PROJECT ON

CNC MACHINE

Presented by
Amit Kumar Gupta
 INDEX

 DEVELOPMENT OF CNC MACHINES

 CNC SYSTEM

 PROGRAMMABLE LOGIC CONTROLER

 SERVO DRIVES

 CNC RETROFITTING

 MAINTENANCE MANAGEMENT
DEVELOPMENT OF CNC MACHINES

 EVOLUTION OF THE CNC MACHINES

 CNC MACHINES DEVELOPMENTS

 BENEFITS OF CNC MACHINES

 MAJOR FACTORS FOR ENHANCING THE UTILISATION

 CELLULAR MANUFACTURING SYSTEM

 FLEXIBLE MANUFACTURING SYSTEM

 EVOLUTION OF THE CNC MACHINES

 The first CNC Machine was built in 1949 at MIT ,USA for
manufacturing of the Air Craft components having intricate
profiles using electron tubes & core memory.

 The technology advancement from the Tube technology to the

open architecture system has enabled to revolutionize the
manufacturing processes.
 CNC MACHINES DEVELOPMENTS

 VERTICAL MACHINING CENTRE (VMC)

 TURRET MACHINING CENTRE (TMC)

 HORIZONTAL MACHINING CENTRE (HMC)

 UNIVERSAL MACHINING CENTRE (UMC)

 CNC TURRET PUNCH PRESS

 CNC BENDING MACHINE

 CNC UNIVERSAL GRINDING MACHINE

 CNC GEAR CUTTING MACHINE

 BENEFITS OF CNC MACHINES

 INCREASED FLEXIBILITY.

 IMPROVED QUALITY.

 REDUCED LEAD-TIME.

 HIGHER PRODUCTIVITY.

 ECONOMICAL BATCH PRODUCTION.

 REDUCED CYCLE-TIME.

 REDUCED SCRAP GENERATION.

 MAJOR FACTORS FOR ENHANCING
THE UTILISATION

* REDUCTION IN IDLE-TIME.

* INCREASE IN (CUTTING) MATERIAL REMOVAL TIME.

* EFFECTIVE PROGRAMMING, OPERATION AND

MAINTENANCE.
CELLULAR MANUFACTURING SYSTEM
(GROUPING OF MACHINES)

REDUCED MATERIAL HANDLING.

SET-UP TIME.

W I P INVENTORY.
FLEXIBLE MANUFACTURING SYSTEM
(F.M.S.)

 LEAD-TIME REDUCTION.

 INCREASED MACHINE UTILISATION.

 RECUCED W I P.

 REDUCED PRODUCTION COST.

 100% INSPECTION.

 QUICKER RESPONSE TO BUSINESS ENVIRONMENT.

 REDUCED OVERHEAD COST.

 MAIN CONSTITUENTS OF FMS

FM S

C N C M A C H IN E S M A T E R IA L H A N D L IN G S Y S T E M A U X IL IA R Y E Q U IP M E N T CENTRAL COM PUTER

M A C H IN IN G C E N T R E S R A IL G U ID E D V E H IC L E PALLET STORE S C H E D U L IN G S O F T W A R E
T U R N IN G C E N T R E S A U T O M A T IC G U ID E D V E H IC L E L O A D /U N L O A D S T A T IO N S IM U L A T IO N S O F T W A R E
G R IN D IN G C E N T R E S ROBOT T O O L S T O R E /P R E S E T E R DNC SOFTW ARE
G E A R C U T T IN G M /C E T C . M E A S U R IN G E Q U IP M E N T
FLEXIBLE MANUFACTURING SYSTEM
(FMS)
ASRS

FMC 1 FMC 2

INPUTS

FMC 3

OUTPUTS
AGV

FMC 5 FMC 4
 TOOL MONITORING ON CNC
MACHINES
 TOOL LIFE MANAGEMENT

 MINITORING BY MEASUREMENT OF ELECTRIC CURRENT

 MONITORING BY FORCE MEASUREMENTS

 MONITORING VIA GEOMETRIC MEASUREMENTS.

