Design of Computer Numerical Control

Plotter Using Combination of Servo Motor

and Stepper Motor

Authors

Hafiz Khurram Iqbal 14EL07

Fizza Mehboob 14EL03

Amina Arshad 14EL01

Supervisor
Engr. M Shoaib Rabbani

DEPARTMENT OF ELECTRICAL (POWER) ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING AND

TECHNOLOGY, THE ISLAMIA UNIVERSITY OF

BAHAWALPUR

July, 2018
(In the Name of Allah, the Most Gracious, the
Most Merciful)
Design of Computer Numerical Control Plotter Using

Combination of Servo Motor and Stepper Motor

Hafiz Khurram Iqbal 14EL07

Fizza Mehboob 14EL03

Amina Arshad 14EL01

A thesis submitted in partial fulfillment of the requirements for the degree of

B.Sc. Electrical (power) Engineering

Supervisor
Engr. M Shoaib Rabbani
Assistant Professor, Electrical Engineering

Thesis Supervisor Signature: ________________________________________

External Examiner Signature: _______________________________________

DEPARTMENT OF ELECTRICAL (POWER) ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING AND

TECHNOLOGY
The Islamia University of Bahawalpur

July, 2018
 University College of Engineering & Technology
Department of Electrical (Power) Engineering

CERTIFICATE
This is to certify that work presented in this project thesis on
Computer Numerical Control Plotter Using Combination of Servo Mo
and Stepper Motor” is entirely written by following students under
supervision of Engr. M Shoaib Rabbani

Submitted By:
Hafiz Khurram Iqbal 14EL07

Fizza Mehboob 14EL03

Amina Arshad 14EL01

Project Supervisor Head of Department

Engr. M Shoaib Rabbani Dr. Abdur Raheem
UCET-IUB, Bahawalpur UCET-IUB, Bahawalpur

Principal External Examiner

Dr. Muhammad Amjad
UCET-IUB, Bahawalpur

Date:
 ABSTRACT

The method that allows computer to automate machine is called Computer Numerical

Control (CNC). The machine which can move along different axis like x and y, is

controlled by computer to tell it where to go exactly. By including z-axis the depth of

machine can also be controlled. The same concept is used in mini 3D printers. The

sketches or 2D graphs can be plotted on paper using computerized numerical control

plotter. It can draw circuit layout on PCB.

We use two stepper motors and a servo motor for the construction of machine. Stepper

motors are used to cover the movement along x and y axis. Servo motor is used for up

and down movement of z axis. The movement of motors are controlled by main

controller called Arduino UNO. The UNO controller controls the movement of motors by

interpreting the G-code. G-code is the code which tells the machine where to go in terms

of distance co-ordinates. Any SVG diagram drawn in computer is converted into G-code.

By using Universal G-code Sender or grbl controller, G-code is sent to Arduino

microcontroller via serial communication to start the plotting process.

Keywords: CNC, plotter, Automate, 3D printer, Stepper Motor, Arduino, G-code, Grbl,

UGS.

i
 UNDERTAKING

We certify that the research work titled “Design of Computer Numerical Control Plotter

Using Combination of Servo Motor and Stepper Motor” is our own work. The work has

not been presented anywhere else for assessment. Where material has been used from

other sources it has been properly acknowledged / referred.

__________________________

Hafiz Khurram Iqbal 14EL07

__________________________

Fizza Mehboob 14EL03

__________________________

Amina Arshad 14EL01

ii
 ACKNOWLEDGMENTS

First, thanks to Almighty Allah, the most Beneficent and Merciful, who provided us with

this opportunity and ability to complete this contribution towards knowledge.

It is pleasuring to add heartfelt words for the people who provide us with ending support,

precious time and inspiration. We would like to express thanks of gratitude to our project

supervisor Engr. M Shoaib Rabbani as well as Head of Department Dr. Abdur Raheem

for his help and encouragement.

We are thankful to our parents, teachers and friends for their sincere cooperation,

support, appreciation and pleasant attitude.

iii
 TABLE OF CONTENTS
Abstract.................................................................................................................................i

Undertaking.........................................................................................................................ii

Acknowledgments...............................................................................................................iii

Table of Contents................................................................................................................iv

List of Figures.....................................................................................................................vii

List of Tables......................................................................................................................viii

Chapter 1: Introduction....................................................................................................1

1.1 Problem Statement.....................................................................................1

1.2 Project Objective........................................................................................1

1.3 Methodology..............................................................................................2

1.4 Thesis Outline............................................................................................3

Chapter 2: Literature Review...........................................................................................5

Chapter 3: Computer Numerical Control Plotter and Hardware Components................8

3.1 Areas of Knowledge...................................................................................8

3.2 Main Parts of CNC Machine......................................................................9

3.3 Precision in CNC.....................................................................................11

3.4 Components of CNC................................................................................12

3.5 Stepper Motor..........................................................................................13

3.5.1 Motor Operation...................................................................................14

3.5.2 Types of Stepper Motor.......................................................................14

3.5.3 Hybrid Stepper Motor..........................................................................14

3.5.4 Principle Operation of Hybrid Stepper Motor.....................................15

3.5.5 Technical Specifications......................................................................16

3.5.6 Step Modes...........................................................................................17

iv
 3.6 Servo Motor.............................................................................................18

3.6.1 Servo Operation...................................................................................19

3.7 Arduino UNO...........................................................................................20

3.7.1 Programming........................................................................................22

3.7.2 Power...................................................................................................22

3.7.3 Input and Output..................................................................................24

3.8 CNC Shield..............................................................................................25

3.8.1 Technical Data.....................................................................................25

3.9 Motor Driver............................................................................................26

3.9.1 Configuration of Micro-stepping.........................................................27

3.10 GT2 Timing Belt and Pulley....................................................................28

3.11 Other Accessories....................................................................................28

Chapter 4: Software Description....................................................................................30

