manufactured, in this unit there are basically of these tests For power transformer routine test Ratio test: Special equipment transformer from routine meter. Resistance test: Special equipments Kelvin and Wheatstone bridge. Insulation resistance test: Special equipment megger. Separate source voltage withstand test: Special equipments HV transformers with associated control and measuring desk, standard capacitance potential divider. Iron loss measurement test: Special equipment : Electro dynamometer RMS voltmeter Average voltmeter Precision class measuring VT Variable frequency sine wave generator
TEST OF CURRENT TRANSFORMER 1. POLARITY TEST: INSTRUMENT USED: Polarity meter analog multimeter One of the winding is supplied with 1.5V D.C supply and other is connected to ammeter. If the direction of the deflection is correct implies the connections are correct else it is wrongly connected. 2. ACCURACY TEST: It is the test for rechecking various parameters like turn ratio, phase angle etc. 3. INTER TURN INSULATION TEST: First current is given to the primary while the secondary is kept open circuited Either of the rated primary current or the 4.5kV peak secondary voltage, whichever occurs first is allowed to withstand for 1 min. Then if the insulation can withstand it, it is said to be okay.
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TECHNOLOGY
This department analyses the changes taking place in the world and suggest changes accordingly. This is very important because the product must not get obsolete in the market otherwise they will be rejected by customer. Function: Technology function can be classified as: Processing sequence: The sequence of process of manufacturing is decided for timely and economic completion of the job. Operation time estimate: It includes incentive scheme management. Allowed operation time: It includes incentive amount. Facilities identification: It includes looking for new equipment, plant or tools to increase productivity. Special process certification: Special processes are the once required expertise for example identifying errors, cracks, air bubble in winding. Special tool requirement: Special tools are allotted if possible. When required else the design has to be reconsider. Productivity projects compilation: It includes the initial analysis of the problem and their appropriate solution to enhance productivity. The principle of working is that IF YOU DONT MAKE CHANGES IN YOUR COMPANY, THE COUSTMER WILL CHANGE YOU.
BUS DUCT
Bus duct is used as connection between generators and transformer. Bus duct are used in power connection over 150 M V. The question now arise that why are bus duct preferred over normal conductors. In high power application, insulations are the major problems and frequent insulation breakdown occurs. If this does happens then possibility of shorting of conductors and hence serious damage may occur to both transformer and generators. Bus duct are hollow pipes made of aluminum the cross section of these ducts depends on requirements of the customer and is done by the design department. It has also the separate department BUS DUCT COMMERCIAL.
LOCOMOTIVE
A locomotive is a rail vehicle that provides the motive power for a train. Loco means from a place Motive means causing motion. A locomotive has no payload capacity of its own. It is used to move a train.
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Main Equipment of DESL Traction Alternator/Generator. Traction Motor. Blower. Compressor or Expresser. Switchgear Equipments Drive Desk. Fuel Tank. Batteries Radiator
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Traction Transformer: It is fixed on under frame and gets supply from an overhead line by equipment called pantograph. The type of pantograph depends on supply. This transformer steps down voltage and is fitted with a tap changer. Different taps are taken from it for operating different equipment. One tap is taken rectified into DC using MSR and is fed to the DC motor.
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PROJECT REPORT
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Description
Modern CNC mills differ little in concept from the original model built at MIT in 1952. Mills typically consist of a table that moves in the X and Y axes, and a tool spindle that moves in the Z (depth). The position of the tool is driven by motors through a series of step-down gears in order to provide highly accurate movements, or in modern designs, direct-drive stepper motors. Closed-loop control is not mandatory today, as open-loop control works as long as the forces are kept small enough. As the controller hardware evolved, the mills themselves also evolved. One change has been to enclose the entire mechanism in a large box as a safety measure, often with additional safety interlocks to ensure the operator is far enough from the working piece for safe operation. Most new CNC systems built today are completely electronically controlled. CNC-like systems are now used for any process that can be described as a series of movements and operations. These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, bending, spinning, pinning, gluing, fabric cutting, sewing, tape and fibre placement, routing, picking and placing (PnP), and sawing.