 CNC SYSTEM

 INTRODUCTION
 CNC SYSTEM
 CLOSE LOOP SYSTEM
 OPEN LOOP SYSTEM
 CNC CONTROLLER
 CNC SYSTEM BLOCK DIAGRAM
 MODES OF CNC M/C OPERATION
 CNC MACHINES COORDINATES
 ZERO OFFSET
 CNC CONTROLLER OPEARTING AREAS
 BENEFITS OF CNC MACHINES
 INTRODUCTION

 CNC controllers are the heart of a machine or process. They provide control information used to produce
parts. CNC controllers range in capability from simple point-to-point linear control to highly complex
lagorithms that involve multiple axes control.  CNC controllers can be used to control various types of
machine shop equipment.  These include horizontal mills, vertical mills, lathes and turning centers,
grinders, electro discharge machines (EDM), welding machines, Flame Cutting machines ,Press
machines and inspection machines.  The number of axes controlled by CNC controllers can range
anywhere from one to five, with some CNC controllers configured to control greater than six axes. 
Mounting types for CNC controllers include board, stand alone, desktop, pendant, pedestal, and rack
mount.  Some units may have integral displays, touch screen displays, and keypads for control and
programming.  

 Industrial communications options for CNC controllers include ARCNet, CANBus, ControlNET, Data
Highway Plus, DeviceNet, Ethernet 10/100 Base-T, parallel, PROFIBUS, SERCOS, Universal Serial Bus
(USB), serial (RS232, RS422, RS485), and web-enabled.  Communications language choices include
bitmap, conversational, DXF file, G/M codes, Hewlett Packard graphics language, and ladder logic.  A bit
map (often spelled "bitmap") defines a display space and the color for each pixel or "bit" in the display
space.  Conversational language is a higher level, easy to learn programming tool. It performs the same
functions as the standard G-code commands.  Drawing eXchange Format (DXF) file that was created as
a standard to freely exchange 2 and 3 dimensional drawings between different CAD programs.  It
basically represents a shape as a wire frame mesh of x, y, z coordinates.  G-code is the programming
language for the Computer Numerically Controlled (CNC) machine tools that can be downloaded to the
controller to operate the machine.  M-code is the standard machine tool codes that are normally used to
switch on the spindle, coolant or auxiliary devices.
 CNC SYSTEM

CNC stands for Computer Numerical Control and has been around since the early 1970's. Prior to this, it
was called NC, for Numerical Control .CNC controller are able to execute binary coded commands. The
control code for a machine contains positioning as well as switching information. Positioning information is
intended to position the workpiece or else the tool .Switching information controls the machines servo
components. The coded instructions are entered manually at the control as well as DNC (Distributed
Network Controller).
Measuring system record when the position of the workpiece or tool indicated on the part program has
been reached. Function such as lubrication , coolant on/ off and workpiece clamping are activated using
PLC (Programmable Logic Controller ) through relays & contactor at electrical panel.

CNC controllers have several choices for operation.  These include polar coordinate command, cutter
compensation, linear and circular interpolation, stored pitch error, helical interpolation, canned cycles,
rigid tapping, and auto-scaling.  Polar coordinate command is a numerical control system in which all the
coordinates are referred to a certain pole. The position is defined by the polar radius and polar angle. 
Cutter compensation is the distance you want the CNC control to offset for the tool radius away from the
programmed path.  Linear and circular interpolation is the programmed path of the machine, which
appears to be straight or curved, but is actually a series of very small steps along that path.  Machine
precision can be remarkably improved through such features as stored pitch error compensation, which
corrects for lead screw pitch error and other mechanical positioning errors.  Helical interpolation is a
technique used to make large diameter holes in workpieces. It allows for high metal removal rates with a
minimum of tool wear.  There are machine routines like drilling, deep drilling, reaming, tapping, boring,
etc. that involve a series of machine operations but are specified by a single G-code with appropriate
parameters.  Rigid tapping is a CNC tapping feature where the tap is fed into the work piece at the
precise rate needed for a perfect tapped hole. It also needs to retract at the same precise rate otherwise it
will shave the hole and create an out of spec tapped hole.  Auto scaling translates the parameters of
the CNC program to fit the work piece.
 CNC MACHINE TOOL (CLOSE LOOP SYSTEM)
CNC TACHO / POSITION S
BALL ENCODER
SENSOR P
SCREW I
N
SERVO SERVO D
L
DRIVE
PLC NC MOTOR E

JOB
VELOCITY
FEEDBACK

TABLE

POSITIONAL FEEDBACK

D N C LINK
TAPE READER
OTHER DEVICES

MACHINE ELEMENTS
I/P DISPLAY UNIT
INPUT/OUTPUT
O /P KEYBOARD
FLOPPY DISC / CD
 CNC MACHINE TOOL (OPEN LOOP SYSTEM)
CNC TACHO / POSITION S
SENSOR BALL P
SCREW I
N
SERVO SERVO D
L
DRIVE
PLC NC MOTOR E

