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Journal of Manufacturing Systems xxx (2017) xxx–xxx

Contents lists available at ScienceDirect

Journal of Manufacturing Systems


journal homepage: www.elsevier.com/locate/jmansys

Technical Paper

A modular-architecture controller for CNC systems based on


open-source electronics
Jorge E. Correa ∗ , Nicholas Toombs, Placid M. Ferreira
Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, IL, USA

a r t i c l e i n f o a b s t r a c t

Article history: Open control architectures regain relevance with the new revolution of open source electronics. This
Received 23 November 2016 paper presents the general ideas, examples of implementation and latest advances of a new, open archi-
Received in revised form 21 February 2017 tecture controller for CNC systems based on open source electronics. The multiprocessor and distributed
Accepted 3 March 2017
architecture of this controller leverages the power of platforms like Arduino or TI Launchpad to realize
Available online xxx
CNC systems of increased computational resources, closed-loop position of the tool, smoother motions
and higher feeds. Additionally, this work demonstrates the first steps in the development of virtual
Keywords:
machine as a new software component of the architecture. A “tight binding” between the real and vir-
Open architecture control
Modular control
tual machines will delineate the path for realistic, machine monitoring, remote operation and process
Open electronics planning environment.
CNC © 2017 Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers.

1. Introduction open OAC was developed by the US National Institute of Stan-


dards and Technology (NIST) initially named the enhanced machine
Capable of interpreting and precisely executing commands controller (EMC) and later changed to LinuxCNC [7]. The control
containing numerical information, the past 50 years have seen architecture of LinuxCNC consists of a motion controller (EMC-
NC machines become platforms for automating processes like 3- MOT), a discrete I/O controller (EMCIO), a task coordinating module
D printing, laser cutting, machining, assembly and many other (EMCTASK) and a GUI user interface. LinuxCNC is implemented
applications. With a booming industrial-automation market and on a real-time extension to the Linux kernel and it uses differ-
hundreds of controller manufacturers, incompatibilities between ent off-the-shelf ISA/PCI express bus-based cards to interface with
products became a challenge to the integration of new manu- the hardware. Systems based on computer cards require hardware
facturing units outside the scope of these controllers [1]. This modifications of the PC, which restricts the hardware modularity of
motivated the development of vendor neutral, open architecture the controller and they can be difficult to update because of compat-
controllers (OAC) around the world; e.g. OMAC in the United States, ibility issues with new mother board technologies. Although some
OSACA in Europe and OSEC in Japan. These controllers promised the advances at the research and development levels had been made in
integration of independent application program modules, control open control and modular architecture controllers (MAC) [8,9], the
algorithms, sensors and computer software/hardware developed idea was ahead of its time because of flexibility of vendors, liability
by different manufacturers. and standardization issues.
OAC is a base of communication protocols and system capabili- The open-electronics ecosystem, provides affordable micro-
ties that enable reliability, stability and modularity in both software processing and sensing technologies that have the potential to lead
and hardware [2]. The underlying idea was to decentralize the con- the way for intelligent servo-controlled machining tools. Guided by
trol task into modular algorithms (i.e. the operating system [3], the declining cost of microprocessor-based developing platforms
the motion interpolation [4,5], and the servo-control algorithms (Arduino, Ti LaunchPad, Teensy, Beaglebone), some of the NC appli-
[6]), while maintaining an open flow of machine states (e.g. posi- cations (CNC routers, laser cutters and 3D printers) have rapidly
tion, velocity, acceleration, temperature, forces). One of the first migrated from a proprietary hardware to open source hardware
systems. However, most of these controllers (such as GRLB, RepRap,
Smoothie) resemble a monolithic architecture (the interpretation
and the interpolation algorithms execute in the same processing
∗ Corresponding author. unit) that focuses on generating the sequence of output pulses to
E-mail addresses: jcorre20@illinois.edu (J.E. Correa), pferreir@illinois.edu acute stepper motors in an open-loop configuration as oppose to
(P.M. Ferreira).

http://dx.doi.org/10.1016/j.jmsy.2017.04.013
0278-6125/© 2017 Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers.

Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
J Manuf Syst (2017), http://dx.doi.org/10.1016/j.jmsy.2017.04.013
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Fig. 1. Software (a) and hardware (b) architecture of the controller.

be fed as the reference to a closed-loop system. This limits the com- servo-control algorithms, thus capturing the physics of the machine
puting resources, flexibility, modularity and overall performance. and the controller. We envision that this strategy will delineate
The OAC paradigm regains relevance with the new revolution the path for realistic machine monitoring, remote operation and
in open electronics. Free from proprietary hardware implemen- process planning environment in CNC.
tation, an OAC based on open electronics would represent a step
forward in the flexibility and openness of this systems, creating an
2. Controller overview
opportunity for easy automation of new manufacturing processes
and custom-based CNC solutions. Next generation of open elec-
The open CNC architecture controller in this paper consists of
tronics in CNC should leverage the power of multiple-processing
four control programs executed independently on different pro-
units to perform tasks requiring increased computational resources
cessing units, namely, the executive program or operating system,
[10], online machine monitoring [11], better integration with CAM
the interpolation program or motion controller, the servo control
software packages [12], better control of the position of the tool
program and the PLC. The executive program is a PC-based appli-
through closed-loop configurations, smoother motions and higher
cation in charge of managing the non-real time services of the
feeds.
architecture; the interpolation program is a micro-controller pro-
This paper presents the general overview and latest advances of
gram in charge of the online coordination of the axis, feed rate
a new, open, multi-processor architecture controller for multi-axis
control, acceleration and deceleration; and the servo control, in
servo control of CNC systems, based on open electronics. Its purpose
turn, executes in a micro-controller and drives each axis indepen-
is to provide researchers and enthusiasts with a new control archi-
dently with a velocity close-loop control. The rates of execution of
tecture for the rapid design of CNC systems that will allow them to
the algorithms are adjusted according to their priority and worst-
experiment with these platforms and create special purpose appli-
case execution time [18]. For example, the maximum interpolated
cations. The four major programs of the architecture: the machine
frequency cannot exceed the execution frequency of servo-loop
executive, the motion interpolation, the programmable logic con-
interrupt. A detailed discussion on the communication protocols
troller (PLC) and the servo-controller algorithms, are coded in a
and rates of execution of the different programs is presented in our
general manner that the architecture is modular in both software
previous work [15].
and hardware. Examples of the main programs are presented in
Fig. 1. shows a diagram with the software (Fig. 1(a)) and a pos-
the Texas Launchpad [13] and Arduino development platforms
sible hardware (Fig. 1(b)) architectures of the controller to a 3-axis
[14]. Because the interpolation and servo-control algorithms have
CNC machining center. The control architecture is a component
been previously demonstrated [15], the discussion on this paper
base-approach aimed to achieve software modularity. This means
focuses on the executive program The OAC in this work offers
that each of the components has a unique Finite State Machine
increased computational resources and flexibility of reconfigura-
(FSM) that ensures the coordinated execution of the tasks in the
tion of manufacturing units. Additionally, this work is the first one
controller. When executing a NC program or a manual command
in demonstrating the first steps towards incorporating a virtual
from the graphical user interphase (GUI), the executive program
representation of the machine [16,17], to the OAC paradigm. The
calls the RS-274 interpreter service to parse the instructions into
“virtual machine” has a replica of the interpolation, the PLC and the
sequence, preparatory, dimension and feed words. The interpreter

Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
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uses this information to generate the desired-state vector of the number “05”. The Yacc-generated parser contains the programing
machine (a C type structure with information on the position of the rules (grammar) that make syntactic sense of the RS-274 code. Each
axis, type of motion, process parameters among others) and the set of the grammar descriptions in the parser is associated with a cor-
of atomic actions (a linked list with the ordered sequence of actions responding C action aimed to the generation of the of the desired
such as “straight transverse”, “arc feed”, “tool change”) required to state vector of the machine and the set of atomic actions to bring
arrive to said state. Finally, the atomic actions are sent to the exec- the machine to that state. For example, the block “N10 G01 × 10
utive program which, in turn, send them to the interpolator and F300” corresponds to the production rule:

block : {;}
| block seq_word prep_word dim_word feed word { process_block (); }
;
seq_word : {;}
| T_N number { update_verctor(seq, $2);}
;

