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JMSY-563; No. of Pages 7 ARTICLE IN PRESS
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

and the servo control. and the controller. online machine monitoring [11]. the executive program or operating system. and hardware. The control architecture is a component been previously demonstrated [15].E. an OAC based on open electronics would represent a step forward in the flexibility and openness of this systems. the programmable logic con- interrupt. preparatory. dimension and feed words.org/10.1016/j. creating an 2. 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 executive program is a PC-based appli- through closed-loop configurations. We envision that this strategy will delineate The OAC paradigm regains relevance with the new revolution the path for realistic machine monitoring. 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. modularity and overall performance. acceleration and deceleration. architecture. open. remote operation and in open electronics. servo-control algorithms. A detailed discussion on the communication protocols troller (PLC) and the servo-controller algorithms.jmsy.04. / Journal of Manufacturing Systems xxx (2017) xxx–xxx Fig. 1. to the OAC paradigm.17]. Examples of the main programs are presented in Fig. For example. tation. smoother motions and higher cation in charge of managing the non-real time services of the feeds. the PLC and the sequence. Its purpose turn. process planning environment in CNC. better control of the position of the tool program and the PLC. the maximum interpolated cations. J Manuf Syst (2017). the servo control software packages [12]. the motion interpolation. the discussion on this paper base-approach aimed to achieve software modularity.013 . be fed as the reference to a closed-loop system. When executing a NC program or a manual command in demonstrating the first steps towards incorporating a virtual from the graphical user interphase (GUI). shows a diagram with the software (Fig. based on open electronics. http://dx. flexibility. No.G Model JMSY-563. 1(b)) architectures of the controller to a 3-axis [14]. [10]. 1.2017. multi-processor architecture controller for multi-axis control. Correa et al. The interpreter Please cite this article in press as: Correa JE. Because the interpolation and servo-control algorithms have CNC machining center. thus capturing the physics of the machine puting resources. 1(a)) and a pos- the Texas Launchpad [13] and Arduino development platforms sible hardware (Fig. 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]. et al. Additionally. 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. 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]. This limits the com. Software (a) and hardware (b) architecture of the controller. Controller overview opportunity for easy automation of new manufacturing processes and custom-based CNC solutions. A modular-architecture controller for CNC systems based on open-source electronics. Free from proprietary hardware implemen.doi. this work is the first one controller. the executive program representation of the machine [16. better integration with CAM the interpolation program or motion controller. in servo control of CNC systems. of Pages 7 ARTICLE IN PRESS 2 J. feed rate a new. namely. 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. The four major programs of the architecture: the machine frequency cannot exceed the execution frequency of servo-loop executive. The calls the RS-274 interpreter service to parse the instructions into “virtual machine” has a replica of the interpolation.

of the control algorithms of the architecture (interpolation and ing the non-real-time services of the architecture i. the block “N10 G01 × 10 utive program which. send them to the interpolator and F300” corresponds to the production rule: block : {. For • Joint: A joint describes the relative motion between two links by example. ent architectures) or linked as an object in the compilation of the nication bus to transmit the messages from the executive program executive program. machinery. In the latter.org/10. The main entities of this hierarchy commands for moving the tools and auxiliary functions in CNC [19]. 2(a) shows the finite state machine of the interpretation pro- gram. lar manner. The virtual machine is an object-oriented model of the con- 3. A link has a list of coordi- convert G-code input strings in the file source to tokens [20] (char. 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. execute Numerical ing a convenient tool for real-time monitoring of automated CNC Control (NC) programs.1016/j. Finally. the atomic actions are sent to the exec. The virtual machine in this architecture has exact replicas graphic user interphase GUI. in charge of: (a) execut. of this. Because G-code (RS-274). while (b) coordinating the execution of real time numerical control program completely in computer software. the virtual machine receives the desired state vector according to the value “number”.G Model JMSY-563. the machine to that state. There is a secondary bus of com. machine is an object oriented.2).} | T_N number { update_verctor(seq. When active. This section delineates the ideas behind the implementation of a virtual machine to the open-architecture. of Pages 7 ARTICLE IN PRESS J. are: Fig. handled by out coordinating with programs of the architecture) and standard hardware interrupts in the servo-controllers. hierarchical. seq_word : {..04. http://dx. Correa et al. cate the servo-loop configuration parameters. with services such as the interpolation. the block “N05” returns the character token “T N” and the means of a joint transformation (either a rotation or a translation Please cite this article in press as: Correa JE. Interpreter trolled mechanical system with a 3D representation that includes the full definition of its links and joints.e. can be compiled as a standalone (for the integration with differ- The hardware architecture uses a serial-port. and handle troubleshooting services. planning environment and. in general. Each axis. Virtual machine servo-control units via Inter-Integrated Circuit protocol of commu- nication (I2C). 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. corresponding action.1. as a test bed for different This production results in updating the member “sequence” of the control algorithms. only the sentation of the machine tailored for remote monitoring. nate frames (shape transforms) defining the pose of its joints. 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. input modes (user input blocks).E. Embedded inside the GUI. For example. $2). processing servo control).jmsy. coded in C++. and (b) communi. 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. Lex is used to with a coordinate frame attached to it. This software component is the the drives. 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”. compiled mode (all the blocs are parsed with- the interpolator to drive the position of the axes. the PLC routines and the man. virtual of atomic actions. et al. No. The interpreter machine. 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.doi.} . the supervisory control can execute a user command or a tion parameters. 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. “tool change”) required to state vector of the machine and the set of atomic actions to bring arrive to said state. send manual commands. 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. Traditionally.} | block seq_word prep_word dim_word feed word { process_block (). shares its communication structures and protocols of manual instructions and overrides. servo variables and automatic motion routines from the interpolator and PLC to the 3.013 . Both word. Computer 3. In this a simi- atomic actions from the executive program and simulates the cor. based on the parsed state vector of the machine. “arc feed”. parsing and interpretation of and mimics the hardware characteristics of the machine. and modular repre. the interpreter operates in inter- to the interpolator and the PLC. after the execution of the block. acters or numbers) for the subsequent use of the Yacc parser. In this production. preted mode (each block is feed individually upon completion of munication in charge of: (a) transmitting the train of pulses from the previous one). type of motion. primary commu. in turn. 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. and setting of motion and servo-loop configura. a dimension word and a feed word. } . a preparatory the execution of the automatic motion routines respectively. For the sake of brevity. In the example. A modular-architecture controller for CNC systems based on open-source electronics. / Journal of Manufacturing Systems xxx (2017) xxx–xxx 3 uses this information to generate the desired-state vector of the number “05”.2.2017. accurate simulation of the trajectories down to the basic step of agement of the virtual machine. 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. J Manuf Syst (2017). 3. process non-terminal production “seq word” is shown in the example.