JOB
VELOCITY
FEEDBACK

TABLE

D N C LINK
TAPE READER
OTHER DEVICES

MACHINE ELEMENTS
I/P DISPLAY UNIT
INPUT/OUTPUT
O /P KEYBOARD
FLOPPY DISC / CD
 CNC CONTROLLER

Electrically, a CNC Machine consists of a multi-axis servo drive, spindle (cutting) drive, one or more
controllers, power supplies, and safety circuits. On larger systems, a programmable logic controller (PLC)
may be used to handle auxiliary functions such as water cooling and lubrication functions ATC (Automatic
Tool Changer) system, APC (Automatic Pallet Changer) system.

CNC Controller consist of various electronic cards such as Memory Board, NC-PLC communication
Board, Input-Output Board, Video Board, PLC-CPU board, MCP(Machine control Panel), OCP (Operator
Control Panel), Display unit etc.

In CNC System Part program is feed through manual or through program transfer device like digitek
instrument & DNC (Distributed Network Controller) system. This part program stored in RAM memory of
CNC controller. When machine is work in automatic mode the part program is called. Part program
commands are executed by NC controller and give signal to Servo-drives, PLC etc.

In above CNC system block diagram commands are generated by CNC controller fed to Servo drive for
axis movement. Servo drive generate the electrical power to move the servo motor for axes movements.
In Servo loop the Tacho-generator which is coupled with servo motor give the velocity feedback signal to
Servo drive .This system is known as velocity feedback system. For positioning of axis the encoder or
Linear Scale-Transducer give positional feedback system to CNC controller. Apart from the positional
command spindle CW/CCW, coolant ON/OFF, Tool change, Feed , G codes are executed by CNC
controller & give signal to PLCs.
 TYPE OF CNC CONTROLLER

 Siemens Sinumerik controller 8T, 810GA3,

840C, 840D, 802D, 810D

 HMT Hinumerik Controller, 3100M,2000V2

 Heidenhain TNC135, TNC415

 Fanuc Controller Fanuc 6M, 16M,18M, Fanuc0, Fanuc0I

 CNC SYSTEM BLOCK DIAGRAM

MEMORY

SYSTEM
PROGRAM
SOFTWARE
PLC

MAIN MACHINE
INTERFACE DRIVE
PROCESSOR

INPUTS OUTPUTS MACHINE

~MDI ~ DISPLAY UNIT
~ PAPER TAPE ~ REMOTE LINK
~ MAGNETIC TAPE ~ D N C LINK
~ REMOTE LINK ~ FLOPPY DISC / CD
~ D N C LINK
~ FLOPPY DISC / CD
 MODES OF CNC M/C OPERATION

CNC machine operates in different mode like JOG,MDI, AUTO, Increment mode 1, 10, 100, 1000, 10000
micron, REF, Data input / output mode, Repositioning mode .These all mode are to be selected from
Machine Control Panel

JOG Mode: In this mode machine is operated in manually. In JOG mode machine moves in
respective direction of axis when key is pressed. This mode is normally use for machine setting. when
switch is not pressed machine can not move. Axis feed can be change by feed override switch.
REF Mode: In this mode machine is referenced before operating the CNC machine in Automatic
mode (programming mode), machine needed to be referenced. Reference means machine zero position.
It is very necessary to reference M/c because during power off CNC system loose its positional value.
AUTO Mode: In automatic mode, individual NC traversing programs are processed. The axes cannot be
traversed by means of the direction keys. In this mode machine works in part programs .Part program is
program of particular job. part program contains various codes like that the numeric value of axis position
,tool command, spindle rotation , spindle speed, coolant on/off, G-codes, M-codes, T-codes etc.

INCR 1,10,100,1000,10000 Mode: In this mode machine move in 1, 10, 100 , 1000, 10000 microns when
switch is pressed with respect to direction of axis. This mode is normally is used for fine setting of jobs.

