RETROFITMENT OF CNC MACHINE CONTROL WITH

PLC

SANJAY B S
SAPNA U TILWANI
SAURAV BASU
VARUN IYER S

UNDER THE GUIDANCE OF

MAHESH C
ENGINEER (ELEC. MAINT.)
HINDUSTAN AERONAUTICS LIMITED
 CONTENTS
1. INTRODUCTION

2. ABSTRACT

3. BROACHING
3.1 CONVENTIONAL BROCHING MACHINE

4. NUMERICAL CONTROL(NC)

5. PROBLEMNS ASSOCIATED WITH NUMERICAL CONTROL MACHINES

6. RETROFITTING

7. CNC RETROFITS-MACHINE TOOL RETROFITS

8. CNC

9. PLC

10. SINUMERIK 840D

11. ADVANTAGES OF CNC OVER NC

 INTRODUCTION

Industrial machines have become advanced tools where automation and advanced feedback is made possible through
dedicated control computers. The computers allow us to fully or partially automate complex procedures and can help
make manual control more secure and precise. Real-time data from the process is available and many parameters can
be interactively controlled through the computer interface. Automation can also allow an operator to monitor multiple
machines simultaneously, reducing the number of required personnel for a machine pool.

Many critical procedures exist, however, that cannot be completely automated. In such cases, the operator might need
to be able to visually follow and interactively control parts of the current operation, while simultaneously monitoring
numerous rapidly changing parameters.

The control computer often has access to a large amount of process information and we can expect this to increase as
the systems become more sophisticated and complex. It is thus important that the data is clearly presented and easily
accessible, in order to avoid unnecessarily attention-demanding interfaces and information overload for the user.
Today’s control computers typically present their data on a traditional computer display and often use a
keyboard/mouse or a touch-screen as input devices. The operator observes the process through the machine’s safety
glass, while using a computer to the side for control and feedback. This setup results in divided attention if the
operator has the need to both follow the procedure visually and simultaneously monitor important values on the
computer display. While this problem can in part be addressed through display placement, it inherently separates the
process data from the process itself.

ABSTRACT

Multi-axis Computerized Numerical Control (CNC) machines have become the application of choice for complex
sculptured surface machining. Simulation of tool paths and machine operations is desirable for cost and time savings.

Goals of these projects include: extend students’ knowledge in CNC machines, programming, simulation, verification
and optimization; teach students how to model and machine the complex free-form surface; and foster students’
independent learning.
 BROACHING

Broaching is the machining process of cutting a shape by moving a broach cutting tool, usually just called a broach,
over material such as metals or plastics. The broach's rows of teeth, or chisels, progressively increase in size. Each
tooth removes the excess material gradually and the desired shape is complete only after the final broach tooth has
passed through the material.

The shape found in an internal keyway in a pulley or gear is the most common shape produced by broaching since
broaching is the simplest method of cutting internal forms known as splines on gears, sprockets, and hubs. Polygons
such as squares are also commonly and easily produced by a broach, especially when a round hole needs to be
enlarged into a square or other non-circular shape. Sometimes, broaches are also used to cut external shapes such as
slots.

The broaching which we observed was to produce a spur tree for the turbine blades of the engines.
 CONVENTIONAL BROACHING MACHINE

Broaching machines are relatively simple as they only have to move the broach in a linear motion at a predetermined
speed and provide a means for handling the broach automatically. Most machines are hydraulic, but a few specialty
machines are mechanically driven. The machines are distinguished by whether their motion is horizontal or vertical.
The choice of machine is primarily dictated by the stroke required. Vertical broaching machines rarely have a stroke
longer than 60 in (1.5 m).

Vertical broaching machines can be designed for push broaching, pull-down broaching, and pull-up broaching or
surface broaching. Push broaching machines are similar to an arbor press with a guided ram; typical capacities are 5 to
50 tons. The two ram pull-down machine is the most common type of broaching machine. This style machine has the
rams under the table. Pull-up machines have the ram above the table; they usually have more than one ram. Most
surface broaching is done on a vertical machine.

Horizontal broaching machines are designed for pull broaching, surface broaching, continuous broaching, and rotary
broaching. Pull style machines are basically vertical machines laid on the side with a longer stroke. Surface style
machines hold the broach stationary while the work pieces are clamped into fixtures that are mounted on a conveyor
system. Continuous style machines are similar to the surface style machines except adapted for internal broaching.

Numerical Control

Numerically controlled means that all control commands, such as position information and switching functions,
are given as numeric code. Punched tape was originally used as the memory medium. Modern systems such
as the 840D/810D hold control commands in the internal memory (RAM). The NC decodes the numeric code
information, post-processes it, and transfers it to the machine.
In addition to the control commands for DIN programming, additional system commands and variable displays
are possible.
Not only internal data memory, but also connectable memory media, such as discs or a hard drive serve as
information media.