In this production, the left recursion indicates that a block can


PLC for the generation of the coordinated motion of the axis and have more than one block with a sequence word, a preparatory
the execution of the automatic motion routines respectively. Both word, a dimension word and a feed word. A production rule can be
the interpolation and PLC transmit the motion instructions to the terminal or non-terminal in which case it has a sub-grammar with
servo control units. corresponding action. In the example, the entry production “block”
Central to the executive program is a virtual representation triggers the action “process-block ()” which generates the linked list
of the machine (See Sec. 3.2). Embedded inside the GUI, virtual of atomic actions, based on the parsed state vector of the machine,
machine is an object oriented, hierarchical, and modular repre- after the execution of the block. For the sake of brevity, only the
sentation of the machine tailored for remote monitoring, process non-terminal production “seq word” is shown in the example.
planning environment and, in general, as a test bed for different This production results in updating the member “sequence” of the
control algorithms. When active, the virtual machine receives the desired state vector according to the value “number”. In this a simi-
atomic actions from the executive program and simulates the cor- lar manner, the interpreter program is able to maintain the G-code
responding motions and automatic routines thus creating a tight references (modal and non-modal preparatory words) and check
binding between the physical and virtual representations of the for syntax errors and conflictive preparatory words. The interpreter
machine. can be compiled as a standalone (for the integration with differ-
The hardware architecture uses a serial-port, primary commu- ent architectures) or linked as an object in the compilation of the
nication bus to transmit the messages from the executive program executive program. In the latter, the interpreter operates in inter-
to the interpolator and the PLC. There is a secondary bus of com- preted mode (each block is feed individually upon completion of
munication in charge of: (a) transmitting the train of pulses from the previous one), compiled mode (all the blocs are parsed with-
the interpolator to drive the position of the axes, handled by out coordinating with programs of the architecture) and standard
hardware interrupts in the servo-controllers, and (b) communi- input modes (user input blocks).
cate the servo-loop configuration parameters, servo variables and
automatic motion routines from the interpolator and PLC to the 3.2. Virtual machine
servo-control units via Inter-Integrated Circuit protocol of commu-
nication (I2C). This section delineates the ideas behind the implementation of a
virtual machine to the open-architecture. Traditionally, Computer
3. Executive program Aided Manufacturing (CAM) software has been tailored to pro-
cess planning and NC-code generation of general purpose machine
The executive program is a PC-based application program with tools. The virtual machine in this architecture has exact replicas
graphic user interphase GUI, coded in C++, in charge of: (a) execut- of the control algorithms of the architecture (interpolation and
ing the non-real-time services of the architecture i.e., processing servo control), shares its communication structures and protocols
of manual instructions and overrides, parsing and interpretation of and mimics the hardware characteristics of the machine. Because
G-code (RS-274), and setting of motion and servo-loop configura- of this, the supervisory control can execute a user command or a
tion parameters, while (b) coordinating the execution of real time numerical control program completely in computer software, with
services such as the interpolation, the PLC routines and the man- accurate simulation of the trajectories down to the basic step of
agement of the virtual machine. This software component is the the drives. This component can also be executed in parallel with
operating system of the controller and it has a user interface to set the physical (lower-level) components of the architecture provid-
the servo-variables, send manual commands, execute Numerical ing a convenient tool for real-time monitoring of automated CNC
Control (NC) programs, and handle troubleshooting services. machinery.
The virtual machine is an object-oriented model of the con-
3.1. Interpreter trolled mechanical system with a 3D representation that includes
the full definition of its links and joints. It is hierarchically organized
The code interpreter is an executive program service which in a structural and control basis with exact replicas of the control
translates the part program and manual commands into internal algorithms of the architecture. The main entities of this hierarchy
commands for moving the tools and auxiliary functions in CNC [19]. are:
Fig. 2(a) shows the finite state machine of the interpretation pro-
gram. The interpreter is programed with the help of Lex and Yacc • Link: A link refers to a component (one or more faceted solids)
for the generation of the lexical analyzer and parser. Lex is used to with a coordinate frame attached to it. A link has a list of coordi-
convert G-code input strings in the file source to tokens [20] (char- nate frames (shape transforms) defining the pose of its joints.
acters or numbers) for the subsequent use of the Yacc parser. For • Joint: A joint describes the relative motion between two links by
example, the block “N05” returns the character token “T N” and the means of a joint transformation (either a rotation or a translation

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Fig. 2. A simplified finite state machine (FSM) diagram of the architecture.