4.1 G-Code.....................................................................................................30

4.1.1 Other Codes.........................................................................................33

4.1.2 G-code Generation...............................................................................34

4.1.3 Example G-code...................................................................................35

4.2 Arduino Software.....................................................................................36

4.3 GRBL.......................................................................................................36

4.4 Program Codes.........................................................................................38

4.5 Universal Serial G-code Sender...............................................................39

5 Conclusion.......................................................................................................41

5.1 Critical Assessment..................................................................................42

5.2 Future Work.............................................................................................42

Abbreviations.....................................................................................................................44

v
References.........................................................................................................................45

vi
 list of figures

Fig 1.1: Block Diagram of Project......................................................................................3

Fig 2.1: Main Parts of CNC..............................................................................................11

Fig 2.2: Path in point to point system...............................................................................13

Fig 3.1: Construction of Hybrid Stepper..........................................................................15

Fig 3.2: Working of Hybrid Stepper Motor......................................................................16

Fig 3.3: Full Step Excitation.............................................................................................17

Fig 3.4: Half step Excitation.............................................................................................18

Fig 3.5: Micro-stepping mode..........................................................................................18

Fig 3.6: Servo Motor.........................................................................................................19

Fig 3.7: Arduino UNO......................................................................................................21

Fig 3.8: Arduino UNO Pinout..........................................................................................23

Fig 3.9: CNC Shield Pinout..............................................................................................26

Fig 3.10: A4988 Stepper Motor Driver............................................................................27

vii
 LIST OF TABLES

Table 3.1: Technical Specification of NEMA 17, Stepper Motor.....................................16

Table 3.2: Technical Specification of SG90 Servo Motor................................................20

Table 3.3: Specifications of Arduino UNO.......................................................................21

Table 3.4: Stepping Schemes.............................................................................................27

Table 4.1: G-code Commands...........................................................................................31

Table 4.2: Miscellaneous Function....................................................................................33

viii
 CHAPTER 1

1 Introduction
CNC plotter is capable of drawing sketches which are fed by computer in the form of

Geometric code that are x, y and z co-ordinates. This G-code is sent to microcontroller

using Universal G-code Sender (UGS). Microcontroller interprets the commands and

send signals to motor drivers which drive the motors through steps. It provides easiness

in manufacturing complex curved geometries. The exciting features are much greater

precision than the hand work and mass number of sketches in short time. It can also draw

circuit layout directly on the printed circuit board (PCB). Keeping in view of above

mentioned benefits, the purpose of this project is to develop a low-cost CNC plotter

capable of drawing accurately. Plotter can be modified by using pen with 3D printer

head, milling tool or any other cutting tool for different purpose of cutting materials

instead of sketching.

1.1 Problem Statement

Drawing of simple and small sketches is quite easy but for complex sketches it requires

highly skilled professionals. For this purpose, many years of education and training is

necessary. Moreover, probability of inaccuracy in hand made design is also frequent.

There are wide ranges of technologies for the fabrication of CNC machines but are very

costly. Also, manual designing of PCB layout is quite time-consuming process.

1.2 Project Objective

The purpose of this project is control movement of electrical motors using mechanical

structures. To explain the key idea behind numeric control and interaction between

1
hardware, software and communication between them. The Printed Circuit Board (PCB)

has made an enormous contribution in electrical and electronic devices industry. This

project will present a robust cost-effective method of controlling a specific designed

machine to sketch the PCBs, plot 2D graphs or sketches.

Computer Numerical Control machine is run by CNC machine language (G-code) that

are generated by unique method, moreover, there is microcontroller and drivers to control

the movement of motors. The user just needs to generate the G-code of any circuit

diagram or a sketch. The machine will automatically respond to the generated G-code and

will draw the desired result. Thus, this project will be helpful for engineering students

and for them having interest in art and designing during project implementation.

1.3 Methodology

The most accurate controlling technique is Computerized Numerical Control. This

method is not too much complex due to multiple steps and easy to implement. The block

diagram is presented below which demonstrate the detail mechanism of project.

The sketch of any drawing or circuit layout is designed in CAD. This layout is then

imported in software that produce g-code file of that image. The G-code is sent to

microcontroller Arduino by computer or laptop using grbl controller software.

Microcontroller interprets the commands and send signals to motor driver. Motor driver

generate step signal accordingly and drive the motors.

2
 Fig 1.1: Block Diagram of Project

1.4 Thesis Outline

The thesis work is divided into 5 chapters. The contents of these chapters are summarized

as:

Chapter 1 is the introduction to the technology involved in CNC plotter. It consists of

brief introduction of technology, project overview and problem statement. The main

objective of project is also explained in detail.

Chapter 2 consists of literature review of the project work.

3
Chapter 3 is the introduction to Computerized Numerical Control and the technology

behind CNC. After detailed introduction, main hardware components and its working is

described.

Chapter 4 is about software and coding of project. It described the flow of tasks among

different components. The libraries and standard directives used in the coding are also

enlisted.

Chapter 5 is the conclusion.

4
 CHAPTER 2

2 Literature Review
Numeric control (NC) was the first step in the designing of computer numeric control

(CNC) machine. So, in the era of 1940’s ,50’s United State Airforce and Parson’s

company introduced the method for moving two axis simultaneously and utilizing punch

cards including coordinate data to machine aircraft parts.so servo laboratory in

Massachusetts Institute of Technology (MTI) designed first numeric control (NC)

machine tool. Due to lack of transistors and IC’s the NC was very much huge in size due

to utilization of vacuum tubes [1].

Although this technology proved to be cost effective but do not provided with any

universal code, so every individual manufacturer used their own language for defining

part programs. The NC consist of fixed logical functions.no changes in the function could

be made by any programmer or machine operator [2].

As the time passes other technologies were also developing at the same time. In these

technologies the DNC (Direct numerical control) ONC (Open Numerical Control) and

other like CNC were developing as each technology has its own features and drawbacks.

