Cncdncadaptivecontrol 120412055029 Phpapp02

CNC, DNC &
Adaptive Control
Arvind Deshpande
Problems with Conventional NC

1. Part
programming mistakes
2. Nonoptimal speeds and feeds
3. Punched tape
4. Tape reader
5. Controller
6. Management information
4/10/2012
Arvind Deshpande(VJTI)
Computer Numerical Control

Conventional hard- wired NC controller
unit replaced by computer.
NC system that utilizes stored programs in
a dedicated computer to perform some or
all NC functions
Soft-wired
Flexibility
4/10/2012
CNC
4/10/2012
Functions of CNC
1.
Machine tool control

Hybrid CNC Hard-wired logic circuits for
functions like feed rate generation , circular
interpolation etc. in addition to computer
Mass production of circuits and less expensive
computer
Straight CNC Computer to perform all NC
functions
4/10/2012
Hybrid CNC
4/10/2012
Straight CNC
4/10/2012
Functions of CNC
2.
In-process compensation Dynamic correction of

machine tool motion for changes or errors that occur
during processing
Adjustment of errors sensed by in-process inspection
probes and gauges
Recomputation of axis positions when an inspection
probe is used to locate a datum reference on the work
part
Offset adjustments for tool radius and length
Adaptive control adjustments to sped and feed
Computation of predicted tool life and selection of
alternate tooling when indicated.
4/10/2012
Functions of CNC
3.
Improved programming and operating features

Use of tape and tape reader only once
On-line editing of part programs at the machine
Special canned cycles.
Graphic display of tool path to verify the tape
Various types of interpolation: circular, parabolic, cubic
Support of various units. Conversion from one unit to another
unit.
Use of specially written subroutines or macros
Manual data input (MDI)
Several part programs in bulk can be stored.
4/10/2012
Functions of CNC
4.
Diagnostics Equipped with diagnostic

capability to assist in maintaining and
repairing the system
Identification of reason for downtime
Indication of imminent failure of certain
component
Redundancy of components
4/10/2012
10
Direct Numerical Control
A manufacturing system in which no. of

machines are controlled by a computer
through direct connection and in real time.
4/10/2012
11
DNC with satellite computer
4/10/2012
12
DNC Drip Feeding

Very complex part shapes very large NC program
NC controller memory may not handle HUGE part program
computer feeds few blocks of

NC program to controller
When almost all blocks executed,

controller requests more blocks
4/10/2012
13
Behind the Tape Reader (BTR)
4/10/2012
Computer is linked
directly to regular NC
controller unit
The connection is
made behind the tape
reader
Two temporary
storage buffers
Less cost
14
Special Machine Control Unit
4/10/2012
Regular NC controller is
replaced by special MCU
More accuracy in circular
interpolation and fast
material removal rates
than BTR systems
Most CNC machines are
sold with computer
15
NC, CNC and DNC
4/10/2012
16
Functions of DNC
1.
2.
NC without punched tape

NC part program storage
Programs must be made available for downloading to CNC machine tools
Part program can be uploaded after editing from CNC machine
Entry of new programs. Editing of programs , deletion of programs
Tool management
Tool offsets can be downloaded in to MCU
Postprocessor
Data processing and management functions
Primary storage and secondary storage
Syntax checking and graphic proving of programs on CNC computer
CNC can be operated directly from DNC computer
Flexibility in shop floor scheduling
Part program preparation
Machinability database for calculating speed/feed
4/10/2012
17
Functions of DNC
3.
4.
Data collection, Processing and reporting

Monitor production in the factory
Data processing and report generation by DNC computer
Getting the data about health of the machine in the form of sensor
signals or diagnostic messages which can be used for
preventive/predictive maintenance
Metrological data in the form of dimensional acceptance
Communications
Central computer and machine tools
Central computer and NC part programmer terminals
Central computer and bulk memory, which stores the NC
programs
CAD system
Shop floor control system
Corporate data processing
Remote maintenance diagnostics system
4/10/2012
18
Justification of DNC
Interconnected CNC machines are large in
number
Very large program size. Can not be
accommodated in the part program
memory of MCU
Large variety of part programs and small
batch sizes
Frequent changes in program designs
4/10/2012
19
Advantages of DNC
1.
2.
3.
4.
5.
6.
7.
Elimination of punched tape and tape reader