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(a)Axial path
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These are the most complex, costly & versatile systems & usually require the assistance of a computer because of large data regarding positional values to be processed.
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Open Loop
Open loop is characterized by no feedback system in the drive system. MCU provides control to the drive motors. It is being assumed by the system that the machine table will reach the target position. There is no way from the MCU to know the actual performance of the system. Figure shows a block diagram of an open loop CNC drive system.
Closed Loop
With closed loop drive systems, feedback sub systems are used to monitor the actual output and correct any discrepancy between the desired and the actual system performance. Feedback subsystems are of two types: 1. Analog feedback system: Variations in physical systems such as position and velocity are being measured as voltage levels in analog feedback system. Tachometers are typically used to measure the velocity, whereas the resolvers are used to measure position. There are two feedback loops in CNC drive systems; position loop and velocity loop as shown in figure, the position loop is the outer loop, which consists of comparator, an amplifier circuit, a velocity loop, a resolver, and a resolver interface.
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Construction
A CNC system basically consists of the following: Central processing unit (CPU) Servo-control unit Operator control panel Machine control panel Other peripheral device Programmable logic controller (PLC)
Central Processing Unit (CPU) T h e C P U is t h e he art an d b rai n o f a C NC s y s t em . I t acc e pts t h e i n fo rm at i o n s t o re d i n t h e memory as part program. This data is decoded and transformed into specific position control and velocity control signals. It also oversees the movement of the control axis or spindle whenever this does not match the programmed values, a corrective action is taken. All the compensations required for machine accuracy (like lead screw pitch error, tool wear out, backlash, etc.) are calculated by the CPU depending upon the corresponding inputs made available to the system. The same will be taken care of during the generation of control signals for the axis movement. Also, some safety checks are built into the system through this u ni t an d t h e CP U u n i t w i ll pro vi de c o n t i nu o us ne ces s ary c o rre c t i ve ac t i o ns . Wh e ne ve r t h e situation goes beyond control of the CPU, it takes the final action of shutting down the system in turn the machine.
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Servo-Control Unit The decoded position and velocity control signals, generated by the CPU for the axis movement forms the input to the servo-control unit. This unit in turn generates suitable signals as command values. The servodrive unit converts the command values, which are interfaced with the axis and the spindle motors .The servo-control unit receives the position feedback signals for actual movement of the machine tool axes from the feedback devices (like linear scales, rotary encoders, resolves, etc.).The velocity feedback is generally obtained through tacho generators. The feedback signals are pas s e d o n t o t h e C P U fo r fu rt h e r p ro c e s s in g. Th u s t h e se rvo -c o n t ro l u n i t pe rfo rm s t h e dat a communication between the machine tool and the CPU.As explained earlier, the actual movement of the slides on the machine tool is achieved through servo drives. The amount of movement and the rate of movement are controlled by the CNC system depending upon the type of feedback system used, i.e. closed-loop or open-loop system.
