NUMERICAL CONTROL

BASI C COMPONENTS OF AN NC SYSTEM

An operational numerical control system consists of the following three basic components:
1. Program of instructions or part program
2. Controller unit, also called a machine control unit (MCU)
3. Machine tool.




PROGRAM OF I NSTRUCTI ONS / PART PROGRAM
The program of instructions is the detailed step-by-step set of directions which tell the
machine tool what to do.
It is arranged in the form of blocks of information, where each block contains the numerical
data required to produce one segment of the workpiece.
The block contains in coded form all the information needed for processing a segment of the
workpiece, the segment length, its cutting speed, feed etc.
Dimensional information (length, width and radii of circles) and the contour form (linear,
circular or other) are taken from an engineering drawing.
Dimensions are given separately for each axis of motion (X,Y etc.)
NC MACHINE TOOL
Cutting speed, feed rate and auxiliary functions (coolant on and off, spindle direction, clamp,
gear changes etc.) are programmed according to surface finish and tolerance requirements.
The part program can be entered into the system either manually or in the form of punched
tape.
The punched tape is moved forward by one block each time the cutting of a segment is
completed.

CONTROLLER UNI T
The second basic component of the NC system is the controller unit. This consists of the
electronics and hardware that read and interpret the program of instructions and convert it
into mechanical actions of the machine tool. The typical elements of a conventional NC
controller unit include the tape reader, a data buffer signal output channels to the machine
tool, feedback channels from the machine tool, and the sequence controls to coordinate the
overall operation of the foregoing elements.
The tape reader is an electromechanical device for winding and reading the punched tape
containing the program of instructions. The data contained on the tape are read into the data
buffer. The purpose of this device is to store the input instructions in logical blocks of
information. A block of information usually represents one complete step in the sequence of
processing elements. For example, one block may be the data required to move the machine
table to a certain position and drill a hole at that location.
The signal output channels are connected to the servomotors and other controls in the
machine tool. Through these channels, the instructions are sent to the machine tool from the
controller unit. To make certain that the instructions have been properly executed by the
machine, feedback data are sent back to the controller via the feedback channels. The most
important function of this return loop is to assure that the table and work part has been
properly located with respect to the tool.
Another element NC system, which may be physically part of the controller unit or part of
the machine tool, is the control panel. The control panel or control console contains the dials
and switches by which the machine operator runs the NC system. It may also contain data
displays to provide information to the operator. Although the NC system is an automatic
system, the human operator is still needed to turn the machine on and off, to change tools
(some NC systems have automatic tool changers), to load and unload the machine, and to
perform various other duties. To be able to discharge these duties, the operator must be able
to control the system, and this is done through the control panel.
MACHI NE TOOL OR OTHER CONTROLLED PROCESS
The third basic component of an NC system is the machine tool or other controlled process.
It is the part of the NC system which performs useful work. In the most common example of
an NC system, one designed to perform machining operations, the machine tool consists of
the work table and spindle as well as the motors and controls necessary to drive them. It also
includes the cutting tools, work fixtures, and other auxiliary equipment needed in the
machining operation.
CLASSI FI CATI ON OF NUMERI CAL CONTROL (NC) SYSTEMS:
1. ACCORDI NG TO THE TYPE OF MACHI NE:

POI NT-TO-POI NT (PTP) SYSTEMS:-

In a PTP system, the workpiece is moved with respect to the cutting tool until it arrives at
a numerically defined position and then the motion is stopped.

Now the cutting tool performs the required task with the axes stationary.

Upon completion of the task, the workpiece moves to the next point and the cycle is
repeated.

In this system, the path of the cutting tool and its federate while traveling from one point
to the next do not have any significance.

Thus only the final position of the tool upon reaching the point to be machined needs to be
controlled and not the path from the starting point to the final position.

An example of this system is the drilling machine.

In a drilling machine, the workpiece is moved along the axes of motion until the centre of
the hole to be drilled is exactly beneath the drill. Then the drill is automatically moved
towards the workpiece and the hole is drilled.

Now the drill moves out rapidly.

The workpiece moves to a new point and the above sequence of actions is repeated.


STRAI GHT CUT NC
Straight cut control systems are capable of moving the cutting tool parallel to one of the
major axes at a controlled rate suitable for machining.
Eg. Shaping machine.

Cutting of the workpiece is done while the cutting tool is moving.

The cutting tool can move along either the X,Y or Z axis.

It is not possible to combine movements in more than single axis direction.

Therefore, angular cuts on the workpiece would not be possible.

The feed rate is programmed on the tape and may be selected by the programmer.



CONTOURI NG SYSTEMS:-
POINT TO POINT SYSTEM
STRAIGHT LINE SYSTEM
In contouring or continuous path systems, the tool is cutting while the axes of motion are
moving.

All axes of motion might move simultaneously, each at different velocity.

In contouring machines, the position of the cutting tool at the end of each segment
together with the ratio between the axial velocities determines the desired contour of the
part, and at the same time the resultant feed also affects the surface finish.