The associated services are the joint model.jmsy. 3(b) shows a rendered image with the simulation results of a 2D-machined trajectory. The openGL. of Pages 7 ARTICLE IN PRESS 4 J. readable text file (see appendix). to “virtually machine” the workpiece. 3(a) shows a three-axis virtual machine. e. the interpolation. To demonstrate the potential of tightly-bound vir- this area include the implementation of efficient algorithms to sim- tual machines and controls. and the servo-control. The standard machine data file • Mechanism: A collection of links and joints working together to (. constructor. speed. PLC and rendering services. 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. The material is removed by driving the 4. Fig. 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. along the Z-direction). For a combination of linear and circular segments. as in traditional CAM software.g. This is used by the render service to populate the scene services. 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.2017. 4). The interpolator coordinates the motion of the axes to drive the resentation of the tool from that of the workpiece. / Journal of Manufacturing Systems xxx (2017) xxx–xxx Fig. for higher graphics performance. 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 360.5 GHz.04. explained in detailed in reference [4]. Fig. Virtual machin. graph of machine to find the sequence of shape-joint transforms of • Machine: A mechanism with its associated control and operation each link. the machine. 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. The output of the instance. The simulated machine tool along the required trajectories.org/10. The total number of pulses add to the position of the A second three-axis. A simplified finite state machine (FSM) diagram of the architecture. planning environment.E. A modular-architecture controller for CNC systems based on open-source electronics. 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. embedded inside the machine-object Analyzer (DDA) technique. using the Fusion 360 joint definitions. ing service after a number of iteration. 2. the program spans the for the kinematic and rendering services. 4 shows the openGL rendered machine with it link and joint transforms. algorithm (See Sec. J Manuf Syst (2017). 2(b) shows the surface is shown in the detailed view of Fig. Following steps in Fusion 360. virtual machine was coded in C++ and axis. Fig. Please cite this article in press as: Correa JE.1016/j. to parse the mechanism information from a human- joint limits. the feed. http://dx. Fig.smd) was created to load the machine geometry and assembly produce functional motion. in a virtual machine. 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.. Correa et al. while intersecting and subtracting the solid rep.doi.013 . each equivalent to one basic length-unit (BLU) of and inertial loads within the safety range of the machine. This implementation interpolator in this paper is based on a software Digital Differential required a loader method. After loading the geometries. 3(b). 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. The virtual machine representations of the machine. with machine assembly at its configuration given by the joint trans- forms. and the frequency of the pulses represents their velocity. finite state machine of the interpolator program. No.G Model JMSY-563. et al. Interpolator machine along the interpolated trajectories. creates a tight binding between the real and the virtual lation algorithms before rendering the scene.