As direct control was not so simple and complex engineering was required for controlling

purposes and as open control was not so precise so the requirement was the simple

system with high efficiency as well as with simple engineering [3]

Computer numeric control (CNC) took a step in this field in 1960’s because of the

provision of the standardized programming language and the invention of

microcomputers. The introduction of computer technology into the concept of numeric

5
control was the magnificent step in revolutionizing the industry [2]. CNC is the very vast

term that encircles a variation of types of machines with diversity in shape size and

function [4]. CNC follows a preset sequence of machining operations, to produce a

desired workpiece [5].

CNC machine would include plotters, cutters,3D printers, milling machines and many

other which keeps on modifying with the impressive development in technology. The

manufacturing methods for PCB’s also proved to be the milestone for industry [6]. The

PCB’s electronic circuit are operated by the flow of current through specific paths. These

paths are not possible to be traced without the assistance of CNC machines, previously

liquid ferric chloride was used to carve the board for clearance of current flow path but it

induces high insecurity to human life [7].

CNC machines are most efficiently utilized in the industry where there is excessive work

load. CNC machine is the form of automatic machine, which is provided with motors that

provides us with favorable merits that include much greater precision than hand working,

high efficiency, less working time, less human interference, greater dimensional

accuracy, reduces energy cost and consumable materials so that production is efficient

and profitable. If they are correctly programmed, they do not require advanced skills and

they are easier to operate [8].

The modern CNC system, uses an internal microprocessor, thus the machine operator or

the part programmer can vary the program of control system [2]. CNC’s are controlled

using a special programming language called G-code. G-code provides with ease to

gather information of all the moving motors, as the status of the moving motors is seen,

thus the control over motors can be gained. G-code is much simpler than any other high-

6
level programming language. There is the possibility to generate g-code either manually

or automatically. Computer aided design (CAD), CAE etc. are the software that assist in

generating the g-codes[9]. So, the combination of hardware and g-code yields advantages

that include the higher accuracy and reducing the work load. In actual the CNC machine

synchronizes the Arduino software for better response [10].

As the technology developed gradually the CNC machines that make use of the motors to

carry out their work, are becoming more and more cost effective and highly demanding

and can be easily constructed by the individuals or companies. CNC plotters are very

versatile and fully automatic machineries that integrate the function of drawing, sketching

etc. using computer controlled pen. This is 2D plotting machine which can be further

modified for 3D plotting by further advancement. Even new tools such as the 3D printers

can be programmed using mostly the same algorithms used for more classical processes

[11]. These machines ensure the controlled and precise movement of motors.

7
 CHAPTER 3

3 Computer Numerical Control Plotter and Hardware

Components
Computer numerical control is a method in which motion of machines (i.e. servo and

stepper motors) is controlled by computers using numeric [12]. The design or sketch is

converted into special codes using computers with which the interacted motion of motors

controls the tools, for example pen, drills or lathes. As the machine is driven by

computer, a software program is needed to modify or create shapes and develop the paths

that the machine will follow.

Prior to CNC machines, conventional machines have 2-axis and the working bed move

vertically. The spindle did not move as it is fixed with machine body. In CNC machine,

there are minimum 3-axis. The construction of CNC is more rigid than conventional

machines.

3.1 Areas of Knowledge

To command in the subject of CNC there are a few key areas which should be

concentrated on:

i. Computer Skills

There are 2 types of tasks performed during the process. Firstly, we will be

working with software programs for editing, copying, saving files, starting and

8
 stopping operation. Meanwhile CNC is run by a computer, which can be a PC or

some control box.

ii. Design and tool path software:

Before the machine start drawing, we need to create design layout in software

program that the machine will follow. The chosen software will play significant

role in creating projects successfully using CNC. This design software allows us

to transform our idea into a set of instructions.

iii. Operation and maintenances:

It is important to properly maintain and adjust CNC to know its limitations and to

set it up to do a job correctly. While building own machine, its size, speed,

efficiency, cost and accuracy are important considerations.

3.2 Main Parts of CNC Machine

The main parts of the CNC machine are

i. Part Program:

All the CNC machining begins with a part program, which is sequential

instructions or coded commands that direct the specific machine functions. When

running, a part program is interpreted one command line at a time until all lines

are completed.

Part program is mainly comprised of:

G-code: Machining setup and operating conditions

N-code: specify program line number to be executed by MCU

Axis codes: x, y, z directions

9
 Feed and speed codes

Miscellaneous codes

ii. Input Device

Program input device imports the part program into the CNC control. Input device

in this project is a computer via serial communication.

iii. Machine Control Unit (MCU):

MCU performs all the controlling actions of CNC according to the part program.

It is a microcontroller such as an Arduino. MCU issues commands in the forms of

numeric data to motors.

 MCU reads the coded instructions fed into it

 Decodes the coded instructions

 Implements the interpolation to generate axis motion commands

 Implements auxiliary control functions

MCU consists of two main units:

Data Processing Unit

Control loop Unit

iv. Drive System

Drive system consists of motor drivers, timing belt and lead screws. The control

signal consisting position and speed are sent by MCU to the amplifier circuit.

These control signals trigger motor drivers which in turn rotate the lead screws to

position the correct location.

v. Machine Tool:

10
 A CNC machine always has a working bed and a clamp for the machine tool.

Machine tool could be one of following: laser, lathe, mill, plasma, pen etc. In our

project, it is a drawing pen. Machine tool clamp is controlled in z-axis only.

The whole discussion can be summarized in following block diagram:

Input
device

Part Program

MCU
Motion Data Miscellaneous Function

Driving
Machine tool
system

Fig 3.2: Main Parts of CNC

3.3 Precision in CNC

Following factors determine the precision of machine control:

i. Resolution

Control resolution (BLU) is the space separating two adjacent points in the axis motion.