Problems Associated with the Conventional NC Machines

1) Mistakes related with part programming (programming for the parts to be manufactured): When the
programs of instructions related to the particular part to be manufactured are written on the punched tape, the syntax or
numerical mistakes are quite common. The NC tape is not completed correctly in a single pass and at least three passes
are required to get the correct program written. Another major problem with the part programming is achieving the
best sequence of steps required for the machining the part.

2) Non optimal speed and feeds: For most economic manufacturing of the object from the raw material it should be
given optimum speed and feeds during manufacturing. The conventional numerical control does not provide
opportunity to change the speeds and feeds during the cutting operations, so the programmer is compelled to set the
speeds and feeds for the worst-case conditions that can result in highly expensive manufacturing due to wastages, and
low quality jobs. This also results in manufacturing of the jobs at lower than optimum productivity.

3) Punched tape: The punched, which is made up of paper and on which the program is written is the problem in
itself. This tape is fragile and susceptible to wear and tear so it has short life and cannot be reliable enough for the
repeated use. Instead of paper, other media like Mylar can be used for writing the program of instructions, but these
materials are quite expensive.

4) Unreliable tape reader: The tape reader reads the program of instructions from the punched tape, but it is
considered to be highly unreliable hardware component of the NC machine. When the NC machine breaks down the
first thing the maintenance personnel checks is the tape reader.

5) The inflexible controller: The conventional NC machine has the controller unit which is hard wired and the
making the changes in the controls of the machines is a tough task. The controller used in the CNC machines is the
computer, which is highly flexible.

Retrofitting

Essentially involves enhancing of the machine performance either through change of mechanical or electrical or a
combination of both the systems.
Retrofitting refers to the addition of new technology or features to older systems.

Retrofit projects replace or add equipment to existing power plants to improve their energy efficiency, increase their
output and extend their lifespan.

Retrofitting is useful in utilizing the residual life of existing machines.

 Replace the controller.

 Design the interface.
 Replace the operator panel.
 Replace the magnetic controls.
 Replace the control cabinet.
 Replace the servo motors and amplifiers.
 Replace the spindle motor drive.
 Provide documentation.
 Provide training.
 Provide after installation support.

CNC retrofits –Machine tool retrofits

A CNC retrofits in its basic lowest cost form is a replacement of the existing control with a new more flexible, and
powerful, latest generation control
In addition at extra cost the whole or part of the electronics maybe replaced including drives, re-wires of machine,
new electrical cabinet and replacement of feedback measurement devices.

BENIFITS
 Improved machine utilization.
 Increased accuracy.
 Faster part programming.
 Greater flexibility of part type, methods and storage.
 Reduced scrap.
 Linkage to your computer network.
 Decreased repair cost.
 Long term support and backup.

CNC
Numerical control (NC) refers to the automation of machine tools that are operated by abstractly programmed
commands encoded on a storage medium, as opposed to manually controlled via hand wheels or levers, or
mechanically automated via cams alone. The first NC machines were built in the 1940s and 1950s, based on existing
tools that were modified with motors that moved the controls to follow points fed into the system on punched tape.
These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern
computer numerical control (CNC) machine tools that have revolutionized the manufacturing process.

In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and
computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract
the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for
production. Since any particular component might require the use of a number of different tools-drills, saws, etc.,
modern machines often combine multiple tools into a single "cell". In other cases, a number of different machines are
used with an external controller and human or robotic operators that move the component from machine to machine.
In either case, the complex series of steps needed to produce any part is highly automated and produces a part that
closely matches the original CAD design.

Siemens CNC panel

 Application Distribution of a CNC

MMC/OP (HMI)
Operator control and process
Start-up
Parts programming
System data management
User data management
Interfaces

PLC NCK Drive/Motor

Communication
Administration parts programs
Machine logics Actual value collection
Release signals Speed control
Disable signals Channel 1 Channel n Current control
Machine operation Power supply
Interpretation Interpretation
Preparation Preparation
Processing Processing
Interpolation Interpolation

Position control

SINUMERIK Sin 810D/840D

Automation and Drives - Motion Control
Siemens Ltd. All rights reserved.
 Major Features
 