along the Z-direction). The associated services are the joint model, constructor, to parse the mechanism information from a human-
joint limits, and the servo-control. readable text file (see appendix). The standard machine data file
• Mechanism: A collection of links and joints working together to (.smd) was created to load the machine geometry and assembly
produce functional motion. This object contains the graph of the information form a commercial CAD software such as Autodesk
mechanism (with the links as nodes and the joints as arcs) used Fusion 360. After loading the geometries, the program spans the
for the kinematic and rendering services. graph of machine to find the sequence of shape-joint transforms of
• Machine: A mechanism with its associated control and operation each link. This is used by the render service to populate the scene
services; e.g., the interpolation, PLC and rendering services. with machine assembly at its configuration given by the joint trans-
forms. Fig. 4 shows the openGL rendered machine with it link and
joint transforms. The interpolation service coordinates the motion
The information flows through the virtual machine services in
of the axes by updating the joint transforms and calling the render-
the exact order than it does through the physical architecture.
ing service after a number of iteration. The velocity of interpolation
The fact that these services are exact replicas of the control pro-
is modified by changing the number of iterations of the interpo-
grams, creates a tight binding between the real and the virtual
lation algorithms before rendering the scene. The virtual machine
representations of the machine. Such a binding is key aspect in the
program has been successfully tested for interpolation frequencies
implementations of a real-time monitoring application and process
higher than 40 kHz in an Intel Quad core CPU @ 2.5 GHz.
planning environment. Fig. 3(a) shows a three-axis virtual machine,
This are the first steps towards the integration of a virtual
coded inside the application user interface (API) of Autodesk
machine to the open architecture of this paper. Following steps in
Fusion 360. To demonstrate the potential of tightly-bound vir-
this area include the implementation of efficient algorithms to sim-
tual machines and controls, this implementation uses Fusion 360
ulate the material removal process that account for the dynamics
CAM trajectories and an internal reference-pulse interpolation
of the drives and the material properties of the workpiece.
algorithm (See Sec. 4), to “virtually machine” the workpiece.
Fig. 3(b) shows a rendered image with the simulation results of
a 2D-machined trajectory. The material is removed by driving the 4. Interpolator
machine along the interpolated trajectories, using the Fusion 360
joint definitions, while intersecting and subtracting the solid rep- The interpolator coordinates the motion of the axes to drive the
resentation of the tool from that of the workpiece. The simulated machine tool along the required trajectories. Fig. 2(b) shows the
surface is shown in the detailed view of Fig. 3(b). Virtual machin- finite state machine of the interpolator program. A basic interpo-
ing uses the control algorithms and physics of a specific system to lation algorithm uses the set of atomic actions (generated by the
simulate the machining processes rather than recreating them for interpreter from the part-data program) to obtain the tool path as
a general purpose CNC machine, as in traditional CAM software. For a combination of linear and circular segments. The output of the
instance, in a virtual machine, the feed, speed, material removal and interpolator is transmitted to the servo controllers in a sequence of
accelerations are kept below critical values to keep the machining reference-pulses, each equivalent to one basic length-unit (BLU) of
and inertial loads within the safety range of the machine. the machine. The total number of pulses add to the position of the
A second three-axis, virtual machine was coded in C++ and axis, and the frequency of the pulses represents their velocity. The
openGL, for higher graphics performance. This implementation interpolator in this paper is based on a software Digital Differential
required a loader method, embedded inside the machine-object Analyzer (DDA) technique, explained in detailed in reference [4].

Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
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Fig. 3. A virtual machine implementation in Autodesk fusion 360.

Fig. 4. A virtual machine implementation in openGL.

The implementation of this algorithm to the control architecture of


this paper is discussed in our previous work [15].
The software DDA interpolation routine, for linear and circu-
lar motions, was programmed on the boards Arduino Mega 2560
and Texas Instruments Launchpad C2000. The interpolator inter-
rupt service routine (ISR) has a maximin execution time of 72 ␮s
in the Arduino Mega and 4 ␮s in the TI Launchpad C2000, this
corresponds to maximum interpolating frequencies of 13 kHz and
230 kHz respectively. Fig. 5 shows the interpolation of a 2D trajec-
tory on the Arduino Mega 2560. The graphics software Inkscape
[21] was used to trace the vector trajectory from a bit-map image
(Fig. 5(a)) and to generate the G-code approximation (Fig. 5(b)).
Fig. 5(c) shows the NC trajectory sampled in real time by a serial
communication interrupt while interpolating at a frequency of
Fig. 5. An interpolation example of a 2D trajectory using linear and circular refer-
8 kHz. This test demonstrates the ability of the architecture to main- ence pulse interpolation. A vector trajectory (a) and its G code approximation (b)
tain an open flow of information during interpolation. are generated in Inkscape [21]. The trajectory is interpolated with reference pulses
of 8 kHz and sampled in real time through a serial communication interrupt (c). A
zoom view of interpolated path is shown in (d).
5. Servo control