The electromechanical elements of the positioning system that influence the resolution

are the lead screws, the gear ratio and the step angle in stepper motor.

ii. Accuracy

11
Accuracy of a CNC system depends on the resolution, the computer control algorithm

and machine inaccuracies. The inaccuracy due to resolution is considered half of BLU on

the average. The control algorithm inaccuracy is due to the rounding off error in

computer which is insignificant. The machine inaccuracy could be due to many reasons.

iii. Repeatability

Repeatability is a statistical term associated with accuracy. It refers to the capability of a

positioning system to return to a programmed point and is measured in terms of errors

associated with that programmed point. the repeatability is always better than accuracy.

The mechanical inaccuracy can be considered as repeatability.

3.4 Components of CNC

i. Basic Length Unit

Each basic length unit corresponds to the position resolution of the axis of motion. For

example, 1 BLU = 0.0001” means that the axis will act 0.0001 inch for every electrical

pulse sent to the motor. The BLU is also termed as Bit.

ii. Point to Point System

Points to point system are those that move the tool or the work piece from one point to

another point and then the tool perform the required task. Upon completion, the tool (or

work piece) moves to the next position and the cycle is repeated. In this system, the feed

value and the track of the pen or work piece have no signification on the machine

operation. The accuracy of placement depends upon the system’s resolution in terms of

BLU which is broadly between 0.001” and 0.0001”.

12
 Fig 3.3: Path in point to point system

iii. Continuous Path System

These systems provide continuous path such that the tool can perform while the axis is

moving, enabling the system to generate angular surfaces, two dimensional curves, or

three-dimensional contours. Every axis might act continuously at various speeds.

Velocity error effectively impact the location of the pen. It is often more significant

sketching where one axis adopts sine function while the other compiles cosine function.

Hardware Details

In the context of technology, hardware refers to physical elements that make up a system.

The implementation of hardware component is the major task in project designing. The

detail of different components used in this project is elaborated in subtopics.

3.5 Stepper Motor

A stepper motor is a special type of synchronous motor which is designed such that its

rotor rotates in discrete step for an electric signal received by its driver [13]. Due to this

property exhibited by stepper motors, these motors are used for precise positioning of

13
shaft or other machinery. Therefore, stepper motors are the base of computer numerical

control plotter to precisely move the drawing pen. The control signal to the stepper motor

must be sent one at a time. The direction of rotation of shaft depends on the sequence of

electric signal. The complete revolution of shaft is divided into equal length of steps and

the speed of shaft is related to rate of input pulses.

3.5.1 Motor Operation

The stepper motor used in our project is NEMA 17, 4-wire, bipolar stepper motor. Two

stepper motors are used for x and y axis each. The operation of stepper motor is open

loop control which means no feedback system about position is required. Thus, it

eliminates the expenses of sensing and feedback system.

3.5.2 Types of Stepper Motor

Stepper motor are of three types:

 Variable reluctance motor: As the name implies, VR stepper motor works on

the principle that rotor tooth are attracted by minimum gap due to minimum

reluctance.

 Permanent magnet stepper motor: It consists of a PM rotor and an

electromagnet stator. The motor operation due to the attraction or repulsion

between rotor and stator.

 Hybrid synchronous stepper motor: Hybrid stepper motor combines the

features of PM and VR, and give favorable results. The stepper motors used in

this project are hybrid stepper motors, so we discuss them in detail:

14
3.5.3 Hybrid Stepper Motor

The exciting features of these motors are there better performance in torque, speed and

step resolution, compared with PM and VR stepper motor. It borrows the favorable

features of PM and VR. The rotor of hybrid stepper motor is a permanent magnet and it

is split in two halves and each half is multi-toothed/ geared. Steps range of hybrid stepper

motor is 100-400 steps per resolution. The angle resolution is 1.8°. It does not create any

noise.

Fig 3.3: Construction of Hybrid Stepper

3.5.4 Principle Operation of Hybrid Stepper Motor

The rotor is magnetized and its teeth. Stator has number of teeth or poles as well. The

rotor consists of two cups, one in the front and one in the back. The two rotor cups are

opposite in polarity. The teeth on one cup is offset by one tooth to the teeth on the other

cup. When a phase is energized, it energizes four poles on stator. Suppose, initially the

stator poles A and A’ are aligned perfectly with one of the rotor cup teeth. On the other

hand, B and B’ stator poles are halfway of the pole attracting the one cup’s teeth while

repelling the other. In the next step the direction of current is changed by reversing the

15
current direction. Winding B maintains the current direction from previous stage. Now,

the stator poles A and A’ are half on each rotor cup while B and B’ align up perfectly

with each cup. The rotor has rotated a very small amount due to this construction of

hybrid motor.

Fig 3.4: Working of Hybrid Stepper Motor

3.5.5 Technical Specifications

Technical specifications of Nema 17 stepper motor used in this project are as follows:

Table 3.1: Technical Specification of NEMA 17, Stepper Motor

1 Phases 2
2 Steps/ Revolution 200
3 Step Accuracy ±5%
4 Rated current 2A
5 Rated voltage 12V
7 Holding Torque 0.48 Nm

16
3.5.6 Step Modes

For the configuration of step resolution, there are three pins for each motor. Many step

modes can be obtained by using different configuration schemes of pins. These modes

determine the running properties and torque of motor [14].

Full Step Mode

Hybrid stepper motors usually have two hundred rotor teeth; therefore, they complete a

revolution in two hundred steps. So, in full step mode one phase is energized at a time. In

this way the step angle of motor is 1.8°. In this step mode motor requires less amount of

power.

Fig 3.5: Full Step Excitation

Half Step Mode

In half step mode, a phase is energized sequentially just before the previous de-energizes.

Thus, rotor tooth moves halfway the distance of tooth width. In this way the rotor

completes one revolution in four hundred steps and provide more smoother operation.

17
 Fig 3.6: Half step Excitation

Micro-stepping Mode

This mode of step resolution is used in situations where very accurate positioning is

required. It improves the motion control at the cost of low torque. In micro step operation

one rotation of rotor is obtained in very small steps i.e. fifty-one thousand two hundred

steps. The step angle becomes very small. Thus, the motor can position every small

distance.