Greater computational capability and flexibility
Convenient storage of NC part programs in computer
files
Programs stored as CLFILE
Reporting of shop performance
Establishes the framework for evolution of future
computer automated factory (CIM)
2-5 % increase in operational efficiency of CNC
machine tools. Cost of DNC installation can be
recovered quickly.
4/10/2012
20
Combined CNC/DNC systems
Development of hierarchical computer systems in

manufacturing
Flexibility
Ability to gradually build the system
More versatile and economic approach
Distributed Numerical System
Part program downloaded only once
Redundancy
Improved communication between central computer and
shop floor
4/10/2012
21
Adaptive Control
A control system that measures certain output process

variables like spindle deflection, force, torgue, cutting
temperature, vibration amplitude, horse power and uses
them to control speed or feed
NC reduces non productive time in a machining
operation
AC determines proper speeds and feeds during
machining as a function of variation in work piece
hardness, width or depth of cut, air gaps in part
geometry etc.
Increased metal removal rate and reduced cost per
volume of metal removed
4/10/2012
22
Where to use adaptive control?

1.
2.
3.
4.
In-process time consumes significant

portion of the machining cycle time.
(>40%)
Significant sources of variability in the job
Higher cost of operation of machine tool
Work material steel, titanium, high
strengh alloys
4/10/2012
23
Sources of variability in machining

1.
2.
3.
4.
5.
Variable depth/width of cut

Variable workpiece hardness and
variable machinability
Variable workpiece rigidity
Toolwear
Air gaps during cutting
4/10/2012
24
Adaptive Control Optimization

(ACO)
Index of performance is a measure of overall

process performance such as production rate or
cost per volume of metal removed.
Objective is to optimize the index of performance
by manipulating speed or feed in the operation
IP = MRR/TWR
MRR Material removal rate
TWR Tool wear rate
Sensors for measuring IP not available
4/10/2012
25
Adaptive control Constraint (ACC)

Nearly all AC systems is of this type
Less sophisticated and less expensive
than research ACO systems
Objective is to manipulate speed or feed
so that measured process variables are
maintained at or below their constraint limit
values.
4/10/2012
26
Operation of ACC system
1.
2.
3.
4.
Profile or contour milling on NC machine tool

Feed is controlled variable
Cutter force and horsepower are used as measured
variables
Hardware components
Sensors mounted on the spindle to measure cutter
force
Sensors to measure spindle motor current
Control unit and display panel to operate the system
Interface hardware to connect the AC system to
existing NC/CNC system
4/10/2012
27
Relationship of AC software to APT

program
4/10/2012
28
Operation of ACC system during

machining process
4/10/2012
29
Benefits of AC
1.
2.
3.
4.
5.
6.
Increased production rate

Increased tool life
Greater part protection
Increases machine life
Less operator intervention
Easier part programming
4/10/2012
30

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CNC, DNC &

Problems with Conventional NC

Computer Numerical Control

Machine tool control

In-process compensation Dynamic correction of

Improved programming and operating features

Diagnostics Equipped with diagnostic

Direct Numerical Control

A manufacturing system in which no. of

DNC with satellite computer

DNC Drip Feeding

computer feeds few blocks of

When almost all blocks executed,

Behind the Tape Reader (BTR)

Special Machine Control Unit

NC, CNC and DNC

NC without punched tape

Data collection, Processing and reporting

Elimination of punched tape and tape reader

Combined CNC/DNC systems

Development of hierarchical computer systems in

A control system that measures certain output process

Where to use adaptive control?

In-process time consumes significant

Sources of variability in machining

Variable depth/width of cut

Adaptive Control Optimization

Index of performance is a measure of overall

Adaptive control Constraint (ACC)

Operation of ACC system

Profile or contour milling on NC machine tool

Relationship of AC software to APT

Operation of ACC system during

Increased production rate

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