 Competitively priced, feature rich, and reliable CamSoft systems are the perfect solution for Retrofitters,
Machine Shops and OEMs looking to retrofit or upgrade any CNC machine tool controller on-site.
 The control can accept many different formats of G & M codes and CAD files.
 CamSoft controllers are your cost-effective way to give your customers what they want.
 Open & flexible operator interfaces for Windows 98 through XP.
 The operator interface is simply a collection of bitmapped images.
 Easily configure each machine to your customer's exact feature specification.
 Create an operator interface that simulates your customer's existing controller.
 Patent Pending 3D and 5-axis tool compensation at the CNC controller.
 Adaptive control feedrates automatically adjust in real time based on feedback.
 Fastmode allows huge programs with small moves to execute fast. Great for mold makers.
 Patent Pending Smart Path option available - look ahead intelligent tool path optimizer.
 If you don't see a canned cycle you need, create one yourself.
 Digital I/O events, timed sequential events and logic flows can be tested off line to ensure the machine is
properly functioning.
 If tool or axes reach or pass the user-defined crash barrier, motion automatically stops.
 Backup or visually restart using the mouse along the profile past the point of the last cut, replace the tool or
restart the spindle, water or flame and press Cycle Start to continue.
 Optionally press a button on the screen to call for technical help via a modem.
 Select from several ready-to-go control enclosures.
 User-serviceable spare parts are available off the shelf from many sources.
 No need to understand C++, Visual Basic or Ladder Logic.
 No PLC hardware needed, the computer becomes the PLC and does the logic.
 Retrofit or upgrade using your own control enclosure
 Spare parts are based on off the shelf PC sources. In case of future repair the system is based on a standard
Windows PC design and spare parts are available from many sources
 Our company experience and know how servicing America's largest corporations, Government facilities and
Universities with over 7,000 systems sold worldwide since 1981 is comforting factor. 
 Uses Servo AC, DC, Velocity mode, Current mode, Brush, Brushless, PWM, Stepper or Hydraulic. Keep your
existing motors and amps.
 Device Drivers:

A device driver must be developed to connect a mechanism device directly to CAD/CAM. It may be Useful to think of
a complete mechanism device driver as a container for a collection of methods and classes. These Methods and classes
can be called by CAD/CAM systems To perform various operations on the connected
Mechanism device and to read back the mechanism

Operational parameters, such as current feedrate, spindle speed, joint value, current torque, etc. Each device driver
must be able to entirely determine a particular mechanism’s behavior and understand exactly how to
make the mechanism work for the user. Specifically, the device driver should be designed with the following
functions:
• Apply a self-contained device database to expose the details of a mechanism device.
• Expose functions required by CAD/CAM.
• Communicate directly with the DMAC reconfigurable controller.
The device driver is designed as a DLL. Under the RMAC paradigm, each device driver is assigned to a mechanism
class. The functionality of a DLL makes it the perfect form for a mechanism device driver. By using DLLs, the
machine-specific software modules can be designed, linked, and debugged independently. These DLLs are separate
executable files and are completely independent of all other software. If the functionality of a mechanism device
driver
needs to be updated or enhanced, the driver developers only need to update this device driver DLL
 PLC

An integrated PLC (Programmable Logic Control) based on the S7-300 platform is used as an interface control. The input
signals and output signals from or to the machine are processed in an S7 program. This program monitors the machine states
and to reacts to them using enable/disable signals. In addition to that, the PLC program may be used to switch machine
functions on and off.
A PLC basic program is necessary to transfer interface signals between NC and PLC. The user can neither read nor change
the blocks in the PLC basic program. A PG740 programmer with Step7 software can be connected to start-up and service
functions of the PLC.

Features

Control panel with PLC (grey elements in the center). The unit consists of separate elements, from left to right; power
supply, controller, relay units for in- and output

The main difference from other computers is that PLCs are armored for severe conditions (such as dust, moisture,
heat, cold) and have the facility for extensive input/output (I/O) arrangements. These connect the PLC to sensors and
actuators. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of
complex positioning systems. Some use machine vision. On the actuator side, PLCs operate electric motors,
pneumatic or hydraulic cylinders, magnetic relays, solenoids, or analog outputs. The input/output arrangements may
be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into
the PLC.
System scale

A small PLC will have a fixed number of connections built in for inputs and outputs. Typically, expansions are
available if the base model has insufficient I/O.

Modular PLCs have a chassis (also called a rack) into which are placed modules with different functions. The
processor and selection of I/O modules is customized for the particular application. Several racks can be administered
by a single processor, and may have thousands of inputs and outputs. A special high speed serial I/O link is used so
that racks can be distributed away from the processor, reducing the wiring costs for large plants.

User interface

PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday control.

A Human-Machine Interface (HMI) is employed for this purpose. HMIs are also referred to as MMIs (Man Machine
Interface) and GUIs (Graphical User Interface).

A simple system may use buttons and lights to interact with the user. Text displays are available as well as graphical
touch screens. More complex systems use programming and monitoring software installed on a computer, with the
PLC connected via a communication interface.