It is the most complex, flexible and the most expensive type of machine tool control.

It is capable of performing both PTP and straight cut operations.

In addition, the distinguishing feature of the contouring NC system is their capacity for
simultaneous control of more than one axis movement of machine tool.



2. ACCORDI NG TO THE PROGRAMMI NG METHOD:

I NCREMENTAL SYSTEM
An incremental system is one in which the reference point to one instruction is the
endpoint of the preceding operation.

Each piece of dimensional data is applied to the system as a distance increment, measured
from the preceding point at which the axes of motion was present.

As shown in the example below, five holes have to be drilled on the workpiece and the
distances from the zero point to the various holes are given in the figure.

In incremental systems, the command to drill the holes will be given as below:
CONTOURING SYSTEMS

X +30
X +40
X +40
Y +30
Y +30
Y +30



ABSOLUTE SYSTEM
An absolute NC system is one in which all moving commands are referred to one
reference point, which is the origin and is called the zero point.

The zero point may be defined as a point outside the workpiece or at a corner of a part.

In the above example, the part program will be

X +30
X +70
X +110
Y +30
Y +60
X +90


3. ACCORDI NG TO THE TYPE OF CONTROL LOOPS:

OPEN LOOP SYSTEM
The term open loop means there is no feedback.

The action of the controller has no information about the effect of the signals that it
produces.

The open loop NC systems are of digital type and use stepping motors for driving then
slides.

A stepping motor is a device whose output shaft rotates through a fixed angle in response
to an input pulse.

The stepping motors are the simplest way for converting electrical pulses into
proportional movement and they provide a relatively cheap solution to the control
problem.

Since there is no feedback from the slide position, the system accuracy is solely a
function of the motors ability to step through the exact number of steps which is
provided at its input.


CLOSED LOOP SYSTEM

The closed loop system measures the actual position and velocity of the axis and
compares them with the desired references.

The difference between the actual and desired values is the error.

The control is designed in such a way as to eliminate or reduce to a minimum, the error.

In NC system both the input to the control loop and the feedback signals may be a
sequence of pulses.

The digital comparator correlates the two sequences and gives, by means of a digital-to-
analog convertor (DAC), a signal representing the position error of the system, which is
used to drive the DC servomotor.




DDA INTEGRATOR:

Digital differential analyzers (DDA) are a special type of computer in which all variables are
represented by digital words, but the solution technique is similar to that used in analog
computers.
The DDA computer has the advantages of both digital and analog computers, and combines the
accuracy of digital computation with the continuity of operation of the analog computer.
Consequently it is suitable for digital solution of differential equations in real time.

The fundamental element of the DDA computer is the DDA integrator, which plays a role similar
to the operational amplifier in analog computers and forms the basic block for integration.
The DDA integrators are interconnected similarly to analog computer setups.
The difficulty of transferring n-bit words between integrators is avoided by using an incremental
transfer computation method.
This means that only increments of variables and their sign bit are transferred, so that only two
lines, instead of (n+1) transmitting lines are required

NC PART PROGRAMMING
Numerical control part programming is the procedure by which the sequence of
processing steps to be performed on the NC machine is planned and documented. It involves the
preparation of a punched tape (or other input medium) used to transmit the processing
instructions to the machine tool. There are two methods of part programming: manual part
programming and computer-assisted part programming.
PUNCHED TAPE IN NC
The part program is converted into a sequence of machine tool actions by means of the
input medium, which contains the program, and the controller unit, which interprets the input
medium. The controller unit and the input medium must be compatible. That is, the input
medium uses coded symbols which represent the part program, and the controller unit must be
capable of reading those symbols. The most common input medium is punched tape. The tape
has been standardized. The punched tape used for NC is 1 in. wide. .

THE APT LANGUAGE
In this section we present an introduction to the APT language for computer assisted
part programming. Our objectives are to demonstrate the English-like statements of this NC
language and to show how they are used to command the cutting tool through its sequence of
machining operations.
APT is not only an NC language; it is also the computer program that performs the
calculations to generate cutter positions based on APT statements. We will not consider the
internal workings of the computer program. Instead, we will concentrate on the language that the
part programmer must use.
APT is a three-dimensional system that can be used to control up to five axes. We will
limit our discussion to the more familiar three axes, x, y, and z, and exclude rotational
coordinates. APT can be used to control a variety of different machining operations. We will
cover only drilling and milling applications. There are over 400 words in the APT vocabulary.
Only a small (but important) fraction will be covered here.
There are four types of statements in the APT language:
1. Geometry statements. These define the geometric elements that comprise the workpart.
They are also sometimes called definition statements.
2. Motion statements. These are used to describe the path taken by the cutting tool.
3. Postprocessor statements. These apply to the specific machine tool and control system.
They are used to specify feeds and speeds and to actuate other features of the machine.
4. Auxiliary statements. These are miscellaneous statements used to identify the part, tool,
tolerances, and so on.