MDI Mode: This mode in known as manual data input mode .In MDI mode machine execute the program
block.MDI mode normally is for small program.like Tool change Pallet change ,Spindle ON /OFF etc.
 CNC MACHINES COORDINATES

 Coordinate systems: Right–handed, rectangular coordinate systems are used for machine tools.
Such systems describe the movements on the machine as a relative motion between tool and work
piece.
 Machine Coordinate System( MCS) :The orientation of the coordinate system on the machine tool
depends on the particular machine type. It can be turned to various positions. The origin of the
coordinate system is the machine zero. All axes are in zero position at this point. This point is
merely a reference point determined by the machine manufacturer. It need not to be approachable.
 CNC MACHINES COORDINATES

 WORKPEICE COORDINATE SYSTEM (WCS): The workpiece coordinate system described is also used
to describe the geometry of a workpiece in the workpiece program. The workpiece zero can be freely
selected by the programmer. The programmer need not know the real movement conditions on the
machine, i.e. whether the workpiece or the tool moves; this can be different in the individual axes. The
definition of the directions is based on the assumption that the workpiece does not move and the tool
moves.
 ZERO OFFSET

 ZERO OFFSET: The actual values are referred to the machine zero after a reference point approach. The
machining program of the workpiece refers to the workpiece zero. Machine zero and workpiece zero need
not be identical. Depending on the type of workpiece and the way it is clamped, the distance between the
machine zero and workpiece zero can vary. In part program processing this is compensated for by the
zero offset.

P - Tool setting point

W- Workpiece zero
F - Slide reference point
XMR, ZMR Reference point
coordinates
XMW, ZMW Zero offset
M- Machine zero
R - Machine reference point
WR- Workpiece reference point
 TYPE OF ZERO OFFSET

 SETTABLE ZERO OFFSET: Settable zero offset in the program e called with G54 to G57
and other G functions Basic zero offset (Basic frame): displayed like a settable ZO.

 PROGRAMMABLE ZERO OFFSET: programmable zero offset program an additional

zero offset for geometry and special axes in the part program called. The values of the
programmed zero offsets are deleted with end of program or reset..

 EXTERNAL ZERO OFFSET : In addition to all the offsets which define the position of the
workpiece zero, an external zero offset can be overlaid by means of the handwheel (DRF
offset) or from the PLC.

 DRF OFFSET: Differential Resolver Function: NC function that works in conjunction with
an electronic handwheel to generate an incremental zero offset in Automatic mode.

 FRAME: Frame is the conventional term for a geometrical expression that describes an
arithmetic rule, such as translation or rotation. Frames are used to describe the position of
a destination coordinate system by specifying coordinates or angles starting from the
current workpiece coordinate system. Possible frames
Basic frame (basic offset)
Settable frames (G54...G599)
Programmable frames
 CNC CONTROLLER OPEARTING AREAS

 CNC system have different type of operating areas for various functions. These windows are

Machine
Parameter,
Program
Services
Diagnosis
Startup,
Cycles
 CNC CONTROLLER OPERATING AREA
(MACHINE)

 Machine: This operating area is used for Execution of part programs, Manual control operation
of machines. In this operating area we can see the different area of mode Operating areas, Channel
status, Program status, Channel name, Alarm and message line, Operating mode, Program name of
selected program, Channel operational messages, Channel status display, Additional explanatory text
(Help) can be called, Working windows, NC displays The working windows (program editor) and NC
displays (feedrate,tool) available in the selected operating area are displayed here, Dialog line with
Operator prompts , Recall function, ETC. function, Horizontal softkeys, Vertical softkeys,. When press
the "Area switchover" key, operating areas are displayed on the horizontal softkey bar and operating
modes are displayed on the vertical softkey bar. By this key to go to the area menu bar from any location
in the menu hierarchy if you wish to select another operating mode or a different operating area.
 CNC CONTROLLER OPERATING AREA
(PARAMETER)
 CNC system have many type of parameters which control the different function of machine.
Too Data, Tool Compensation, tool Management, Setting parameters, Zero Offsets,R-parameter
Machine parameter,Working Area Limitation
Setting Parameter: Setting parameter contains various setting data, Jog data, Spindle data, Dry run
feed rate, Starting angle thread cutting,Zero Offsets, Setting bits, etc. Setting data are related with jog
feed, dry run feed, Spindle max & min. speed, axes negative & positive limitation etc.
R-Parameter: This is programming parameter. R-parameter mainly used for arithmetic function in in part
program .
Machine Parameter: Machine parameter is heart of CNC system. Without this parameter machine never
work. M/c parameter contains various data like machine configuration data, Servo drive configuration
data, Individual Axis data, Display data, Channel data,
Configuration data decide the no. of axes in CNC machine, which type of drive used in machine, rating of
servo drives. Drive configuration data indicate the power of servo motor & drives, Its current capacity ,
torque, acceleration, Gain etc. Axis parameter contains the each individual axis parameter like axis
traverse limit in both direction, type of measuring system, encoder pulse,
 CNC CONTROLLER OPERATING AREA
(PROGRAM)
 Program: In program operating area the following are contain.
Program Type: Workpiece, Part Program,Subroutine, Cycles
Storing programs
Program Basic display
Editing programs
User-defined contour programming
Program simulation
Program management
Memory info
Part Program: A part program consists of a sequence of instructions to the NC control. In its entirety, this sequence
effects the production of a specific workpiece or a particular machining process on a given blank.
Subroutine: A subprogram is a sequence of instructions in a part program which can be called repeatedly with different
defining parameters. Cycles area type of subprogram.
Workpiece: A workpiece is a part to be produced/machined by the machine tool or a directory in which programs and
other data are stored.
Cycles: Cycles are subprograms for the execution of a recurring machining process on the workpiece.
 CNC CONTROLLER OPERATING AREA
(SERVICES)