Fig 3.7: Micro-stepping mode

3.6 Servo Motor

Servo are small, light-weight and efficient motors. The selection of motor depends on the

types of use and requirements. For example, for reliable and long run time use the motor

with metal gears instead of plastic gears is used to compensate for wear and tear. Next,

18
the task may be accomplished by half or full circle rotation so one of the 180°∨360 °

rotating gear arrangement can be used. The most important parameter of concern is the

torque. It determines the amount of load that the motor can pick. For our requirement a

1.8kg is sufficient. On receiving the pulse signal servo rotates a specified degree i.e. 180

degrees. It moves both clockwise and anticlockwise for 90 degrees.

In CNC plotter servo motor is used is to lift drawing pen up and down. Servo has it its

own feedback and gear box yet it is compact in size. 3 wires come out of the servo motor:

Brown (ground), Red (5V), Orange (PWM). Through orange wire PWM signal is given

to drive the motor.

3.6.1 Servo Operation

Serve operates using the three wires, two for the power supply to make motor rotating.

The third wire is for PWM signal that is generated from microcontroller. The direction

and degrees of rotation is controlled by varying the on time of pulse. Suppose the on time

of signal is 2ms out of total 20ms for 50Hz frequency. Thus, when the on time is 1ms

motor is at 0° ,for 1.5ms it rotates 90°and for full on time 180°.

Fig 3.8: Servo Motor

Technical specifications of SG90 servo motor are listed in table below:

19
 Table 3.2: Technical Specification of SG90 Servo Motor

1 Voltage 4.8V

2 Weight 9g

3 Torque 1.80kg-cm

4 Speed 0.12s/60°

5 Rotation 0°-180°

6 Motor type 3-pole

7 Pulse width 500-2400μs

8 Dead band width 1 μs

3.7 Arduino UNO

Arduino Uno is a micro-controller board based on the ATmega328P. It has 14 digital

input/output pins, 6 analog input pins, a 16 MHz quartz crystal oscillator, a USB port, an

external power jack, 5 power pins and a reset button. There is a test LED and two TX/RX

LEDs. This is a complete board to support the controller. It can be powered by

connecting the board to a computer with the help of a USB cable or with a DC adapter or

battery [15]. Arduino Uno is shown in Fig 3.9.

20
 Fig 3.9: Arduino UNO
UNO is an Italian word which means “one’ and it was chosen to mark the release of

Arduino Software IDE 1.0. The Arduino UNO and version 1.0 of Arduino Software IDE

were the reference versions of Arduino, now there are several new releases. The UNO

board was the very first in the series of USB Arduino boards. The technical specifications

of Arduino UNO are given in table 3.3.

Table 3.3: Specifications of Arduino UNO

1 Micro-controller ATmega328

2 Running Voltage 5 volts

3 Input Voltage Range 7-12 volts

4 Input Voltage limits 6-20 volts

5 No. of Digital Input/Output Pins 14 from which 6 can provide PWM output

6 No. of PWM Output Pins 6

7 No. of Analog Input Pins 6

8 DC Current per Input/Output Pin 40 mA

21
 9 DC Current for 3.3 V Input Pin 50mA

10 Flash Memory Size 32 KB of which 0.5 KB is used by

bootloader
11 Size of SRAM 2KB

12 Size EEPROM 1 kB

13 Clock Speed (Oscillator) 16 MHz

14 Length of Board 68.6mm

15 Weight of Board 25 grams

3.7.1 Programming

Arduino Software (IDE) is used to program the Arduino UNO board. The ATmega328

microcontroller on the Arduino UNO board is already pre-programmed with a bootloader

that allows the user to upload new code into the board without the need of an external

hardware programmer. The Arduino UNO communicates with computer by using the

original STK500 protocol. Arduino IDE is used to program Arduino for the computer

numerical control plotter. User can also program the micro-controller by using the ICSP,

which stands ‘In-Circuit Serial Programming’, header using Arduino ISP.

3.7.2 Power

The power can be provided to the Arduino UNO board via the USB connection or with

an external DC power supply. The power source is chosen automatically by the board.

External DC power can be provided either by an AC-to-DC adapter or DC battery. The

adapter can be attached by plugging in a 2.1mm center-positive plug into the Arduino

board's power jack. Wires coming from a DC battery can be putted in the GND and Vin

pins of the POWER connector.

22
 Fig 3.10: Arduino UNO Pinout

In computer numerical control plotter, there are two sources of power. External 12V

power supply power to motors. USB power supply of laptop/pc is used to power Arduino

UNO board. The UNO board can also be run on an external power supply ranging from 7

to 12V. If the power supplied is less than 7V, the 5V pin may provide less than 5V and

the UNO board may become unstable. If power is supplied more than 12V, the voltage

regulator may overheat and destroy the board. The suggested range of power is 7 to 12V.

The power pins are as follows:

 Vin: It is the input voltage pin on the Arduino UNO board. When using an external

power source, voltage can be provided via this pin. Or if providing voltage through

the power jack, voltage can be accessed via this pin.

23
 5V: The function of this pin is to provide a regulated five volts from the voltage

regulator installed on the UNO board. Applying voltage through the 5 or 3.3 volts

pins bypasses the voltage regulator and can severally damage the board.

 GND: Ground pins

 3.3V: A 3.3V supply generated by regulator.

3.7.3 Input and Output

The 14 digital pins on the UNO board can be used as either input or output by using

‘pinMode()’, ‘digitalWrite()’ and ‘digitalRead()’ functions. Among the digital PWM

pins, pin 2, 3 and 4 are used for sending step signals to each corresponding motor and pin

5, 6 and 7 for controlling the direction of movement of motors. These pins are connected

to ‘step’ and ‘dir’ pins of motor driver. In this way, pin 2 and 5 are step and direction pins

for first motor and so on. Each pin can supply or receive only 20 mA current as suggested

operating condition and has an internal pull-up resistor of 20-50 kilo ohm. The current

must not exceed greater than 40mA on any digital pin to prevent permanent damage to

the controller. Some pins also have specialized functions:

 Serial: 0 as RX used to receive and 1 as TX is used to transmit TTL serial data.