The servo-control algorithm was programmed on the Arduino culates the output voltage to the motor driver proportionally to
Nano with the microprocessor ATmega328 and the Texas Instru- the instantaneous error count (proportional controller in positon).
ments Launchpad C2000. Fig. 2(c) shows the finite state machine The servo-loop ISR exhibited a maximum execution time of 76 ␮s
of the interpolator program. Here, a set-point external interrupt in the Arduino Nano and 2 ␮s, in the TI Launchpad C2000, this
increments a counter whenever the interpolator requests a pulse allowed servo-frequencies of 10 kHz and 30 kHz respectively. Con-
while a timer interrupt controls the execution of the servo-control ventionally, the maximum interpolated frequency should be below
loops. In a single iteration of the servo-loop interrupt, the ISR cal- the execution frequency of servo loop interrupt. The output volt-

Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
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Fig. 6. Servo-controller breakout board design. Printed Circuit Board (PCB) design (a) and circuit board assembly (b).

arbitrary 2D piecewise trajectory, comprised of 40 arc segments


with regions of low and high curvature. The purpose of this was
to test continuity and smoothness of the motions, produced by the
control in different interpolation scenarios. The reference- pulses
are interpolated at a frequency of 3.5 kHz and the position updates
from the interpolator and servo-controller are received by the exec-
utive program at frequencies of 100 Hz and 20 Hz respectively.
The experiment shows that the following error in the system
is around 12 steps corresponding to 12 ␮m. This value error can
be reduced by implementing higher order control law such as a
proportional-integral (PI) or a feed forward controller. The follow-
ing error was our first choice for criteria used to evaluate the system
against as the architecture has not been tested in a real machining
scenario. In the absence of machining forces the combined position-
ing error of the system is 6 steps (equal to +−6 um). The frequency
mismatch between servo and interpolation updates resulted in a
trajectory data acquisition delay of 200 steps. This is a synchroniza-
tion error due to the speed of the communication interrupt rather
than an accuracy error of the servo-controllers.

Fig. 7. 3-axis CNC systems as example of the proposed controller. 7. Conclusions and future work

The price, performance and availability of open source elec-


age to the motor drive is sent in an 8-bit Pulse Width Modulation tronics has grown considerably over the last years and begs the
(PWM) signal in the Arduino Nano and a 16-bit PWM signal in the consideration of their use in manufacturing and numerical control
Launchpad C2000. The position and resolution of each platform is automation. This paper provided readers with a general purpose,
proportional to the resolution of the PWM signal and is inversely open architecture for the design of CNC system based on open elec-
proportional to the execution frequency of the servo-loop interrupt. tronics and detail information to experiment with these platforms.
A plug-on servo-controller breakout board (See Fig. 6(a) and Preliminary results demonstrate that such an architecture can have
(b)) was conveniently designed for the integration of the Arduino practical implications in the development and prototyping of new,
Nano with the PWM driver MC33936 from NXP USA Inc. and the NC schemes for special purpose applications and research. More-
LS7366R 32-bit quadrature counter from US Digital. The quadrature over. With a strong Do It Yourself (DIY) movement, this paper is an
counter (interfaced via SPI communications) offloads the compu- example of how to construct CNC systems with open electronics.
tations of the microcontroller. This solution is tailored to compact We conclude that this implementation can be deploy in high per-
applications with basic level of performance and high flexibility. formance table top CNC systems. However, we caution against its
use on larger machinery.
6. Preliminary experimental results The architecture in this paper is simple, modular and open. This
component-based approach offers the possibility of adding micro-
Fig. 7 shows an experimental implementation of the open archi- processing units and axis of motion without modification of the
tecture to a two-axis CNC machine tool. In the photograph, an interpolation or servo-control algorithms. This kind of software and
Arduino Mega 2560 interpolator is connected to the X and Y servo- hardware modularity is important for the reconfiguration of new
controller (SC) breakout boards. The rotary encoders on the stages manufacturing units. The flexibility of the architecture makes it a
have 2000 pulses per revolution and the leadscrews have a pitch convenient testbed for the implementation of new control algo-
of 2 mm. These values correspond to a BLU of 1 ␮m. Fig. 8(a) and rithms on different electromechanical systems. The open control
(b) show the interpolated and the encoder feedback trajectories of architecture was implemented in the Arduino platform for a basic
a test NC program. In this example, the stages are driven along an level of performance and high flexibly, and in the Texas Launch-

Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
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Fig. 8. Test trajectory of the control with the interpolated and feedback trajectories (a). A zoom view of a high curvature region in the interpolated path (b).

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Please cite this article in press as: Correa JE, et al. A modular-architecture controller for CNC systems based on open-source electronics.
J Manuf Syst (2017), http://dx.doi.org/10.1016/j.jmsy.2017.04.013