 Services The Operating Area "Services" provides the following functions:

Function: Read data in/out, Manage data, Series start-up
Directory structure: All files are organized in a directory structure.

NC active data :The NC memory contains data (e.g. R parameters, tool offsets, machine data …) that
are not stored in the form of files. However, to allow the operator to access these data and store them as
files on the hard disk, the file tree contains a directory named "NC-active data". This directory contains an
overview of data that can be copied from the NC memory.
The following directories contain special files:
1. Clipboard: Files and directories of any type may be created/stored in the clipboard. The clipboard is a
directory on the hard disk, where files, which cannot be included in the copy target directory, are stored.
This may be the case, for example, if their file type is unknown, or is not permitted in the copy target
directory.
2. Archive: For save several files, store them in an archive file (.ARC). Archive files are generated in a
special format: a. Punched tape format b. PC format The source path of files stored in an archive file is
also saved in the archive. allowing the packed file to be transferred back to the same directory from which
it was copied when the archive file is unpacked again. Series start-up archives are also stored in this
directory.
Data are to be import & Export by V24 interface .V24 interface parameter are to be set for data transmit
devices such like parity, baud rate, stop bit, X ON/OFF, Device type etc.
 CNC CONTROLLER OPERATING AREA
(DIAGNOSIS)

 Diagnosis basic display: A display headed “Alarms, message, alarm log, PLC status” appears when
selected operating area Diagnosis
Explanation of display: Number The alarm number is output under "Number". The alarms are output in
chronological order. Date The date and time at which the alarm occurred is displayed with the date, in
hours, min, sec, 1/100 sec (MMC 100.2 only). Clear criterion The symbol denoting the alarm abort key is
displayed for every alarm. Text The alarm text is displayed under "Text".
• Information on the current status of the PLC memory locations.
 BENEFITS OF CNC SYSTEM

 INCREASED FLEXIBILITY.

 IMPROVED QUALITY.

 REDUCED LEAD-TIME.

 HIGHER PRODUCTIVITY.

 ECONOMICAL BATCH PRODUCTION.

 REDUCED CYCLE-TIME.

 REDUCED SCRAP GENERATION.

PROGRAMMABLE LOGIC CONTROLLER

 WHAT IS PLC ?

 BASIC ELEMET OF PLC CONTROLLER

 PLC PROGRAMMING

 PLC LANGUAGES

 PLC HARDWARE

 BENEFITS OF PLC
 WHAT IS PLC ?

 A programmable logic controller, PLC, or programmable controller is a small computer used

for automation of real-world processes, such as control of machinery on factory assembly lines
CNC machines . The PLC usually uses a microprocessor. The program is usually created by an
engineers at an industrial site, rather than a professional computer programmer. The program is
stored in battery-backed memory.
 PLC is actually an industrial microcontroller system (in more recent times we meet processors
instead of microcontrollers) where you have hardware and software specifically adapted to
industrial environment. Block schema with typical components which PLC consists of is found in the
following picture. Special attention needs to be given to input and output, because in these blocks
you find protection needed in isolating a CPU blocks from damaging influences that industrial
environment can bring to a CPU via input lines. Program unit is usually a computer used for writing
a program (often in ladder diagram).
 The main difference from other computers are the special input/output arrangements. These
connect the PLC to a process's sensors and actuators. PLCs read limit switches, dual-level
devices, temperature indicators and the positions of complex positioning systems. Some even use
machine vision. On the actuator side, PLCs drive any kind of electric motor, pneumatic or hydraulic
cylinders or diaphragms, magnetic relays or solenoids. The input/output arrangements may be built
into a simple PLC, or the PLC may have external I/O modules attached to a proprietary computer
network that plugs into the PLC.
 PLCs were invented as less-expensive replacements for older automated systems that would use
hundreds or thousands of relays and cam timers. Often, a single PLC can be programmed to
replace thousands of relays. Programmable controllers were initially adopted by the automotive
manufacturing industry, where software revision replaced the re-wiring of hard-wired control panels.
BASIS ELEMENT OF PLC
CONTROLLER
 PLC PROGRAMMING