These pins are connected to corresponding pins on ATmega which is a USB-to-

TTL serial convertor chip. In CNC plotter these pins are used for serial

communication for sending commands and G-Code between Arduino and

controller.

 Reset Pin: Bring the value of this pin LOW to reset the microcontroller. It used to

add a reset button to external shields which block the reset button on the board.

This pin is used to reset the Controller manually. By connecting this pin to GND

24
 pin the Controller will be reset and all the positions and variables values will be

lost. All motions and movements will be halted and Controller will reboot.

3.8 CNC Shield

CNC shield helps in building large number of projects including CNC drawing, CNC

routers, printers, robotics and other linear motion projects. An open source software

‘grbl’ is used on Arduino to control any required number of motors ranging from one to

four using the same number of A4988 motor drivers. The CNC shield used in this project

is Arduino CNC shield V3.0.

3.8.1 Technical Data

 GRBL compatible

 Compact and easy to understand design

 Enable Coolant

 4- axis support namely X, Y, Z, A

 2 end stops for each axis

 Removable A4988 motor drivers

 Micro-stepping setting using jumpers

 12-36 VDC

The CNC shield fits well on the top of Arduino without any extra jumper. CNC shield

layout with micro-stepping pins highlighted is shown in Fig 3.11:

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 Fig 3.11: CNC Shield Pinout

3.9 Motor Driver

A4988 Motor driver is used to control the motion of stepper motors. It is shown in fig

2.6. It can control the stepper motor with only two pins namely step and direction, one for

controlling the steps and the other for direction of rotation, either clockwise or

anticlockwise. The function of motor driver is to convert the step and direction signals

into electronic pulses. These signals are sent from Arduino. The built-in translator in

motor driver makes its function easy. The supply pins on motor driver are VDD and

GND. VDD can range from 3-5.5V. It is supplied with 5V from Arduino board. Next 4

pins are to connect motor wires, 1A and 1B for one coil, 2A and 2B for the other coil.

Following next two pins are used for powering motor, so VMOT and GND are connected

to 8-35V power supply through a capacitor for protection against voltage spikes. Now the

actual pins for motor control are STEP and DIR. Whenever a pulse is sent to STEP pin,

the motor moves one step. The resolution of these steps is controlled by three pins MS1,

26
MS2, MS3. Reset pin is used to put the translator to home state and sleep is for

minimizing power consumption when motor is not doing any job. The value of current is

limited by potentiometer on the board to make sure that it is within the motor limits.

Fig 3.12: A4988 Stepper Motor Driver

3.9.1 Configuration of Micro-stepping

There are 3 pins with each motor driver on CNC shield for configuring step resolution

according to one’s requirements. So, there are 5 different step resolutions. Following is

the scheme of stepping:

Table 3.4: Stepping Schemes

MS0 MS1 MS2 Micro-step Resolution

Low Low Low Full Step
High Low Low ½ Step
Low High Low ¼ Step
High High Low 1/8 Step
High High High 1/16 Step

As we are using full step mode so we don’t insert any jumper. For full step the step angle

can be calculated as:

360
Stⅇpanglⅇ =
no of steps
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 360
stⅇp anglⅇ= =1.8°
200

The linear distance travelled by one step depends on the pitch of leadscrew.

3.10 GT2 Timing Belt and Pulley

Timing belt is a toothed belt which provide non-slippery motion. Timing belts are used to

convert the rotational motion of motors into linear motion. GT2 timing belt is 1164mm

long. The pitch of belt is 2mm and it is 6mm wide. It means for one revolution the

distance moved is 2mm. If there are 200 steps per resolution, the step resolution comes

out to be 0.00001m that is quite good.

3.11 Other Accessories

In addition to above mentioned components, other minor components are briefly

described:

 Power Adaptor: 12V AC-DC adapter is used to power Arduino UNO. Its current

rating is 2A. The adapter can be attached by plugging in a 2.1mm center-positive

plug into the Arduino board's power jack.

 Idler Pulley: For proper functioning of belt, it is necessary to provide appropriate

tension in the belt. For this purpose, a pulley or tensioner is used. An idler pulley

is a device that held the belt in place tightly to avoid slipping. We have used a 20

teeth GT2 idler pulley with 3mm bore.

 X and Y-axis Clamps: x-axis and y-axis clamps are used to mount x and y stepper

motors. These are made of plastic and are 3d printed.

 Pen Holder: Pen holder is also 3d printed part. It consists of support for the

writing pen and servo motor.

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29
 CHAPTER 4

4 Software Description
Software provide a set of instructions to the physical hardware developed, to perform the

specific job. In CNC working methodology a variety of software can be used to perform a

task such as to generate G-code, pass the instructions to controller and process them.

The sequence of steps with corresponding software is as follows:

Inkscape: G-code Generation

Arduino: load hex file

Universal G-code Sender: sending G-code commands to motors

4.1 G-Code

Programming is the fundamental part of CNC machining process. G-code is a language

for CNC to communicate with machine tools. Codes vary depending on the type and

construction of machine. G-code are preparatory codes and stand for ‘geometric codes’.

The name G-code implies because each instruction starts with the symbol G. Commands

under G-code are like positioning, speed of positioning, linear feed, tool offsets. It tells

machine how to perform an action such as:

 Movement either rapid or slow

 Tool information such as feed, offset

 Coordinate switching

It is one component of CNC whereas other codes are also used in conjunction to perform

a task.

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To write a G-code program a programmer must have wide knowledge of machine actions

and the limits of machine tools. At first, the machining parameters are decided. Second,

the optimal sequence of procedure is measured. Third, the tool path is computed. Fourth,

a program is written. G-code interpreters are case sensitive and whole program is in

uppercase except comments, that can be either upper or lowercase.