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It is always advisable to store the program in a memory sub-module (EPROM/EEPROM) from where the program can be copied to CPU RAM in case the program is lost or corrupted. Operating System (ROM): It determines how the user program is executed, how inputs and outputs are managed, how the memory is divided, and how data are managed. The operating system is fixed and cannot be changed. Process Image Tables (PII, PIQ): The signal status of input and output modules is stored in a specified area of CPU RAM which is known as the process image table. Input and Output modules have the following separate image tables: Process image input table (PII) Process image output table (PIQ)
Serial Interface: Through the serial port programmers, operator panels and monitors are connected through cables and the CPU can be connected as a slave to a local area network. Timers, Counters, Flags: There are Timers, Counters and Flags available internally in the CPU memory that is used by the control program. The program can set, delete, start and stop the timers and counters and the values are stored in reserved area of RAM memory. A separate area in the RAM memory stores some intermediate results as flags. Input/output Modules: These modules transfer information between CPU and process peripherals as sensors, transducers and actuators. These are of the following type: Digital Input and Output Module These involve signal states 0 and 1 only These record and generate variable quantities as voltage and current These are used to record counters pulses of 25/500 kHz (typical value for Siemens S5100U PLC). It can be used for position detection tasks. Processor: Depending on the control program the processor calls the statements from the program memory in sequence, executes them, processes information from PII and sets PIQ. Analog Input and Output Module High-speed Counter and Position detection Module
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CNC block diagram This provides the positional feedback to the system. The velocity feedback is directly fed to the drive from the encoder or tacho-generator of the servo motor. The next diagram shows the interface of the CNC with the servo drives. CNC sends a drive enable signal to a drive and the drive tends to retain its position unless some command for movement is send from the CNC. To give feed command CNC along with the drive enable signal sends a reference voltage to the drive in the range of +/-10V proportional to the desired speed. The +/- sign denotes the direction of movement. The reference voltage is calculated as: Reference voltage = (10/n)*S Where n = maximum speed i.e. rated speed of motor (r.p.m) S = desired speed (r.p.m)
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logic. Pressure switch signal comes as input to PLC (signal 4) once clamping operation is completed. PLC sets the read in enable (signal 5) in CNC and execution of part program is resumed. N40.......... N50 Similarly M08 sets a PLC flag (signal 6).PLC resets read in enable in CNC (signal 7).PLC sends output to coolant solenoid (signal 8).Once coolant flow starts flow switch sends input to PLC (signal 9). PLC sets read in enable (signal 10) in CNC and part program execution is resumed till M02. Intelligent Fault Diagnostics: A CNC system is capable of diagnosing some of the machine faults and prompts the operator or maintenance personnel. It is mainly monitored by the PLC logic. There are preset flags for operator messages, fault messages and M-codes. When PLC generates an output and the corresponding feedback signal is not fed back as input to the PLC within a certain time the corresponding fault flag is set. During the time duration the corresponding operator flag is set which will help to prompt the operator that a certain function is going on. To make the system user friendly certain portion of the CNC system memory is reserved which contain the operator and fault messages in text format. So when a particular flag is set the system displays the corresponding text.
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Slideways: In the conventional machine tools, there is a direct metal to metal contact between the
slideway and the slides. Since the slide movement are very slow, & machine utilization is also low, this arrangement is adequate for conventional machine tools. However, the demand on slideways is much more in CNC machines because of rapid movements & higher machine utilisation. The design of slideway in a CNC machine should: a) b) c) d) Reduce friction Reduce wear Satisfy the requirements of movement of slides Improve smoothness of a drives
Siemens offers a range of SINUMERIK
CNC models such as the 810D, 840Di, 840D, and the compact FM357-2 positioning and path control module. These products provide the coordinated multi-axis control needed for milling, drilling, turning, and grinding applications. interconnect SINUMERIK operator CNCs panels also and
To meet these requirements in CNC machine tool slideways, the techniques used include hydrostatic slideways, linear bearings with balls, rollers or needles & surface coatings.
SIMODRIVE servo and spindle drives and associated motors to form a complete control system for the machine tool.
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Surface Coatings
The guiding surfaces of the machines are sometimes coated with low friction material such as polytetrafluoroethylene (PTFE) or replaceable strips of low friction material are used. When the strips wear to such an extent that the alignment is in error, these can be replaced.
Spindle drive: At the high cutting speeds and high material removal rates, the spindle carrying
the work piece or the tool are subjected to deflection & thrust forces. To ensure increased stability & minimise torsional strain, the machine spindle is designed to be short & stiff & the final drive to the spindle is located as near to the front bearing as possible. To meet common features of CNC machines i.e., High power & High speeds, DC motor with SCR control is commonly used to provide step-less variations of wide range of productivity.
Feed drives: The conventional CNC machines use recirculating ball screw and nut arrangement. In
transfers are involved. The connection between the screw & the nut is through
case of light duty machines, stepper motors can also be used. Rack & pinion drivers are used where long
an
endless stream of recirculating balls. Majority of machine tools used permanent type DC motor with SCR control or width modulation drives for
axis
drives.