 PLCs programs are generally written in a special application on a personal computer then
downloaded over a custom cable to the PLC. The program is typically stored in the PLC either in
battery-backed-up RAM or some other non-volatile memory (flash).

 PLC's were programmed in "ladder logic", which strongly resembles a schematic of relay logic.
Modern PLCs can be programmed in a variety of ways, from ladder logic to more traditional
programming languages such as BASIC and C. Another method is State Logic, a Very High Level
Programming Language designed to program PLCs based on State Transition Diagrams.

 Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3 currently
defines 5 programming languages for programmable control systems: FBD (Function Block
Diagram), LD (Ladder Diagram), ST (Structured Text, Pascal type language), IL (Instruction List)
and SFC (Sequential Function Chart). These techniques emphasize logical organization of
operations.

 Ladder logic is widely used to program industrial Programmable logic controllers, where sequential
control of a process or manufacturing operation is required. Ladder logic is useful for simple but
critical control systems, or for reworking old hardwired relay circuits. As programmable logic
controllers became more sophisticated it has also been used in very complex automation systems
 PLC LANGUAGES

 The following is a list of programming languages specified by this standard:

 Ladder diagram (LD)

 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)

 Ladder Logic: Ladder logic is the main programming method used for PLC's. As mentioned
before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic
diagrams was a strategic one. By selecting ladder logic as the main programming method, the
amount of retraining needed for engineers and trades people was greatly reduced.
 Mnemonic Instruction: There are other methods to program PLCs. One of the earliest techniques
involved mnemonic instructions. These instructions can be derived directly from the ladder logic
diagrams and entered into the PLC through a simple programming terminal.
 Sequential Function Charts (SFC) : SFC have been developed to accommodate the
programming of more advanced systems. These are similar to flowcharts, but much more powerful.
This method is much different from flowcharts because it does not have to follow a single path
through the flowchart.
 Structured Text (ST) : Programming has been developed as a more modern programming
language. It is quite similar to languages such as BASIC and Pascal.
 Function Block Diagram (FBD): FBD is another graphical programming language. The main
concept is the data flow that start from inputs and passes in block(s) and generate the output
 PLC HARDWARE

 PLC controller consist of CPU (Central processor

unit) ,PLC Input board, PLC Output board and
Power Supply board.
 Power supply is used in bringing electrical
energy to central processing unit. Most PLC
controllers work either at 24 VDC or 220 VAC.
 Main function of CPU is to process the PLC
program .In CPU board the PLC program is stored
in RAM. This program is backup by Battery. CPU
board contain microprocessor .
 The main function of PLC Input board is to give the
input signal to CPU from sensor like limit switch,
proximity switch ,pressure switch, float switch,
Optical sensor etc.
 The main function of PLC output board is to actuate
the actuator like relays, solenoid valves, contactor
etc. CPU generate the output signal according to PLC
program and this signal is outputted at output board.
 The PLC program is written in Ladder logic ,STL and
CFB (control Function Block) language.
 BENEFITS OF PLC

 Flexibility: One single Programmable Logic Controller can easily run many machines.

 Correcting Errors: In old days, with wired relay-type panels, any program alterations required time
for rewiring of panels and devices. With PLC control any change in circuit design or sequence is as
simple as retyping the logic. Correcting errors in PLC is extremely short and cost effective.

 Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this
means that we can generate more and more contacts, coils, timers, sequencers, counters and so
on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would
be like to have so many things in one panel.

 Low Cost: Prices of Programmable Logic Controlers vary from few hundreds to few thousands.
This is nothing compared to the prices of the contact and coils and timers that you would pay to
match the same things. Add to that the installation cost, the shipping cost and so on.

 Testing: A Programmable Logic Control program can be tested and evaluated in a lab. The
program can be tested, validated and corrected saving very valuable time.

