Extensions of NC

Numerical control has caused a virtual revolution in the discrete metal parts
manufacturing industry. The success of NC has led to number of extensions of
Numeric Control concepts and technology. Four of the important developments
are the following:

Direct numerical control (DNC).

Computer numerical control (CNC).
Adaptive Control.
Industrial robots.

Direct Numerical Control(DNC)

There are number of problems inherent in conventional machiningwhich are

motivated machine tool builders to seek imprivements in the basic NC system.
Among the difficulties encountered in using conventional numerical control
machine are the following Part programming mistakes,Punched tape, Tape reader,
Controller, Management information.

DNC defined

It can be defined as a manufacturing system in which a number of machines are

controlled by a computer through direct connection and in real time. The tape
reader is omitted in DNC thus releiving the system of its least reliable component.
Instead of using tape reader the part program is tranmitted to the machine tool
directly from the computer memory. In principle,one computer can be used to
control more than 100 seperate machines. Figure below illustrates the general DNC
configuration

The system consists of four components.

1. Central computer
2. Bulk memory which stores the NC part programs.
3. Telecommunication lines.
4. Machine Tools.
The computer calls the part program instructions from bulk storage and sends data
back from the machines. This two way information flow occurs in real time,which
means that machine's requests for instructions must be satisfied almost
instantaneously. Similarly, the computer must always be ready to receive
information from the machines and respond accordingly. The remarkable feature of
the DNC system is that the computer is ervicing a large number of seperate
machine tools,all in real time.
Depending upon the number of machines and computational requirements that are
imposed on the computer it is sometimes necessary to make use of satellite
computersas shown in figure.

Computer Numerical Control (CNC)

CNC is a NC system that utilizes a dedicated, stored program computer to perform

some or all of the basic numerical control functions. As of this writing the typical
CNC system uses a minicomputer as the controller unit. It is expected that in future
generations of computer numerical control,microcomputers will become
predominant.
Because a digital computer is used in both CNC and DNC there is often confusion
surrounding the two systems.
Figure below shows the general configuration of CNC

Main differences are :

1. DNC computers distribute instructional data to and collect from a large number
of machines. CNC computers control only one machine or a small number of
machines.
2. DNC computers occupy a location that is typically remote from the machines
under their control. CNC computers are located very near their machine tools.
3. DNC softwrae is developed not only to control individual pieces of production
technology,but also to serve as part of management information system in the
manufacturing sector of the firm. CNC software is developed to augment the
capabilities of a particular machine tool.
Except for the fact that a digital computer is used, CNC machines are similar and
the part programs are entered in a similar manner. Punched tapes are still the
common device for entering the part program into the system

Adaptive Control Machining

One of the priciples reasons for using numerical control(including DNC and CNC)
is that NC reduces the nonproductive time in manufacturing. This is accomplished
through a reduction in the following elements,which constitue a significant portion
of totla production time.

1. Workpiece handling.
2. Setup of the job.
3. Lead times between receipt of a order and production.
4. Tool changes.
5. Operater delays.

For a machining operation the term adaptive control means a control system that
measures output process variables and uses these to control system that measures
certain uotput process variables nad uses these to control speed and or feed. Some
of the process variables and uses these to control speed and feed. Some of the
process variables that have been used in adaptive control machining systems
include spindle deflection or force,torque,cutting temperature viration amplitude
and horsepower .In other words all the metal-cutting variables have been tried in
experimental control systems.
A number of potential befitis accure to the user of an adaptive control machine tool
. The advantage gained will depend upon the particular job under consideration.
There are obviously many machining situations for which adaptive control
system cannot be justified.
1. Increased production rates
2. Increased tool life.
3.Greater part protection.
4.Less operater intervention.
5.Easier part programming.

Industrial Robots
An industrial robot is a general purpose programmable machine possesing certain
anthropomorphic charesteristics. It is most typically used for parts handling tasks
but can also be used in conjuction with a variety of manufacturing processes. The
robots can be programmed to carry out a sequence of mechanical movements. It
will perform that sequence over and over again until reprogrammed to carry out a
sequence of mechanical movements .
General Physical Configuration
There are two principal robot configuration :polar and cylindrical. The two types
are illustrated in figure In the polar configuration the body of the robot pivots
either horizontally vertically or both. Attached to body pivots is the are that moves
by body motion. The are of the robot in the horizontal orientation and can be made
to moive up and down and in or out with respect to the body.

Arm and body motions

1. Vertical traverse Up and down motion of the arm
2.Radial traverse Extension and retraction of the arm
3.Rotational traverse Rotation about the vertical axis

Wrist Motions
4.Wrist swivel Rotation of the wrist
5.Wrist bend Up or down movement of the wrist which also involves a rotational
movements.
6.Wrist yaw Right or left swivel of the wrist.
Numerical Control NC

Getting geometric information from the CAD model is of particular relevance to the
manufacture of parts directly by machining (i.e. by material removal), and to the manufacture
of tooling for forming and molding processes by machining. The use of numerical
information for the control of such machining processes is predominantly through the
numerical control NC of machines.