G-code is not easily readable by human but it is quite easy to look at the program and

know how it all working. Here is an example: G0 X22 Y10. This command makes the

tool to move at maximum speed to the coordinate following the G0. Similarly, for G1 the

feed rate of tool is specified which means the tool moves with specified speed. For

example,

G1 X22 Y10 F540, where feed is in mm/min or in/min. G2 and G3 are used to specify the

motion in a circular path either clockwise or anti-clockwise.

The general methodology of CNC is that machine tool for example, a cutting tool follows

the instructions and moves accordingly to cut away unnecessary stuff leaving only useful.

The same idea is behind the non-cutting tools such as brushing, plotting and 3D printing.

The G-codes (some) are shown below in table 4.1:

Table 4.5: G-code Commands

G00 Point-to-point positioning

G01 Linear interpolation
G02 Clockwise circular interpolation
G03 Counter-clockwise circular interpolation
G04 Dwell
G05 Hold
G09 Exact Stop Check

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 G10 Programmable Data Input
G17 XY plane selection
G18 ZX plane selection
G19 YZ plane selection
G28 Return to machine zero
G33 Thread cutting, constant lead
G40 Cancel tool nose radius compensation
G41 Tool nose radius compensation - left
G42 Tool nose radius compensation - right
G43 Cutter length compensation
G44 Cancel cutter length compensation
G50 Define maximum spindle speed
G70 Dimensions in inches
G71 Metric dimensions
G90 Absolute dimensions
G91 Incremental dimensions
G94 Feed rate/min
G95 Feed rate /rev

G-codes are modeled to use multiples code in same line and also to differentiate the

codes that can’t be used together to avoid over riding. These groups are as follows:

 Group 1 (motion): G00, G01, G02, G03, G80, G81, G82, G83, G84, G85, G86,

G86, G87, G88, G89

 Group 2 (plane selection): G17, G18, G19

 Group 3 (incremental mode): G90, G91

 Group 5 (feed rate mode): G93, G94

 Group 6 (units): G20, G21

32
  Group 8 (tool length offset): G43, G49

4.1.1 Other Codes

N: Line number, to label codes lines with an increment of 5 for easy understanding

X: Horizontal position

Y: Vertical Position

Z: only use two symbols, Z1 for up movement and Z-1 for down movement

F: Feed rate

T: Tool Selection, Select appropriate tool for process

M: Miscellaneous Functions

When the programming is complete a series of functions are used to stop and reset the

machine for use in future.

Some of M functions are listed below in table 4.2 as:

Table 4.6: Miscellaneous Function

M00 Program stop

M01 Optional stop

M02 End of program

M03 Spindle start clockwise

M04 Spindle start counter-clockwise

M05 Spindle stop

M06 Tool change

M07 Mist coolant on

M08 Flood coolant on

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 M09 Coolant off

M10 Clamp

M11 Unclamp

M13 Spindle clockwise, coolant on

M14 Spindle counter-clockwise, coolant on

M30 End of tape, rewind

4.1.2 G-code Generation

G-code programming is easy to learn and understand for beginners. But, writing a g-code

program even for a simple square is quite difficult, time consuming and challenging.

Fortunately, there is software that can generate g-code of any user desired picture. This

software is “Inkscape”. For example, we want to get g-code of a written text, following

are the steps to generate g-code:

 Document Properties: Open inkscape, go to file menu, and click “Document

Properties”. Change the dimension from px to mm. Also adjust height and width

of the area. When we close this window a square drawing area appears on screen.

This area corresponds to the drawing area on hard paper.

 Text: write the text in the square and click apply.

 Object to path: Go to path menu and click “object to path”.

 Saving as g-code: Inkscape can’t save files as g-code on its own. It is required to

install an Add-on. It is a MakerBot Unicorn extension for inkscape that saves

files as g-code.

34
4.1.3 Example G-code

For instance, we want to draw a square box with following dimensions as shown in Fig

4.1:

Fig 4.4: Diagram for G-code

G-code for the above square box is as:

M5 (servo up)

G90 (go to reference/absolute point)

G21 (linear motion command)

G1 F3000 (specify feed rate in mm/min)

G1 X20.1406 Y99.8549 (go to starting point 2 with pen up)

M3 S45 (servo down, set servo angle 45°)

G4 P1 (delay)

G1 F1800.00000

G1 X99.8594 Y99.8594 (from point 2 to 3 with pen down)

G1 X99.8594 Y20.1406 (from point 3 to 4 with pen down)

G1 X20.1406 Y0.1406 (from point 4 to 1 with pen down)

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G1 X20.1406 Y99.8594 (from point 1 to 2 with pen down)

M5 (pen up)

G4 P1

G1 F3000

G1 X0 Y0 (back to point 1)

4.2 Arduino Software

It is used to send g-code to Arduino board through grbl. Arduino is a best software that is

specially designed for such projects used with Arduino boards. The program can be

written in C or C++ language. Program is written in fully optimized C language and then

executed to interface and run through the Arduino boards. Program and coding for this

project is not much. As most of Arduino libraries are used. These libraries are open

source and can be used and modify as desired under the public license.

4.3 GRBL

The g-code file is uploaded to Arduino by grbl. Grbl is commonly used for stepper

motors but as we are using servo motor, grbl servo master is necessary to be installed. It

runs on an Arduino with Atmega 328 controller. It supports all primary g-code functions

as well as full support for arcs, helical and circular motion. It also has ability to look

ahead at future commands to predict velocity for jitter free and smooth motion.

 It has a pulse width range 0.5-2.5ms

 S0 send minimum pulse width instead of deactivating PWM

 Set the maximum S value by using command $30= any number upto 255

 PWM frequency is defined 61 Hz

 M3S0 at start activate servo motor and M5 at the end to deactivate

36
The baud rate is set to 115200 bps and connect using Arduino serial monitor. A welcome

message grbl 0.9i [‘$’ for help], appears which assures the correct working.