Communications

PLCs have built in communications ports, usually 9-pin RS-232, but optionally EIA-485 or Ethernet. Modbus,
BACnet or DF1 is usually included as one of the communications protocols. Other options include various field buses
such as Device Net or Profibus. Other communications protocols that may be used are listed in the List of automation
protocols.

Most modern PLCs can communicate over a network to some other system, such as a computer running a SCADA
(Supervisory Control and Data Acquisition) system or web browser.

PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between processors. This allows
separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the
communication link. These communication links are also often used for HMI devices such as keypads or PC-type
workstations.

Programming

PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-
connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or
some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays.
 810D

 SINUMERIK 810D (now available in power line series) covers the medium performance range of
SINUMERIK Motion Control Systems. All the CNC, PLC, closed-loop control and communication tasks are
combined on one CCU module (Compact Control Unit).
 Up to 6 digital axis, 2 Channel, MMC with hard disk available
 Compact CNC path control which is used worldwide in turning, drilling, milling, grinding, nibbling, stamping,
in tool construction and mold-making as well as in wood processing, handling and large-scale production.
 Having an integrated high-performance SIMATIC S7 PLC CPU, 5 integrated digital SIMODRIVE 611D drive
controls and 3 SIMODRIVE 611 power sections
 Designed for cost optimized machines: turning, milling and drilling are made fast, accurate and economical

840D

 The SINUMERIK 840D (now available in power line series) provides you with modularity, openness, a
uniform structure for operating, programming and visualizing and provides a system platform with innovative
functions for almost all technologies.
 The SINUMERIK 840D power line offers a complete digital system which is especially suitable for complex
processing tasks and is characterized by maximum dynamics and precision through the modular 32-bit
microprocessor CNC continuous path control.
 Specially developed for complex machining tasks, with its state-of-the-art control concept for turning, milling,
drilling, grinding laser cutting, nibbling/punching and handling task as well.
 Capable of handling of up to 10 mode groups, 10 channels, 31 axes/spindles and integrated, powerful PLC.
 Operator Panels are available with integrated hard disk.
 CNC performance can also be adapted to different requirement by selecting the proper NCU and simply
plugged into the common NCU Box.
 NURBS Interpolation capable
 Servo drive system: SIMODRIVE 611D with 1FK7/1FT6 AC servomotor and Siemens Linear motors.
 All NCUs have an integrated PROFIBUS-DP interface (optional).
 Benefits of 840D

 The highest possible degree of performance and flexibility

mainly for complex multi-axis systems
 Uniform system openness 
from operation through to the NC kernel
 Integrated certified safety functions 
for man and machine: SINUMERIK Safety Integrated

Advantages of the CNC Machines over NC Machines

There are various valid reasons for the popularity of the CNC machines over the NC machines, let us see some of
them.

1) Part program tape and tape reader: In the older CNC machines the part program tape and the tape reader is still
required, but they are used only for feeding the program into the memory of the computer. Once the program is saved
into the memory, the tape is no more required and the program stored in the memory can be used repeatedly. Thus the
tape and the tape reader that poses the major maintenance problems are done away with. In fact the latest CNC
machine don’t even require the tape and tape reader, for the program of instructions are fed directly into the mini or
microcomputer via the control panel of the computer.

2) Editing the program: Since the program of instructions is saved in the computer memory, they can be edited and
changed as per the requirements. Thus the CNC system is highly flexible. One can also make necessary changes in the
program for providing variable speeds and feeds for the manufacture of the jobs resulting in economic manufacturing.
Even the NC tape used for the programming in CNC machines can be corrected and optimized since it allows changes
in the tool path, speed, feed etc.

3) Metric conversion: The CNC machine allows the conversion of tapes prepared in the metric system into the SI
system of measurements. Thus programmer does not have to re-enter the whole program of instructions merely
because of the different units of measurements used in the program.

4) Highly flexible: The CNC machines are highly flexible. One can easily make the changes in the program and store
them as the new program. One can also introduce new control options like the new interpolation scheme quite easily.
It is easier to make updates in the CNC machines with lesser cost; hence risk of the obsolescence of the CNC machine
is reduced.
5) Easier programming: The programs are written in the CNC machine using language which has statements similar
to the ordinary English language statements. The programmer can easily master the CNC programming language and
use it for the wide range of the machining operations of the job. The programmer can set the various dimension of the
job, the machining operations to be carried out and their sequence, the amount of metal to be removed in each cutting
operation, the speed of cutting, etc. The program of instructions is written as per the available size of the raw materials
and also the surface finish required for the final finished job. Some of the programs take the form of the macro
subroutines stored in the memory of the CNC machine and the programmer can use them frequently whenever
required. Some of the programs are stored in the library and they can be used wherever required completely or as a
small part of the big program