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ABSTRACT
A conventional Industrial Machine Tool needs to be modernized and its various functions are required to be automated to achieve reduced cycle time, higher productivity, higher levels of accuracy and more reliability. The age of automation has brought a new meaning to the electronics. In the industries, it means the completely automatic operation of the machine tool without human brain intervention, implying automatic inspection and electronics integration and control of the various machining operations. Modernisation and Automation of an industrial machine tool generally comprise modification into a Computer Numerical Control (CNC) machine wherein the conventional relay control is replaced with state-of-art Programmable Logic Controller (PLC). Or it could be upgradation/replacement of the obsolete CNC controller and PLC logic. The PLCs combined with CNC technology are being utilized for a wide variety of automation applications in Automobile industries, in Engineering and Manufacturing industries etc. The present project focuses installation and implementation of the state-of-theart FAGOR 8030MGI CNC & PLC System in BATLIBOI make Vertical Milling Machine ( Model BFV 15) in 01 Block (TC&GT) of BHEL, RC Puram unit, Hyderabad. The project deals with the changes made to the machine, in order to incorporate improvements. The existing machine with General Electric make MARK ONE PLUS CNC is retrofitted with FAGOR make 8030MGI CNC. A PLC Logic is developed and debugged for various control activities of this machine. The PLC programs have been developed using FAGOR PLC. The FAGOR 8030MGI is a powerful CNC which meets the most demanding Machine Tool applications like Lathes and Turning Centres, Milling Machines, Machining Centres and general-purpose applications. The FAGOR offers high-end features with the maximum programming versatility. Apart from being a closed loop CNC, it has a great program and data storage capacity, great communication capability and incredible level of customization. An insight into various features of the CNC and PLC system has been dealt in the context of machine tool applications and various machine operations and the testing and commissioning of control system has been dealt with. Initiating with the basic structure of CNC and PLC, a deep study has been made about the functioning of it and its role in
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interaction between the CNC system and the machine tool. Efforts have been made to deal effectively with the programming of the FAGOR PLC. ***********

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