 Visual observation: When running a PLC program a visual operation can be seen on the screen.
Hence troubleshooting a circuit is really quick, easy and simple.
 SERVO SYSTEM

 SERVOMECHANISM
 SERVO SYSTEM BLOCK DIAGRAM
 SERVO DRIVE
 THE CONCEPT OF A SERVO SYSTEM
 DRIVE TYPES
 SERVO MOTORS
 SERVO MOTOR BENIFITS
 

SERVO MECHANISM

 Servomechanism, usually shortened to just servo, is a device used to provide

mechanical control at a distance. The most common type of servo is that mentioned,
which gives positional control. Servos are commonly electrical or partially electronic
in nature, using an electric motor as the primary means of creating mechanical force,
though other types that operate on hydraulic or magnetic principles are available.
Usually, servos operate on the principle of negative feedback, where the control input
is compared to the actual position of the mechanical system as measured by some
sort of transducer (Tachogenerator or Encoder) at the output. Any difference
between the actual and wanted values is amplified and used to drive the system in
the direction necessary to reduce or eliminate the error. A whole science of this type
of system has been developed, known as servo system .

 Servos are found in many applications. Servos are used to operate the CNC
machines , throttle of engines that use a cruise control. Fly-by-wire systems in aircraft
use servos to actuate the control surfaces that control the aircraft.
SERVO SYSTEM BLOCK DIAGRAM
 SERVO DRIVE

 Servo can be described as follows. A command signal which is issued from the
user's interface panel comes into the servo's "positioning controller". The
positioning controller is the device which stores information about various jobs
or tasks. It has been programmed to activate the motor/load, i.e. change
speed/position. The signal then passes into the servo control or "amplifier"
section. The servo control takes this low power level signal and increases, or
amplifies, the power up to appropriate levels to actually result in movement of
the servo motor/load.These low power level signals must be amplified: Higher
voltage levels are needed to rotate the servo motor at appropriate higher speeds
and higher current levels are required to provide torque to move heavier
loads.This power is supplied to the servo control (amplifier) from the "power
supply" which simply converts.AC power into the required DC level. It also
supplies any low level voltage required for operation of integrated circuits.As
power is applied onto the servo motor, the load begins to move desired speed
and position changes.As the load moves, so does some other "device" move.
This other "device" is either a tachometer,resolver or encoder (providing a signal
which is "sent back" to the controller). This "feedback" signal is informing the
positioning controller whether the motor is doing the proper job.

 Feedback device are Analog Tachogenerator, Digital Tachogenerator, Absolute

Encoder, Incremental Encoder , Resolvers.
THE CONCEPT OF A SERVO SYSTEM
DRIVE TYPES
 SERVO MOTORS

 Servomotors – A motor with a "feedback" device. Electronic packages control

speed and position accuracy.Servo motors are normally used for linear motion &
rotary motion in machine tools application & automation industries.
 Servomotors are mainly two types as AC or DC motors. Servo motor basically
works in velocity feedback system. In servomotor the feedback device is known
as Tachogenerator or Encoder.
 Early servomotors were generally DC motors because the only type of control
for large currents was through SCRs . As transistors became capable of
controlling larger currents and switching the large currents at higher frequencies,
the AC servomotor became used more often. Early servomotors were
specifically designed for servo amplifiers. Today a class of motors is designed
for applications that may use a servo amplifier or a variable-frequency controller,
which means that a motor may be used in a servo system in one application,
and used in a variable-frequency drive in another application.
 Type of servomotor

 DC Servomotor:
 AC servomotor
 SERVO MOTOR BENIFITS

 High intermittent torque

 High torque to inertia ratio
 High speeds
 Work well for velocity control
 Available in all sizes
 High performance
 Small size
 Wide variety of components
 with specialized controls
 CNC RETROFITTING

 OBJECTIVE OF CNC RETROFITTING

 FEATURE OF CNC RETROFITTING

 ADVANTAGES OF RETROFITTING
 WHAT IS CNC RETROFITTING ?

OBJECTIVES
 COST- EFFECTIVE MODERNISATION.
 LARGE SIZE & COSTLIER AGEING MACHINE TOOLS NEED
NOT BE DISCARDED.
 RETROFITTING IS A STEPPING STONE TO A FULL FLEDGED
CNC TECHNOLOGY.