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2. Limit Switch
Limit switches are used to make or break control circuit when mechanically actuated by a moving member. Moving member might be a dog mounted on the moving component, as in the case of traveller over travel limit switches, or may be of plunger actuated type as in case of filter clogged limit switch. The limit switch type may be of normally open type (NO) which will close when switch is actuated or normally close type (NC) which will actuated.
3. Circuit Breaker
A device designed to open and close by non automatic means and to open the circuit automatically on the predetermined overload of current, when properly, applied within its rating. Two types are there: 1) Thermal 2) Hydraulic Thermal circuit breakers respond only to temperature change in the bimetallic element. Heat is generated in the element because of i2rlosses. The element bends or deformed to open the contacts and unlatch the mechanism. Mainly used is MCB (Miniature Circuit Breaker) which offer dual protection i.e., protection against overload and short circuit. MCBs are preferred over fuses as it disconnects supply instantaneously, and requires seldom replacement. Some of the technical features of Circuit Breakers are: Long mechanical and electrical operational life High breaking capacity Overload tripping through accurately calibrated bimetal strip. Short circuit tripping through magnetic coil.
Circuit breakers give protection to the equipments such as motors, transformers, air conditioners, refrigerators, geysers, mixers etc. and cables/wires in electrical distribution system.
4. Overload Relays
It can be defined as the device which is operative by variation in the conditions of one electrical circuit to affect another device in same or another electric circuit. Relays provides overload protection over control circuits when used in conjugation with contactors and other motor control equipments, they provide accurate and reliable control and protection under overload condition.
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6. Fuses
A device used for protection of equipments. A wide range of fuses is available for protection of transformer, cables, capacitors and motors for application in Air or Oil. HRC fuses are used for the interruption of fault current in indoor and outdoor high voltage system and also protection of distribution power equipment.
7. Pressure Switch
The function of pressure switch is to break or make the control circuit whenever the pressure actuates the switch contacts. The switch contacts may be normally open type which closes on increasing pressure or of normally close type which open on increasing pressure. Pressure switches use single pole double throw (SPDT) micro switches as switching element. These switches are use with water, oil, air, nitrogen, inert gases, steam, mineral oil and natural gas etc.
8. Introduction to NC
Automation has been associated with advancement in technology. The problem of automation of small lot production has been overcome by numerical control (NC) machine tools have great extent. NUMERICAL CONTROL (NC) is defines as A system in which actions are controlled by direct insertion of numerical data at some point. The system must automatically interpret at least some portion of this data.
CNC
In CNC system, a dedicated computer is used to perform all the basis NC functions as per the control program also called executive program stored in the memory of the computer. It is this executive program, which makes it flexible/soft wired. Unlike NC systems, machine control data comes directly from the computer memory. Because of the memory availability user can store part programs also in computer. The capability to edit this part program is a real advantage to the part programmer right at the machine station. Additional features such as tape punching option, user oriented subroutine programs etc are also possible on CNC.
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ENCODERS
Incremental rotary encoder is most commonly used feedback device. The rotary encoder is a shaft-driven device delivering electrical pulses at its output terminal. The pulse frequency is directly proportional to shaft speed. Encoder consists of glass disc marked with a precise circular pattern of alternate clear and opaque segments on its periphery. The disc is mounted on the shaft. A fixed source of light is on one side and a photo cell is placed on other side of the disc. As disc rotates, light is permitted to fall on photo cell, to produce the output signal which is approximately sinusoidal. Internal or external amplifier is used to amplify the photocell output to a level suitable for feeding logic circuits. Amplified signal is fed to a circuit which converts the signal to a proper square wave with suitable rise and fall times. To sense direction of rotation a two photocell system is used. Photocell is arranged so that output signals have 900 shifts to each other. External logic circuitry is used to determine the direction of rotation.