The proper scale for drawing is not stored in grbl, so it needs to be set it before starting

drawing. All settings can be accessed from the command tab of UGS by typing $$. These

are system settings that are persistent and stored in EEPROM of Arduino. Check for $100

and $101 commands, that define the number of steps that the machine will go for 1mm.

For a 200-step motor, GT2 timing belt and 20 teeth pulley the correct number of steps is

80. If the value is correct the machine will draw accurately according to inkscape

dimension.

Written libraries and standard directives are used to organize and control the motion.

#include <avr/io.h>

#include <avr/pgmspace.h>

#include <avr/interrupt.h>

#include <avr/wdt.h>

#include <util/delay.h>

#include <math.h>

#include <inttypes.h>

#include <string.h>

#include <stdlib.h>

#include <stdint.h>

#include <stdbool.h>

#include <config.h>

#include <coolant_control.h>

37
#include <cpu_map.h>

#include <defaults.h>

#include <eeprom.h>

#include <gcode.h>

#include <grbl.h>

#include <limits.h>

#include <motion_control.h>

#include <nuts_bolts.h>

#include <planner.h>

#include <print.h>

#include <probe.h>

#include <protocol.h>

#include <report.h>

#include <serial.h>

#include <settings.h>

#include <spindle_control.h>

#include <stepper.h>

#include <system.h>

#endif

4.4 Program Codes

Program codes are written in C language and compiled with AVR compiler. GRBL

library is standard motion control library, that is used in this project. It is an open source

library and can be modified easily. Standard motion control library is used in this project

38
that is GRBL library. GRBL is an open source library and can be modified. So, it is

modified according requirements of the project. Code is basically consisting of two parts

that is header file and actual code of the project. Header file contains the initialization of

different variables and functions. As per standard format of C libraries. Header files of

GRBL are listed above. C files are uploaded to Arduino to perform basic function

settings such as limits, motion control and spindle control [16].

4.5 Universal Serial G-code Sender

Universal g-code sender is a g-code platform that provide visual inside with color coded

segments. It also provides real time tool position feedback and duration estimation. Latest

versions of UGS requires Java 8 or higher. This application is used to send commands to

machine. It has to do nothing with G-code generation, it has already done by inkscape.

Find the right port for hardware from windows start menu and ‘devices and printers’.

Open the specified hard properties and look for the port number specified as COM30.Use

this port number in the UGS window, select baud rate 115200 bps and firmware ‘grbl’.

UGS can execute commands manually or in file mode. These two methods can be

performed selecting any tab either file mode or machine control [l7].

File Mode: In file mode, a complete g-code file is uploaded, saved and sent to the

machine. The software also provides real time tool positioning features like total

commands rows, sent rows, remaining rows and remaining estimated time. At the end of

execution, the total time of duration is displayed in dialog box. Thus, it is very useful

software.

Machine Control: Machine control provide feature of manual control in single steps

using keyboard. It can be done by selecting the ‘Enable Keyboard Movement’ checkbox.

39
On the left side of command window, the machines status is continuously figured out. It

also side by side states the commands work position and machine position to check

compatibility between software and hardware.

40
 CHAPTER 5

5 Conclusion
CNC are very versatile and fully automatic machineries. The faster computing

capabilities have made it possible to perform more complex calculations in a short period

of time. CNC machines require an understanding of motion and position for both the

machine and the workpiece. CNC machines require a combination of hardware and

software to perform operations. The hardware is the physical equipment and software

includes CAD and CAM.

All machining begins with a part program that is the coded commands or sequential

instructions that direct specific machine functions. These commands are interpreted line

by line until all lines are completed. These part programs can be either generated

manually or most commonly by the computer aided part programming systems.

CNC machines have a machine control unit(MCU) that interprets the numerical

information and helps in guiding the movement of machine. The part program supplies

this information to the CNC machine.

The Cartesian coordinate system is the most common system describing the motion, it

has three linear axis X Y Z axis. Each axis is supplied with a separate motor and

individual motor drivers for each motor. X Y axis are supplied with stepper motors

whereas Z axis is being supplied with servo motor. stepper motor drivers are open loop

system, motor drivers with micro-stepping mode to minimize torque pulsation and to

increase angular resolution, while servo mechanism is supplied with feedback sensor,

which sends a return signal to report the actual position.

41
The g-code of each picture is transmitted via the serial communication to the Arduino.

Arduino feeds signal in the form of pulses to the motor drivers which in response control

the motor movement. the pen is attached to the Z axis and the pen movement is

controlled by the controlled and precise movement of servo motor and the progress of the

operation is verified on the computer screen.

CNC allows motion control in a revolutionary manner. CNC machines are very efficient,

accurate and productive.

5.1 Critical Assessment

For the time being the machine control system is open loop. By using a positioning

sensor, the close loop feedback system could be implemented. The smoother motion of

rails may be obtained by using ball bearings with lead screws. For further improvements,

more precision with higher resolution could be obtained using more number of steps per

mm distance. Many advancements could be made with accuracy and parameters of

machine but this project is more than just a satisfaction.

5.2 Future Work

After CNC machines outstanding performance in industry, its work is being enlarged in

terms of speed, by increasing number of axis for higher accuracy, replacement of pen by

lasers, cutters etc.

CNC machines are under further modifications and in future CNC machines might be

networked or linked together, it means programs may be transferred to the CNC control

from a central location in an office around or around the world. Wireless connectivity

might be applied either by using Bluetooth technology or by internet. The working area

42
could be enlarged. The efficiency could be increased by using the higher rating motors

with higher power and torque.

43
 ABBREVIATIONS

CNC: Computer Numerical control

MCU: Machine Control Unit

PCB: Printed Circuit Board

SVG: Scalable Vector Graphics

CAD: Computer Aided Design

GUI: Graphical User Interface

IDE: Integrated Development Environment

VR: Variable Reluctance

PWM: Pulse Width Modulation

UGS: Universal G-code sender

ICSP: In-Circuit Serial Communication

44
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