FACTORS FOR SELECTION

 GEOMETRIC ACCURACY.
 SOUND MECHANICAL CONDITION.
 AVAILABILITY OF SPACE ON THE MACHINE.
 UPGRADATION OF OBSOLETE CNC SYSTEM.
 ADDITION OF FEATURE / FACILITIES

 Complete reconditioning of the machine

 State of the art CNC control system with PLC.
 AC/DC Digital/Analog servo feed drives for individual axes and
Spindle.
 Linear/ Rotary position feedback systems.
 Backlash free re-circulating ball screws & nuts.
 Complete new wiring/ panels cable drag chains.
 Automatic Tool Turrets/Changers.
 Hydraulic Power Packs ,Chucks & Tail-stock.
 Automatic Centralised lubrication system & Coolant
 Chip disposal systems & machine guard & Telescopic covers for
axes.
 ADVANTAGES OF CNC RETROFITTING

 A NEW LEASE OF LIFE TO THE MACHINE TOOLS THROUGH

 COST EFFECTIVE MODERNISTION
 CAPABILITY ENHANCEMENT
 ADDITION OF FACILITIES
 RESTORATION OF ACCURACIES
 QUALITY IMPROVEMENT
 BETTER ACCURACY
 PRODUCTIVITY ENHANCEMENT BY 100-200% By
 CYCLE TIME REDUCTION
 REDUCTION IN REWORK / REJECTION
 REDUCTION IN DOWN TIME
 FLEXIBILITY OF OPERATION & PROGRAMING
CAPABILITY OF ON-LINE PROGRAMMING /MONITORING THROUGH LAN/ DNC
 MAINTENANCE MANAGEMENT

 MAINTENANCE is an important part of the life-cycle of Machine Tools &

Plants, and must be considered from the design stage through the end-of-
life stage of the system. Maintenance covers two aspects of systems -
operation and performance. Maintenance is generally performed in
anticipation of, or in reaction to, a failure. Maintenance is performed to
ensure or restore system performance to specified levels. Improperly
performed or timed maintenance can exacerbate problems because of
faulty parts, maintainer error, or decreased profits. A systematic and
structured approach to system maintenance, starting during the design
process, is necessary to ensure proper and cost-effective maintenance.

 Maintenance operations have been categorized based on their frequency

and their motivating factors. Four of the most common designations are
described Predictive, Preventative, Corrective and Fault-finding.
 TYPE OF MAINTENANCE

 PREDICTIVE MAINTENANCE
Predictive maintenance involves a series of steps prior to actually performing
maintenance. It begins with sampling physical data over time, such as vibration
or particulate matter in oil. Analysis is then performed on the collected data to
create an appropriate maintenance schedule, and maintenance is performed
according to the schedule. This type of maintenance analysis works well for
mechanical systems because the failure modes are well understood.
Additionally there is historical data useful for creating and validating
performance and maintenance models for mechanical systems.

 PREVENTATIVE MAINTENANCE
Preventative maintenance refers to maintenance performed when a system is
functioning properly to prevent a later failure. Generally, it is performed on a
regular basis and the maintenance will be performed regardless of whether
functionality or performance is degraded. The frequency of the maintenance is
generally constant, and is usually based on the expected life of the components
being maintained, but there is not necessarily any monitoring occurring at the
same time (as there would be in predictive maintenance).
 TYPE OF MAINTENANCE

 CORRECTIVE MAINTENANCE
Corrective maintenance refers to maintenance done to correct a problem when
something has failed, or is failing. The need for corrective maintenance can be
beneficial or detrimental depending on the product and the profit model used
during the design phase of the product. On the most obvious level, corrective
maintenance is detrimental to operation because it means that something failed,
and the system is (probably) not available during the time needed to perform the
maintenance. On the other hand, it may be that the economics and planned
functionality of a system are such that using a cheaper, replaceable device for
which failure is anticipated, makes sense.

 FAILURE-FINDING MAINTENANCE
Failure-finding maintenance involves checking a (quiescent) part of a system to
see if it is still working. This is most often performed on portions of a system
dedicated to safety -- protective devices. This is an important type of
maintenance check to perform because failures in safety systems can have
more catastrophic effects, if other parts of the system fail.
 TYPE OF MAINTENANCE

 STRATEGIC PLANNING
Due to ageing of machines the component of machines get detoriated , The
electronic spare of machines get absolute , the Mechanical accuracy of
machines get decreases & due to non standardized spare it is very difficult to
procure all spare of machines.

To resolve the these problem Strategic Planning to be needed.For the improve

the mechanical accuracy machine to reconditioned completely.