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The controlled rectifier produces a crude form of D.C. with a pronounced ripple in the output voltage. This ripple component gives rise to pulsating currents and fluxes in the motor, and in order to avoid excessive eddy-current losses and commutation problems, the poles and frame should be of laminated construction. It is accepted practice for motors supplied for use with thyristor drives to have laminated construction, but older motors often have solid poles and/or frames, and these will not always work satisfactorily with a rectifier supply. It is also the norm for drive motors to be supplied with an attached 'blower' motor as standard. This provides continuous through ventilation and allows the motor to operate continuously at full torque even down to the lowest speeds without overheating. Low power control circuits are used to monitor the principal variables of interest (usually motor current and speed), and to generate appropriate firing pulses so that the motor maintains constant speed despite variations in the load. The 'speed reference' is typically an analogue voltage varying from 0 to 10 V, and obtained from a manual speed-setting potentiometer or from elsewhere in the plant. The combination of power, control, and protective circuits constitutes the converter. Standard modular converters are available as off-the-shelf items in sizes from 0.5 kW up to several hundred kW, while larger drives will be tailored to individual requirements. Individual converters may be mounted in enclosures with isolators, fuses etc., or groups of converters may be mounted together to form a multimotor drive.
CNC MACHINES
There are different CNC machines in Jhansi unit, which serve some special purposes.
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This machine is in boogie shop. It is used for all operation in boogie manufacturing like milling, drilling and boring. All the operation can be done in the single machine. CONTROL SYSTEM : GE FANUC 15M Axis: It works three axis X, Y and Z axis. It can travel up to 8000 mm in X-axis. 4000 mm in Yaxis and 800 mm in Z-axis. Feedback linear scale.
It has auto tool changer, which can change tools automatically. According to program its spindle diameter is 180 mm and 40 KW power is required to operate the spindle.
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3. Inspection
High position accuracies and repeatability are inherent features of CNC machines and reduce inspection time considerably. Normally a 100% inspection of the first component produced by a new tape is all that is necessary to prove the tape and tooling. Subsequently it is required to have only sample inspection. In process gauging and inspection is also provided on modern CNC machines.
4. Floor space
One CNC machine can replace five to six conventional machines. Thus manufacturing activities of a company can be expanded without increasing the floor area proportionately.
5. Inventory
By using CNC machine, procurement sizes and batch sizes can be reduced because of shorter lead times .This results in substantial saving. Lead time is time taken to progress a batch of component through a
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6. Material Handling
Handling of component from machine to machine which is necessary on conventional machine is significantly reduced on CNC machine, as all the operations are performed on one machine. This obviously reduces labour cost.
7. Tooling
This ability to complete machine part in a single setup means that fewer and simpler fixtures are required, which in turns requires less storage space and maintenance. The simpler a fixture is, the less expensive is to manufacture it.
8. Operators Skill
Dependence on skilled labour can be dispensed with. The accuracy of part produced with CNC machines machine depend upon accuracy and ability of machine and tape and not on individual operator.
10. Costing
Time required to produce a component is a function of machining cycle of CNC machines and is not influenced by operators efficiency or variation in labours rate, a great stability of prices can often be achieved throughout the life cycle of the respective product. Also cost accounting becomes very precise.
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CONCLUSION
It is true that CNC machine costs more to install initially. But higher initial cost is set off by the direct & indirect gains resulting from various advantages of CNC machines. In most cases, careful techno-economic evaluation of a given manufacturing situation will clearly bring out that unit cost of production is definitely less tools with that of so called conventional machine. To conclude numeric control is the most sophisticated form of automatic control of machine tool. It has high degree of precision and reliability. The control system has undergone several stage of development. Some of the special features offered by CNC machine manufacture are: Thermal stabilization Axis calibration Lost machine compensation With the various above qualities of CNC machine there are numerous advantages. They are High accuracy High reliability Less scrap and network Better machine utilization Computer control of manufacture capability of integration into distribution numeric control (DNC) etc. The programs written for CNC are easy to write and understand. These programs use either G-cod or M-code that runs the program. The codes are simple to understand. No wonder CNC machines tools are becoming more and more popular day by day in modern industries. In longer run CNC machine pays for itself with such outstanding qualities.
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Bibliography
1. Wikipedia
www.wikipedia.org/wiki/Main
www.bhel.com/home.php
3. www.cnccncmachines.com/
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