Fundamentals of numerical control

Today numerically controlled devices are used in all manner of industries. Milling machines
manufacture the molds and dies for polymer products. Flame cutting and plasma arc
machines cut shapes from large steel plates. Lasers are manipulated to cut tiny cooling holes
in gas turbine parts. Electronic components are inserted into printed circuit boards by NC
insertion machines.

Numerical Control NC is a form of programmable automation in which the mechanical

actions of a machine tool or other equipment are controlled by a program containing coded
alphanumerical data.

Numerical control NC is any machining process in which the operations are executed
automatically in sequences as specified by the program that contains the information for the
tool movements.

The alphanumerical data represent relative positions between a workhead and a workpart as
well as other instructions needed to operate the machine.
The workhead is a cutting tool or other processing apparatus, and the workpart is the object
being processed.

Basic Components of an NC System

The essential features of numerically controlled machines have been established for many
years. They comprise a controller, known as the machine control unit MCU, capable of
reading and interpreting a stored program and using the instructions in this to control a
machine via actuation devices. This arrangement is shown in the following Figure.

An NC system consists of three basic components:

(1) Program of instructions
(2) Machine control unit MCU
(3) Processing equipment

In the most common example of NC, machining, the processing equipment consists of the
worktable and spindle as well as the motors and controls to drive them.

NC Part Programming
NC part programming consists of planning and documenting the sequence of processing steps
to be performed on an NC machine. The documentation portion of part programming
involves the input medium used to transmit the program of instructions to the NC machine
control unit.

Part programming can be accomplished using a variety of procedures ranging from highly
manual to highly automated methods. The methods are:
(1) manual part programming
(2) computer-assisted part programming
(3) part programming using CAD/CAM
(4) manual data input

NC Coding System
The program of instruction is communicated to the machine tool using a coding system based
on binary numbers. This NC coding system is the low-level machine language that can be
understood by the MCU. When higher level languages are used, such as APT, the statements
in the program are converted to this basic code.

EIA and ISO Coding Standards

In addition to number values, the NC coding system must also provide for alphabetical
characters and other symbols. Eight binary digits are used to represent all of the characters
required for NC part programming. There are two standard coding systems currently used in
NC: (1) the Electronic Industry Association (EIA) and (2) the International Standards
Organization (ISO). The Electronics Industry Association system is known as EIA RS-244-B.
The ISO code was originally developed as the American Standard Code for Information
Interchange (ASCII) and has been adopted by ISO as its NC standard.

How Instructions Are Formed?

A binary digit is called a bit. A character is a combination of bits representing a numerical
digit (0-9), an alphabetical letter (A-Z), or symbol. Out of a sequence of characters, a word is
formed. A word specifies a detail about the operation, such as x-position, y-position, feed
rate, or spindle speed. Out of a collection of words, a block is formed. A block is one
complete NC instruction. It specifies the destination for the move, the speed and feed for the
cutting operation, and other commands that determine explicitly what the machine tool will
do. For example, an instruction block for a two-axis NC milling machine would likely
include the x- and y-coordinates to which the machine table should be moved, the type of
motion to be performed (linear or circular interpolation), the rotational speed of the milling
cutter, and the feed rate at which the milling operation should be performed. Instruction
blocks are separated by an end-of-block (EOB) symbol.

The essential information in a part program is conveyed to the MCU by means of words that
specify coordinates, feeds and speeds, tooling, and other commands necessary to operate the
machine tool. Given the variety of machine tool types and the many different companies that
build NC machine tools and MCUs, it is no surprise that several different formats have been
developed over the years to specify words within an instruction block. These are often
referred to as tape formats or block formats.
NC words
By convention, the words in a block are given in the order:
SEQUENCE NUMBER (N code): This is used to identify the block within an NC program
and provides a means by which NC commands may be rapidly located.
PREPARATORY WORD (G code): This word is used to prepare the controller for
instructions that are to follow. For example, the word g02 is used to prepare the NC controller
unit for circular interpolation along an arc in the clockwise direction. The preparatory word is
needed so that the controller can correctly interpret the data that follow it in the block.
COORDINATES (x-, y-, and z-words): These give the coordinate positions of the tool. In a
two-axis system, only two of the words would be used. In a four- or five-axis machine,
additional a-words and/or b-words would specify the angular positions.
FEED RATE (F code): This specifies the feed in machining operation. Units are inches per
minute ipm by convention.

CUTTING SPEED (S code): This specifies the cutting speed of the process, the rate at which
the spindle rotates.
TOOL SELECTION (T code): This code would be needed only for machines with a tool
turret or automatic tool changer. The t-word specifies which tool is to be used in the
operation.
MISCELLANEOUS FUNCTION (M code): The M code is used to specify certain
miscellaneous or auxiliary functions, which may be available on the machine tool. Of course,
the machine must possess the function that is being called. An example would be m03 to start
the spindle rotation. The miscellaneous function is the last word in the block. To identify the
end of the instruction, an end-of-block EOB symbol is punched on the tape.