this increments a counter whenever the interpolator requests a pulse allowed servo-frequencies of 10 kHz and 30 kHz respectively. 5. of Pages 7 ARTICLE IN PRESS J. No.013 . http://dx. are generated in Inkscape [21]. the ISR cal. 5(b)).jmsy. The output volt- Please cite this article in press as: Correa JE. this corresponds to maximum interpolating frequencies of 13 kHz and 230 kHz respectively. 3. Fig. Fig. 5. 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. 5(a)) and to generate the G-code approximation (Fig. ments Launchpad C2000. the execution frequency of servo loop interrupt. A vector trajectory (a) and its G code approximation (b) tain an open flow of information during interpolation. An interpolation example of a 2D trajectory using linear and circular refer- 8 kHz. in the TI Launchpad C2000. Con- while a timer interrupt controls the execution of the servo-control ventionally. the instantaneous error count (proportional controller in positon).1016/j. 5(c) shows the NC trajectory sampled in real time by a serial communication interrupt while interpolating at a frequency of Fig. et al. the maximum interpolated frequency should be below loops. was programmed on the boards Arduino Mega 2560 and Texas Instruments Launchpad C2000. In a single iteration of the servo-loop interrupt. for linear and circu- lar motions. Here. A zoom view of interpolated path is shown in (d).2017. The implementation of this algorithm to the control architecture of this paper is discussed in our previous work [15].04. The software DDA interpolation routine. A virtual machine implementation in Autodesk fusion 360. Fig. A virtual machine implementation in openGL. This test demonstrates the ability of the architecture to main.G Model JMSY-563.doi.org/10. 5 shows the interpolation of a 2D trajec- tory on the Arduino Mega 2560. Correa et al. Fig. / Journal of Manufacturing Systems xxx (2017) xxx–xxx 5 Fig. 4. 2(c) shows the finite state machine The servo-loop ISR exhibited a maximum execution time of 76 ␮s of the interpolator program. A modular-architecture controller for CNC systems based on open-source electronics. ence pulse interpolation. J Manuf Syst (2017). a set-point external interrupt in the Arduino Nano and 2 ␮s. The trajectory is interpolated with reference pulses of 8 kHz and sampled in real time through a serial communication interrupt (c). 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.E. The graphics software Inkscape [21] was used to trace the vector trajectory from a bit-map image (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. formance table top CNC systems.pulses are interpolated at a frequency of 3.jmsy. arbitrary 2D piecewise trajectory. comprised of 40 arc segments with regions of low and high curvature. tronics and detail information to experiment with these platforms. we caution against its use on larger machinery. The quadrature over.013 . More- LS7366R 32-bit quadrature counter from US Digital. http://dx. and in the Texas Launch- Please cite this article in press as: Correa JE. The rotary encoders on the stages manufacturing units. A modular-architecture controller for CNC systems based on open-source electronics. Servo-controller breakout board design. Fig. These values correspond to a BLU of 1 ␮m. et al. 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.1016/j. 7. Fig. processing units and axis of motion without modification of the tecture to a two-axis CNC machine tool. of Pages 7 ARTICLE IN PRESS 6 J. tations of the microcontroller. Printed Circuit Board (PCB) design (a) and circuit board assembly (b). 7 shows an experimental implementation of the open archi. In the photograph. the stages are driven along an level of performance and high flexibly. This value error can be reduced by implementing higher order control law such as a proportional-integral (PI) or a feed forward controller. 6.G Model JMSY-563.doi. The reference. No. and the NC schemes for special purpose applications and research. This is a synchroniza- tion error due to the speed of the communication interrupt rather than an accuracy error of the servo-controllers. an interpolation or servo-control algorithms. The purpose of this was to test continuity and smoothness of the motions. This paper provided readers with a general purpose. 3-axis CNC systems as example of the proposed controller.04.org/10. 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.2017. This kind of software and Arduino Mega 2560 interpolator is connected to the X and Y servo. With a strong Do It Yourself (DIY) movement. example of how to construct CNC systems with open electronics. 7. Preliminary experimental results The architecture in this paper is simple. The position and resolution of each platform is automation. modular and open.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.E. In this example. Conclusions and future work The price. In the absence of machining forces the combined position- ing error of the system is 6 steps (equal to +−6 um). hardware modularity is important for the reconfiguration of new controller (SC) breakout boards. The experiment shows that the following error in the system is around 12 steps corresponding to 12 ␮m. This component-based approach offers the possibility of adding micro- Fig. The frequency mismatch between servo and interpolation updates resulted in a trajectory data acquisition delay of 200 steps. 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. J Manuf Syst (2017). Correa et al. 6. A plug-on servo-controller breakout board (See Fig. 8(a) and rithms on different electromechanical systems. 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. / Journal of Manufacturing Systems xxx (2017) xxx–xxx Fig. 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. However. this paper is an counter (interfaced via SPI communications) offloads the compu. 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. Nano with the PWM driver MC33936 from NXP USA Inc. produced by the control in different interpolation scenarios.

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